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