Form No. 3412-127 Rev A Extension Kit Workman® GTX Series Utility Vehicles Model No. 07049 Installation Instructions WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. © 2016—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Register at www.Toro.com.
Installation Loose Parts Use the chart below to verify that all parts have been shipped. Description Use Qty.
Preparing the Machine 2. Remove the screws that secure the hold-down (Figure 1). Note: Determine the left and right sides of the machine from the normal operating position. 3. Disconnect the vent tube and fuel line from the tank (Figure 1). 1. Move the machine to an area in your work space with enough room to install the kit. Note: Prepare to capture and clean up any fuel that spills when you disconnect the fuel line from the tank. 2. Engage the parking brake. 4. Remove the fuel tank from the tray.
Removing the Right Cover Note: Retain all the hardware that you remove in this procedure. 1. Remove the negative (–) cable from the battery and then the positive (+) cable. g034000 Figure 3 g034125 1. Left panel Figure 4 2. Screw 1. Nut 2. Positive cable (+) 3. Bolt 4. Negative cable (–) 2. Remove the 2 flange bolts that secure the battery tray to the frame (Figure 5). g033999 Figure 5 1. Flange bolt 3. Right panel assembly 2. Self-tapping screw 3.
Disconnecting the Parking-Brake Cables Removing the Left Hip Restraint Remove and retain the 3 flange bolts and flange nuts that secure the hip restraint to the machine (Figure 6). 1. Loosen the jam nut and then turn the adjustment screw 2 turns counter clockwise on both rear-brake calipers (Figure 8). g036760 Figure 6 1. Hip restraint (short) 3. Flange nut (5/16 inch) 2. Flange bolt (5/16 x 3/4 inch) g033992 Figure 8 1. Adjustment screw 3. Brake cable 2.
g033994 Figure 10 g033953 1. Shift cable Figure 12 1. Screw (1/4 x 1-1/4 inches) Note: Mark each end of the cable to identify the front and rear cable ends. Use this as a reference when you install the new shift cable. 2. Dashboard Note: Remove the cable ties that prevent you from partially removing the dashboard. You will need to replace the cable ties in a later step. 7. Remove the retaining nut on the choke cable and pull it through the dashboard. 5.
3. Use the 4 flange bolts to install the support legs to both sides of the machine (Figure 14). 2. Remove the flange bolts (3/8 x 2-1/2 inches) and nuts that secure the side rail to the machine (Figure 16). Do this on both sides of the machine. g034830 Figure 16 g036707 Figure 14 1. Flange bolt (3/8 x 1 inch) 1. Flange bolt (5/16 x 3/4 inch) 3. Side rail 2. Flange bolt (3/8 x 2-1/2 inches) 4. Flange nut (3/8 inch) 2. Support leg 3.
. Have an assistant help you move the front section forward and away from the rear section (Figure 20). 5. Remove the self-tapping screw that secures the brake line tee fitting to the center channel (Figure 18). g034048 Figure 20 1. Brake line 2. Wire harness g034833 Figure 18 1. Self-tapping screw (1/4 x 3/4 inch) Installing the Center Channel 2. Tee fitting Note: Use the hardware that you retained from a previous step to complete the following procedure. 6.
2. Loosely install the extension rail to the right side of the machine (Figure 22). 4. Insert the 2 bolts (3/8 x 3/4 inches) through the center channel and rear mount (Figure 24). g034942 Figure 22 g034943 Figure 24 1. Extension rail 1. Channel extension 3. Use the 2 bolts (5/16 x 3/4 inch) to loosely install the extension rail to the center channel at the front section of the machine (Figure 23). 2. Bolt (3/8 x 3/4 inch) 5.
6. Use the 2 bolts (5/16 x 3/4 inch) to loosely install the extension rail to the center channel at the front section of the machine (Figure 26). 8. Use the 3 bolts (3/8 x 2-1/2 inches) and flange nuts to loosely install the extension rail to the rear frame (Figure 28). Do this on both sides of the machine. g034946 Figure 26 1. Bolts (5/16 x 3/4 inch) 2. Extension rail 7. Have an assistant help you bring the front and rear sections of the machine together (Figure 27). g034053 Figure 28 1.
Installing the Side Supports Note: Use the hardware that you retained from a previous step to complete the following procedure. 1. Use the 4 bolts (5/16 x 3/4 inch) to loosely install the platform support to the center channel (Figure 30). g034837 g034054 Figure 29 1. Platform support Figure 30 Some parts are hidden for illustrative purposes. 2. Bolt (5/16 x 3/4 inch) 2. Perform the previous step to the other side of the machine. 1. Cable exit 4. Bolt (3/8 x 3/4 inch) 2. Flange nuts (3/8 inch) 5.
Adjusting the Choke Cable 1. Place the choke control into the OFF position. 2. Position the bend on the end of the throttle cable into the choke assembly (Figure 34). g033953 Figure 32 1. Screw (1/4 x 1-1/4 inches) 2. Dashboard 10. Ensure that all the hardware you installed in this procedure is securely tightened. g036767 Figure 34 Adjusting the Throttle Cable 1. Cable bend 1. Use the jam nuts on the cable to adjust and secure the cable to the bracket (Figure 33). 2.
Installing the Floor Plate Adjusting the Shift Cable 1. Set the shift lever to the middle position. Use the 4 flange bolt (5/16 x 1-1/4 inches), 4 bolt (1/4 x 1-1/4 inches), and locknuts to secure the rear floor plate to the machine (Figure 36). 2. Thread the ball-joint assembly onto the shift cable and secure it to the shift-arm assembly (Figure 35). g036769 Figure 35 1. Ball-joint assembly 4. Jam nut 2. Shift-arm assembly 5. Jam nuts 3. Shift-cable bracket 6. Shift cable g034126 Figure 36 3.
Installing the Seat Supports Note: Use the hardware that you retained from a previous step to complete the following procedure. 1. Use the 2 bolts (3/8 x 2-1/2 inches), spacers, and flange nuts to secure the seat supports on the front section of the machine (Figure 37). g034056 Figure 39 1. Seat support 3. Spacer 2. Flange bolt (3/8 x 2-1/2 inches) 4. Flange nut (3/8 inch) 4.
Installing the Side Panels 1. Use the 8 self-tapping screws (3/32 x 7/8 inch) to secure the left and right side panels from the kit to the front seat-base panels (Figure 43). g034121 Figure 41 1. Bolt (1/4 x 2 inches) 3. Panel bracket 2. Washer 4. Locknut (1/4 inch) g034123 Figure 43 1. Self-tapping screw (3/32 x 7/8 inch) 7. Use the 2 bolts (1/4 x 2 inches), washer, and locknut to secure the left and right panel bracket the machine (Figure 41). 2. Side panel 2.
3. Use the hardware you removed earlier to install the original right panel assembly to the rear seat-base panels (Figure 45). g033947 Figure 47 1. Tank tray 2. Flange bolt g033999 Figure 45 1. Flange bolt 3. Right panel assembly Connecting the Battery 2. Self-tapping screw 1. Use the bolt and nut to secure the positive (+) cable to the battery terminal (Figure 48). 4.
Connecting the Fuel Tank 2. Use the 3 flange bolt (3/16 x 3/4 inch) and flange nuts that you removed earlier to secure the rear, left-hip restraint to the rear seat base 1. Place the fuel tank on the tank tray (Figure 49). 3. Use the 6 flange bolts (3/16 x 3/4 inch) and flange nuts to secure the left and right hip restraints to the front seat base (Figure 51). g033946 Figure 49 1. Fuel tank 2. Screw 3. Hold-down 4. Fuel line 5. Vent hose 6. Flange bolt g035277 Figure 51 2.
Installing the Seat Assembly 1. Contact your Authorized Toro Distributor to obtain an additional seat assembly. 2. Install the original seat assembly to the rear seat row (Figure 52). g034127 Figure 52 1. Original seat assembly 2. Additional seat assembly (bucket seat version shown) 3. Install the seat assembly to the front seat row (Figure 52).
Installing the Kit on a Machine with an Electric Motor 3. Remove the 4 self-tapping screws securing the right side cover to the machine (Figure 55). Removing the Side Covers 1. Remove the front flange bolt and flange nut on the right hip restraint (Figure 53). g035126 Figure 55 1. Side-cover assembly g033945 2. Self-tapping screw Figure 53 1. Flange bolt (3/16 x 3/4 inch) 4. Remove the 2 bolts securing the charger bracket to the battery tray (Figure 56). 2. Flange nut 2.
Removing the Batteries Note: Retain all the hardware that you remove in this procedure. 1. Remove the flange nut, battery hold-down, and washer securing the batteries to the front battery tray (Figure 57). g035178 Figure 57 1. Hold-down rod 2. Washer 5. Hold-down 6. Watering house 3. Battery 7. Battery cable 4. Locknut 2. Disconnect the watering hose from the batteries in the front battery tray (Figure 57).
g198444 Figure 58 1. Front of the machine 3. Positive (+) terminal 2. Negative (–) terminal 3. Disconnect the positive (+) terminal on the front 4 batteries in the front battery tray (Figure 58). 4. Disconnect the negative (–) terminal as shown in Figure 58. 5. Remove the front 4 batteries (Figure 58).
Disconnecting the Parking-Brake Cable 6. Remove the 2 screws and nuts that secure the fuse block to the front battery tray. 1. Loosen the jam nut and then turn the adjustment screw 2 turns counter clockwise on both rear-brake calipers (Figure 61). g035744 Figure 59 1. Screw (#10 x 3/4 inch) 3. Fuse block 2. Nut (#10) g033992 Figure 61 1. Adjustment screw 7. Remove the 4 bolts securing the battery tray to the machine (Figure 60). 3. Brake cable 2. Jam nut 2.
Separating the Machine Note: Retain all the hardware that you remove in this procedure. 1. Install the support leg to the machine (Figure 63). g035128 Figure 65 3. Side rail 2. Flange bolt (5/16 x 3/4 inch) 4. Flange nut (3/8 inch) 4. Working from front to back, remove the flange bolts (5/16 x 3/4 inch) that secure the side rail to the machine (Figure 65). Do this on both sides of the machine. g036707 Figure 63 1. Flange bolt (3/8 x 1 inch) 1. Flange bolt (3/8 x 2-1/2 inches) 5.
g035131 Figure 69 1. Brake line 2. Wire harness g034833 Figure 67 1. Self-tapping screw (1/4 x 3/4 inch) Installing the Center Channel 2. Tee fitting Note: Use the hardware that you removed earlier to complete the following procedure. 7. Remove the bolts and flange nuts that secure the swing arm mount to the center channel (Figure 68). 1. Use the 4 flange bolts (3/8 x 3/4 inch) to loosely install the top and bottom connection plates to the center channel on the front section (Figure 70).
g034942 Figure 71 g034943 Figure 73 1. Extension rail 1. Channel extension 3. Use the 2 bolts (5/16 x 3/4 inch) to loosely install the extension rail to the center channel to the front section of the machine (Figure 72). 2. Bolt (3/8 x 3/4 inch) 5. Loosely install the extension rail to the left side of the machine (Figure 74). g034836 Figure 72 1. Extension rail g034944 Figure 74 2. Bolts (5/16 x 3/4 inch) 1. Extension rail 4.
Note: Ensure that the wire harness exits the center channel on the right side (Figure 77). 9. Use the self-tapping screw (1/4 x 3/4 inch) to attach the brake line tee to the center channel (Figure 77). 10. Use the 2 bolts (3/8 x 3-3/4 inches), and flange nuts to loosely install the center channel to the rear mount (Figure 77). 11. Tighten all the loosely-installed fasteners. g034946 Installing the Side Supports Figure 75 1.
Installing the Cables 5. Use the 10 screws (1/4 x 1-1/4 inches) to secure the dashboard to the machine (Figure 81). Note: Exit the cables and wire harness on the right side of the center channel. 1. Connect the parking-brake cable to the parking-brake lever in the front section of the machine, run it through the center channel, and connect it to the parking-brake assembly in the rear section of the machine; refer to your Operator’s Manual to adjust the parking brake. 2.
Installing the Rear Seat Base 4. Use the flange bolt (3/8 x 2-1/2 inches) and flange nut to secure the seat support (Figure 85). 1. Use the 2 flange nuts and bolts to secure the rear and front battery trays together (Figure 83). g035743 Figure 83 1. Bolt 3. Bolt (3/8 x 3/4 inch) 2. Flange nut (3/8 inch) 2. Use the 4 bolts (3/8 x 1 inch) to secure the front battery tray to the machine (Figure 83). 3. Use the 2 screws and nuts that secure the fuse block to the front battery tray (Figure 84).
7. Use the 2 bolts (1/4 x 2 inches), washer, and locknut to secure the left and right panel bracket the machine (Figure 87). 5. Use the 2 bolt with washer assemblies (1/4 x 1/2 inch) to secure the angled-support bracket and seat-base panel to the left and right seat supports (Figure 86). g034121 Figure 87 g197332 Figure 86 Some parts are hidden for illustrative purposes. 1. Screw (#10 x 1/2 inch) 3. Support bracket 1. Bolt (1/4 x 2 inches) 3. Panel bracket 2. Washer 4. Locknut (1/4 inch) 8.
10. Use the 4 self-tapping screws to secure the right side cover to the seat assembly (Figure 89). 12. Use the 3 flange bolt (3/16 x 3/4 inch) and flange nuts that you removed earlier to secure the left rear-hip restraint to the seat base assembly (Figure 91). g035278 Figure 91 3. Flange nut 1. Hip restraint (tall) g035126 2. Flange bolt (3/16 x 3/4 inch) Figure 89 1. Side-cover assembly 2. Self-tapping screw Installing the Front Seat Base 11.
g034056 Figure 93 1. Seat support 3. Spacer 2. Flange bolt (3/8 x 2-1/2 inches) 4. Flange nut (3/8 inch) g035126 Figure 95 1. Side-cover assembly 3. Use the 2 bolt with washer assemblies (1/4 x 1/2 inch) to secure the angled-support bracket and seat-base panel to the left and right seat supports (Figure 94). 2. Self-tapping screw 6. Use the 3 self-tapping screws to secure the opening cover to the side plate (Figure 96). g034124 Figure 96 1. Opening cover 7.
2. Use the hold-down rod, washer, hold-down, and locknut to secure the batteries to the battery tray (Figure 98). 3. Connect the battery cables to the positive (+) terminal to the batteries (Figure 98). g035277 Figure 97 1. Hip restraint (short) 3. Hip restraint (tall) 2. Flange bolt (3/16 x 3/4 inch) 4. Flange nut Installing the Batteries 1. Install the 4 batteries into the front battery tray (Figure 98).
g198444 Figure 99 1. Front of the machine 3. Positive (+) terminal 2. Negative (–) terminal 4. Connect the positive (+) terminal on the front 4 batteries in the front battery tray (Figure 99). 5. Connect the negative (–) terminal as shown in Figure 99. 6. Install the watering house to the batteries (Figure 98).
Installing the Seat Assembly 1. Contact your Toro distributor to obtain an additional seat assembly. 2. Install the original seat assembly to the rear seat row (Figure 100). g034127 Figure 100 1. Original seat assembly 2. Additional seat assembly (bucket seat version shown) 3. Install the seat assembly to the front seat row (Figure 100).
Installing the Heavy-Duty Springs (for Gasoline and Electric Machines) Removing the Strut Assembly 1. Use a floor jack under the center channel to support the front of the machine. 2. Remove the front wheel. 3. Remove the hex-head bolt (3/8 x 4-3/4 inches) and flange nut (3/8 inch) from the spindle (Figure 101). 4. Remove the hex-head bolt (3/8 x 3-1/2 inches) and flange nut (3/8 inch) from the control arm (Figure 101). 5.
Installing the Springs Use an approved Toro spring-compression tool to remove and install springs of the strut assembly. Contact your Authorized Toro Distributor. 1. Place the strut assembly into the compression tool and use the tool to compress the spring. 2. While the spring is compressed, remove the collar. 3. Remove the spring from the strut assembly (Figure 101). 4. Install the new spring over the existing strut assembly (Figure 101). 5. Using the Toro spring-compression tool, compress the spring. 6.
