Toro 110-2626 User manual

FormNo.3393-926RevA
RemoteHydraulicsManifoldKit
Heavy-DutyWorkman®Vehicles
ModelNo.110-2626
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
©2015—TheToro®Company
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
2

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
7
Straighthydraulicttings(9/16x9/16x
3/8inch)2
Preparethehydrauliccontrolmanifold.
Flatmanifoldbracket1
Flangedmanifoldbracket(HDX-Auto
Workmanmodels)1
Bolt(5/16x3/4inch)2
8
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
12
Locknut(5/16inch)1
Installthefuseblock.
3-positionswitch1
13CabletiesARInstallthemanifoldcontrolswitch.
Neutralswitch1
Locknut(10-24inch)1
Carriagebolt(10-24x5/8inch)1
14Switchplate1
Installthehydraulicliftleverneutral
switch.
3

ProcedureDescriptionQty.Use
15Nopartsrequired–Installtheseatshroud,ROPshield,and
coolanttank.
16Nopartsrequired–Installtheseatsandcenterconsole.
17Nopartsrequired–Installthehood.
18Nopartsrequired–Installthebed.
1
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.
4

Figure3
1.Forward3.Liftcontrol
2.Backward
2
RemovingtheHood
NoPartsRequired
Procedure
1.Whilegraspingthehoodintheheadlightopenings,lift
uponthehoodtoreleasethelowermountingtabs
fromtheslotsinthebumper(Figure4).
Figure4
1.Hood
2.Pivotthebottomofthehoodupwarduntilthetop
mountingtabscanbepulledfromtheframeslots
(Figure4).
3.Pivotthetopofhoodforwardandunplugthewire
connectorsfromtheheadlights(Figure4).
4.Removethehood.
3
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).
5

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
6

RemovingtheSeats
1.Removethe8socket-headboltsthatsecuretheseat
railsoftheseattothechassisandremovetheseats
(Figure9).
Figure9
1.Socket-headbolts3.Seat
2.Seatrail
2.Repeatstep1fortheotherseat(Figure9).
4
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.
7

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
5
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).
8

Figure15
1.Frontofthemachine3.Tube(liftcylinder—retract
circuit)
2.Liftcylindercontrolvalve4.Tube(liftcylinder—extend
circuit)
4.Removethetubesfromthemachine.
Note:Discardthetubes.
6
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.
9

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.
7
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).
10

Figure19
1.PortB(hydrauliccontrol
manifold)
3.PortA(hydrauliccontrol
manifold)
2.Straighthydraulictting4.45°hydraulictting
B.Installa45°hydraulicttingintoportAof
thehydrauliccontrolmanifold(Figure19).
2.Install90°hydraulicttingsintoportsC1andC2ofthe
hydrauliccontrolmanifold(Figure20andFigure23).
Note:AlignthettingsasshowninFigure20and
Figure23.
Figure20
1.90°hydraulictting3.PortC2(hydrauliccontrol
manifold)
2.PortC1(hydrauliccontrol
manifold)
3.Install2newstraightttings(9/16x9/16x3/8inch)
intoportsC3andC4(Figure21).
Figure21
1.Femalequickdisconnect
coupling
4.Malequickdisconnect
coupling
2.Straightttings(9/16x
9/16x3/8inch—new)
5.PortC3(hydrauliccontrol
manifold)
3.PortC4(hydrauliccontrol
manifold)
4.Installthemalequickdisconnectcouplingthatyou
removedinstep3ofRemovingtheQuickDisconnect
Bracket(page10)ontothestraighthydraulicttings
(9/16x9/16x3/8inch)inportC3(Figure21).
5.Installthefemalequickdisconnectcouplingthatyou
removedinstep3ofRemovingtheQuickDisconnect
Bracket(page10)ontothestraighthydraulicttings
(9/16x9/16x3/8inch)inportC4(Figure21).
(HDX-AutoWorkmanmodels)
Note:EnsurethattheO-ringsareinstalledonthettings
andlubricatedwithhydraulicuidfromthemachinebefore
installingthettingsintothemanifold.
1.Installa45°hydraulicttingintoportBofthehydraulic
controlmanifold(Figure22).
Figure22
1.PortB(hydrauliccontrol
manifold)
3.PortA(hydrauliccontrol
manifold)
2.45°hydraulictting4.90°hydraulictting
2.Installa90°hydraulicttingintoportAofthe
hydrauliccontrolmanifold(Figure22).
3.Install90°hydraulicttingsintoportsC1andC2of
thehydrauliccontrolmanifoldasshowninFigure23.
11

Figure23
1.90°hydraulictting3.PortC2(hydrauliccontrol
manifold)
2.PortC1(hydrauliccontrol
manifold)
4.Install2newstraightttings(9/16x9/16x3/8inch)
intoportsC3andC4(Figure24).
Figure24
1.Femalequickdisconnect
coupling
4.Malequickdisconnect
coupling
2.Straightttings(9/16x
9/16x3/8inch—new)
5.PortC3(hydrauliccontrol
manifold)
3.PortC4(hydrauliccontrol
manifold)
5.Installthemalequickdisconnectcouplingthatyou
removedinstep3ofRemovingtheQuickDisconnect
Bracket(page10)ontothestraighthydraulicttings
(9/16x9/16x3/8inch)inportC3(Figure24).
6.Installthefemalequickdisconnectcouplingthatyou
removedinstep3ofRemovingtheQuickDisconnect
Bracket(page10)ontothestraighthydraulicttings
(9/16x9/16x3/8inch)inportC4(Figure24).
8
InstallingtheManifoldBracket
andHydraulicControlManifold
Partsneededforthisprocedure:
1Flatmanifoldbracket
1Flangedmanifoldbracket(HDX-AutoWorkman
models)
2Bolt(5/16x3/4inch)
2Lockwasher(5/16inch)
InstalltheManifoldBracket
(non-HDX-AutoWorkmanmodels)
1.Aligntheholesintheatmanifoldbrackettotheholes
intheangeofthetransaxlesupport(Figure25).
Figure25
1.Flanged-headbolt3.Manifoldbracket
2.Transaxlesupport4.Flangedlocknut
2.Securethebrackettothesupportwiththe2
anged-headboltsand2angedlocknuts(Figure25)
thatyouremovedinstep1ofRemovingtheQuick
DisconnectBracket(page10).
12

InstalltheManifoldBracket(HDX-Auto
Workmanmodels)
1.Removethe2anged-headboltsthatsecuretheright
differentialsupporttothehousingofthedifferential
(Figure26).
Note:Retainthebolts.
Figure26
1.Differentialsupport
(right—old)
4.Differential
2.Axlesupport5.Flanged-headbolt
3.Flangedlocknut
2.Removethe2anged-headboltsand2angedlock
nutsthatsecuretherightdifferentialsupporttothe
axlesupport(Figure26).
Note:Retaintheboltsandnuts;discardtheold
differentialsupport.
3.Aligntheholesinthenewrightdifferentialsupport
withthethreadedholesinthedifferential(Figure27).
Figure27
1.Axlesupport4.Differential
2.Flangedlocknut5.Flanged-headbolt
3.Differentialsupport
(right—new)
4.Securethedifferentialsupporttothedifferentialwith
the2anged-headboltsthatyouremovedinstep1
(Figure27).
5.Aligntheholesintherightdifferentialsupporttothe
holesintheaxlesupport(Figure27).
6.Securethedifferentialsupporttotheaxlesupport
withthe2anged-headboltsand2angedlocknuts
(Figure27)thatyouremovedinstep2.
13

InstalltheHydraulicControlManifold
1.Aligntheholesinthemanifoldwiththeholesonthe
manifoldbracket(non-HDX-AutoWorkmanmodels)
orrightdifferentialsupport(HDX-AutoWorkman
models)asshowninFigure28.
Figure28
HDX-AutoWorkmanmodelshown
1.Bolt(5/16x3/4inch)3.Rightdifferentialsupport
(HDX-AutoWorkman
models—shown);manifold
bracket(non-HDX-Auto
Workmanmodels—not
shown;similarinstallation)
2.Lockwasher(5/16inch)4.Manifold
2.Securethemanifoldtothebracketorthedifferential
support(Figure28)withthe2bolts(5/16x3/4inch)
and2lockwashers(5/16inch).
9
InstallingtheHydraulicSupply
Hoses
Partsneededforthisprocedure:
2Hose(3/8x95inch)
13-positionswitch
ARCableties
ConnectingtheHydraulicLiftHoses
(3000and4000seriesWorkman)
Connecttheextendandretracthosesthatyoudisconnected
inDisconnectingtheHydraulicLiftHoses(3000and4000
seriesWorkman)(page8)tothestraightttingsinportAand
Bofthehydrauliccontrolmanifold.
InstallingtheHoses(non-HDX-Auto
Workmanmodels)
1.Installthestraightttingofthehydraulicsupplyhose
tothestraightttinginportA(extend)ofthelift
cylindercontrolvalve(Figure29).
Figure29
1.Liftcylindercontrolvalve4.Frontofthemachine
2.Straighttting(Port
A—extend)
5.90°hydraulictting(Port
B—retract)
3.Hydraulicsupplyhose
(straighttting)
6.Hydraulicsupplyhose(45°
tting)
2.Routethehosealongtherightsideofthemachine
alongthepathofthe2hydraulictubes(Figure30)that
youremovedin5RemovingtheHydraulicLiftLines
(page8).
Figure30
1.Hydraulicsupplyhose
(extend)
3.Frontofthemachine
2.Hydraulicsupplyhose
(retract)
14

3.Installthe45°ofthehydraulicsupplyhosetothe
straightttinginportBofthehydrauliccontrol
manifold(Figure31).
Figure31
1.Straighttting(port
B—extend)
4.Backofthemachine
2.Hydrauliccontrolmanifold5.Hydraulicsupplyhose
(straighttting—retract)
3.45°hydraulictting(port
A—retract)
6.Hydraulicsupplyhose(45°
tting—extend)
4.Installthe45°ttingofthehydraulicsupplyhoseto
the90°hydraulicttinginportB(retract)ofthelift
cylindercontrolvalve(Figure29).
5.Routethehosealongtheotherhose(Figure30)that
youroutedinstep2.
6.Installthestraightttingofthehydraulicsupplyhose
tothe45°hydraulicttinginportAofthehydraulic
controlmanifold(Figure31).
7.Securethehosestothechassiswithcabletiesas
requiredtosupportthehosesandpreventinterference
withmovingpartsofthemachine.
InstallingtheHoses(HDX-Auto
Workmanmodels)
1.Installthestraightttingofthehydraulicsupplyhose
tothestraightttinginportA(extend)ofthelift
cylindercontrolvalve(Figure32).
Figure32
1.Liftcylindercontrolvalve4.Frontofthemachine
2.Straighttting(Port
A—extend)
5.90°hydraulictting(Port
B—retract)
3.Hydraulicsupplyhose
(straighttting)
6.Hydraulicsupplyhose(45°
tting)
2.Routethehosealongtherightsideofthemachine
alongthepathofthe2hydraulictubes(Figure33)that
youremovedin5RemovingtheHydraulicLiftLines
(page8).
Figure33
1.Hydraulicsupplyhose
(extend)
3.Frontofthemachine
2.Hydraulicsupplyhose
(retract)
3.Installthe45°ttingofthehydraulicsupplyhoseto
the45°hydraulicttinginportB(retract)ofthelift
cylindercontrolvalve(Figure34).
15

Figure34
1.Hydraulicsupplyhose(45°
tting—extend)
4.Backofthemachine
2.Hydrauliccontrolmanifold5.Hydraulicsupplyhose
(straighttting—retract)
3.45°hydraulictting(port
B—extend)
6.90°hydraulictting(port
A—retract)
4.Installthe45°ttingofthehydraulicsupplyhoseto
the90°hydraulicttinginportB(retract)ofthelift
cylindercontrolvalve(Figure32).
5.Routethehosealongtheotherhose(Figure33)that
youroutedinstep2.
6.Installthestraightttingofthehydraulicsupplyhose
tothe90°hydraulicttinginportAofthehydraulic
controlmanifold(Figure34).
7.Securethehosestothechassiswithcabletiesas
requiredtosupportthehosesandpreventinterference
withmovingpartsofthemachine.
10
ConnectingtheLiftCylinder
HosestotheManifold
NoPartsRequired
Procedure
1.Connecttheliftcylinderhosewiththemale
quick-disconnectcouplingwiththefemale
quick-disconnectcouplingatportC4ofthemanifold
(Figure35).
Figure35
1.Femalequick-disconnect
coupling(manifoldport
C4)
4.Malequick-disconnect
coupling(manifoldport
C3)
2.Malequick-disconnect
coupling(liftcylinderhose)
5.Femalequick-disconnect
coupling(liftcylinderhose)
3.Manifold
2.Connecttheliftcylinderhosewiththefemale
quick-disconnectcouplingwiththemale
quick-disconnectcouplingatportC3ofthemanifold
(Figure35).
3.Replenishthetransaxlereservoir(non-HDX-Auto
Workmanmodels)orthehydraulicreservoir
(HDX-AutoWorkmanmodels)withthespecieduid;
refertotheOperator’sManualforyourmachine.
4.Ensurethatallofthehydraulicttingsaretightand
checkforleaks.
16

11
InstallingtheWiringHarness
Partsneededforthisprocedure:
1WiringHarness
13-positionswitch
ARCableties
Procedure
Important:Whenroutingthewiringharness,keepthe
harnessawayfromanyhot,sharpormovingparts.
1.Plugthe(2)connectorsfromtheenclosedmanifold
harnessintothesolenoidsonthemanifold(Figure36).
Figure36
1.Plugs(kitwiringharness)3.Manifold
2.Sockets(manifold
solenoids)
2.RoutethewireharnessasshowninFigure37.
Figure37
1.Bladesocketterminaland
ringterminal
3.Solenoidplugs(kitwiring
harness)
2.8-socketconnector
(3–positionswitch—dash)
3.Routethewiringharnessundertheseatareatothe
frontofthevehiclealongtheexistingwiringofthe
machine(Figure37).
4.Routethelegofthewiringharnesswiththeblade
socketterminalandringterminalforwardtothevehicle
fuseblock(Figure37).
5.Routethelegofthewiringharnesswiththe8-socket
connectortothelowerleftcorneratthefrontofthe
dashpanel(Figure37).
6.Securethewiringharnesstotheengineandchassis
withcabletiesasrequiredtosupportthewiringharness
andtopreventinterferencewithmovingpartsofthe
machine.
17

12
InstallingtheFuseBlock
Partsneededforthisprocedure:
1Fuseblock
1Fuse(12amp)
1Decal(fuseblock)
1Bolt(5/16x3/4inch)
1Locknut(5/16inch)
Procedure
1.Removethescrewsthatsecurethefuseblockofthe
machinetotheframe(Figure38).
G010461
1
2
Figure38
1.Fuseblockofthemachine2.Newfuseblockforthekit
2.Slidethenewfuseblockassemblyontothesideofthe
existingvehiclefuseblock(Figure38).
3.Mountbothofthefuseblockstothevehicleframe
withfastenersremovedanda#10-24screwand
locknut(Figure38).
4.Insertthe10ampfuseintothetopslotinthenewfuse
block
5.Installthenewfusedecalnexttothefuseblock.
6.Connecttheredleadwiththeblackterminalfromthe
fuseblockofthemachinetotheblackterminalonthe
newfuseblock.
7.Connecttheredleadfromthemanifoldharnesstothe
redwirecomingfromthe10ampfuseonthenew
fuseblock.
8.Connecttheringterminal(ground)wirefromthe
manifoldharnesstothevehicleframeorgroundblock.
13
InstallingtheManifoldControl
Switch
Partsneededforthisprocedure:
13-positionswitch
ARCableties
Procedure
1.Removeaplugfromoneoftheunusedholesindash
panel(Figure39).
G010462
1
Figure39
1.Dashholeplugs
2.Alignthe8-socketconnectorforthekitwiringharness
throughtheholeinthedash(Figure40).
18

G010463
1
2
Figure40
1.Switch2.Decal
3.Connectthe8-socketconnectortothebladeconnector
ofthe3-positionswitch.
4.Alignthewindowfortheindicatorlightinthe
3-positionswitchup.
5.Insertthe3-positionswitchintotheholedashpanel
untiltheswitchsnapssecurelyintoposition(Figure40)
6.Afxthedecaltothedashpanel,nexttotheswitch
(Figure40).
7.Securethewiringharnesstothechassiswithcable
tiesasrequiredtosupportthewiringharnessandto
preventinterferencewithmovingpartsofthemachine.
14
InstallingtheHydraulicLift
LeverNeutralSwitch
Partsneededforthisprocedure:
1Neutralswitch
1Locknut(10-24inch)
1Carriagebolt(10-24x5/8inch)
1Switchplate
Procedure
Installationofthehydraulicliftleverneutralswitchpertain
toWorkmanmodelsthatdonothavethehydraulicliftlever
neutralswitchinstalled.Ifyourmachineisalreadyequipped
withahydraulicliftleverneutralswitch,skipto15Installing
theSeatShroudandROPShield(HDandHDXseries
models),andCoolantTank(non-HDmodels)(page20).
1.Insertthenewneutralswitchintotheslotintheleft
rearcornerofthecontrolconsoleframeandposition
theswitchasshowninFigure41.
Note:Adifferentneutralswitch(ToroPartNo.
105-0023)isrequiredifyourHDseriesWorkmanhas
aserialnumberisintherangeof240000000thru
249999999.
Figure41
1.Slot(controlconsole
frame)
3.Carriagebolt(10-24x5/8
inch)
2.Switchplate4.Neutralswitch
2.Looselysecuretheswitchintheconsoleslot(Figure
41)withaswitchplate,carriagebolt(10-24x5/8inch)
andlocknut(10-24inch).
Note:Makesurethatthetaboftheswitchplate
passesthrutheslotandintotheotherholeinthe
neutralswitch.
3.Inthesameareaofthecontrolconsole,locatethe2
connectorsandjumperwirescomingfromthemain
wireharnessofthemachine.
4.Removeoneofthejumperwiresandplugthat
connectorofthemainwireharnessintotheconnector
fortheneutralswitch.
5.Adjustthepositionoftheswitch(forwardorbackward)
untilthetargetontheswitchisalignedwiththerodfor
thelift-cylindercontrolvalve.
6.Tightenthecarriageboltandlocknuttosecurethe
positionoftheneutralswitch(Figure41).
7.Installtheterminalofthepositivebatterycabletothe
batterypost;referto1PreparingtoInstalltheKit
(page4).
8.Alignthebatterycovertothebatterybase,squeezethe
cover,andinsertthetabsofthecoverintotheslots
inthebatterybase;referto1PreparingtoInstallthe
Kit(page4).
9.Checktheadjustmentoftheneutralswitchasfollows:
A.Ensurethattheparkingbrakeissetand
tranasmissionshiftleverisinNeutral
(non-HDX-AutoWorkmanmodels)orPark
(HDX-AutoWorkmanmodels).
B.Movethehydraulicliftleverforwardtothelower
positionandtrytostarttheengine.
19

Note:Iftheenginedoesnotstarttheswitchis
adjustedproperly.Iftheenginestarts,theposition
oftheneutralswitchisincorrectandyouneedto
adjustitagainbeforecontinuingwiththerestof
theinstallationinstructionsforthiskit;referto
steps5,6,9A,and9B.
15
InstallingtheSeatShroud
andROPShield(HDandHDX
seriesmodels),andCoolant
Tank(non-HDmodels)
NoPartsRequired
InstallingtheSeatShroud
1.Aligntheopeningintheseatshroudfortheparking
brakewiththeparkingbrakehandle(Figure6and
Figure13).
2.ForWorkmanmodelswithanmanualtransmission,
aligntheholeinthegearselectorbootwiththerod
forthegearselector.
3.Aligntheopeningintheseatshroudfortherodsfor
theliftbedcontrol,high-lowrangeshifter,andthe
differentiallock(Figure5andFigure6).
4.Lowertheseatshrouddown(Figure13).
5.Aligntheholesintheshroudfortheseatmounting
withtheseatsupportbracketsofthechassis.
InstallingtheROPSShield
1.AligntheholesintheROPSshieldwiththeholeinthe
bracketsontheROPSbar(Figure12).
2.SecuretheROPSshieldtotheROPSbarwiththe6
carriageboltsand6nuts(Figure12)thatyouremoved
instep1ofRemovingtheROPSPanelandSeatShroud
(page8).
InstallingtheCoolantTank(non-HD
models,)andtheCVTCoolingDuct
(HDX-AutoWorkmanmodels)
1.Fornon-HDmodels,aligntheleftandrightanges
ofthecoolant-tankbracketwiththeslotsintheseat
shroud(Figure11);referto4RemovingtheCoolant
Tank(non-HDmodels),ROPSShield,andSeatShroud
(HDandHDXseriesmodels)(page7).
2.Lowerthetankintotheslotsuntilthetankisrmly
seated(Figure11);referto4RemovingtheCoolant
Tank(non-HDmodels),ROPSShield,andSeatShroud
(HDandHDXseriesmodels)(page7).
3.ForHDXWorkmanmodelswithanautomatic
transmission,installtheCVTcoolingductasfollows:
A.AligntheCVTcoolingducttotheangeofthe
CVTintakeatthebackoftheROPSpanelonthe
passengerside(Figure10).
B.SecuretheducttotheangeoftheCVTintake
withthehoseclampthatyouremovedinstep
Aof4RemovingtheCoolantTank(non-HD
models),ROPSShield,andSeatShroud(HDand
HDXseriesmodels)(page7).
16
InstallingtheSeatsandCenter
ConsolePanel(HDandHDX
seriesmodels)
NoPartsRequired
Procedure
1.Aligntheholesintheseatrailswiththeholesinthe
shroudfortheseatmountingpositions(Figure13).
2.Securetheseatstothechassiswiththe8socket-head
bolts(Figure9)thatyouremovedinstep1ofRemoving
theSeats(page7).
3.Torquethesocketheadboltsto1978to2542N-cm
(175to225in-lb).
4.Alignthecontrolcoveroverthecontrolrodsatthe
centerconsole(Figure7);refertoRemovingthe
Center-ConsoleCovers(page5).
5.Securethecoverwiththe6screws(Figure7and
Figure8)thatyouremovedinstep6ofRemovingthe
Center-ConsoleCovers(page5).
6.ForWorkmanmodelswithanautomatictransmission
installtheshiftindicatorasfollow:
A.Connecttheharnessoftheshiftindicator
tothemachine-harnessconnector(Figure7)
thatyouseparatedinstepBofRemovingthe
Center-ConsoleCovers(page5).
B.Aligntheshift-indicatorcoveroverthecontrol
rodatthecenterconsole(Figure7).
7.Securethecoverwiththe4screws(Figure7)thatyou
removedinstepAofRemovingtheCenter-Console
Covers(page5).
8.ForWorkmanmodelswithanmanualtransmission,
threadthejamnutandshifterknobontothe
20