Toro 07161 User manual

FormNo.3420-758RevA
BallCageKit
Workman®GTXUtilityVehicle
ModelNo.07161—SerialNo.400000000andUp
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCalifornia
tocausecancer,birthdefects,orreproductiveharm.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachineforinstallation.
2Nopartsrequired–Removetheseatassembly,handholds,
sidepanels,andrubbercovers.
Floorbrace2
Flange-headbolts(5/16x1inch)20
3Flangelocknut(5/16inch)20
Installtheoorbraces.
LeftROPSbracket1
RightROPSbracket1
Flange-headbolt(1/2x3inches)6
Flatwasher(1/2inch)10
Locknut(1/2inch)6
Rollbar1
Flange-headbolt(1/2x3-1/2inches)4
Locknut(1/2inch)4
Cabletie2
4
Plasticrivet4
InstalltheROPSassembly.
Seatbelt2
Seatlatch2
Hex-headbolt(7/16x1inch)4
Flatwasher(7/16inch)8
5
Locknut(7/16inch)4
Installthesidepanels,handholds,and
seatbelts.
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3420-758*A

ProcedureDescriptionQty.Use
Leftwindshieldsupport1
Rightwindshieldsupport1
Frontsupport1
Rearcanopysupport1
Left,frontmountbracket1
Right,frontmountbracket1
Left,rearmountbracket1
Right,rearmountbracket1
Left,rearcornergusset1
Right,rearcornergusset1
Left,frontcornergusset1
Right,frontcornergusset1
Frontcrosslink1
Crosslinktube2
Flangenut(5/16inch)30
Nut(1/4inch)2
Hex-headangebolt(1/4x1-1/2inches)2
Carriagebolt(5/16x1-3/4inches)16
Hex-angebolt(5/16x1inch)2
Carriagebolt(5/16x2-3/4inches)6
6
Carriagebolt(5/16x1inch)4
InstalltheROPSextension.
7Nopartsrequired–Installtheseatassembly.
Rightdoorassembly1
Leftdoorassembly1
Doortether2
Rightdoorhinge2
Leftdoorhinge2
Carriagebolt(5/16x2-3/4inches)4
Shoulderbolt(5/16x1/2inch)4
Spacer4
8
Flangenut(5/16inch)8
Installthedoors.
9Nopartsrequired–Removethehoodandbumper.
Headlightguard2
10Flangebolt(5/16x5/8inch)4Installtheheadlightguards.
Ball-pickermount1
Bottombracket1
Flangebolt(3/8x1inch)14
11Flangelocknut(3/8inch)14
Installtheball-pickermount.
12Nopartsrequired–Installthebumperandhood.
Windshield1
Shoulderbolt(5/16x1-1/4inches)8
Hex-headangebolt(1/4x1-1/2inches)5
Rubberbushing16
Backupwasher8
Windshieldsupportassembly1
Windshieldbracket1
Nut(5/16inch)8
13
Nut(1/4inch)5
Installthewindshield.
2

ProcedureDescriptionQty.Use
Latchpin2
Thrustwasher4
Pinguard2
14Jamnut2
Assemblethelatchpin.
Sunshade1
Clip2
Sealingwasher4
Hex-angebolt(1/4x1inch)4
Frictionwasher2
Plasticwasher4
15
Flangebushing2
Installthecanopy.
16Nopartsrequired–Completetheinstallation.
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekey.
g038447
Figure1
3

2
RemovingtheSeat
Assembly,Handholds,
SidePanels,andRubber
Covers
NoPartsRequired
RemovingtheSeatAssembly
1.Pushtheseatassemblyforwardtotheraised
position.
2.Slidetheseatassemblytothesideoutofthe
pins,andlifttheseatassemblyupward(Figure
2).
g190187
Figure2
1.Pins
RemovingtheHandholds
Removethe3angebolts(5/16x3/4inch)and3
angenuts(5/16inch)securingtherightandleft
handholds;removethehandholds(Figure3and
Figure4).
g036760
Figure3
LeftHandholdShown
1.Lefthandhold3.Flangenut(5/16inch)
2.Flangebolt(5/16x3/4
inch)
g036761
Figure4
RightHandholdShown
1.Righthandhold3.Flangenut(5/16inch)
2.Flangebolt(5/16x3/4
inch)
4

RemovingtheSidePanels
ForElectricMachines
1.Disconnectthebatteries;refertoyourmachine
Operator’sManual.
Note:Correctlyfollowtheprocedurefor
disconnectingthebatteries.Disconnectthe
mainnegative-batterycable(black),then
disconnectthemainpositive-batterycable(red).
2.Removethechargerandthechargercablefrom
thechargerbracket(Figure5).
g191363
Figure5
LeftSideShown
1.Charger2.Chargerbracket
3.Removethe4torx-headscrews(M6.0x22mm)
securingthechargerbrackettotheleftside
panel(Figure6).
g193101
Figure6
LeftSideShown(T opView)
1.Leftsidepanel3.Torx-headscrew(M6.0x
22mm)
2.Chargerbracket
5

4.Removethe4torx-headscrews(M6.0x22mm)
fromtheleftsidepanelandremoveit(Figure7).
g193100
Figure7
LeftSideShown
1.Leftsidepanel2.Torx-headscrew(M6.0x
22mm)
5.Repeatstep4ontherightside.
RemovingtheSidePanels
ForGasolineMachines
1.Disconnecttheventtubeandfuellinefromthe
fueltank(Figure8).
DANGER
Incertainconditions,fuelisextremely
ammableandhighlyexplosive.Are
orexplosionfromfuelcanburnyouand
othersandcandamageproperty.
•Drainfuelfromthefueltankwhenthe
engineiscold.Dothisoutdoorsand
inanopenarea.Wipeupanyfuelthat
spills.
•Neversmokewhenhandlingfuel,
andstayawayfromanopenameor
whereasparkmayignitefuelfumes.
2.Removethe2screwssecuringthehold-downto
theleftsidepanel,andremovethehold-down
(Figure8).
3.Removeangeboltsecuringthefueltanktothe
fuel-tanktrayandremovethefueltank(Figure
8).
g033946
Figure8
LeftSideShown(T opView)
1.Fueltank4.Fuelline
2.Screw5.Venthose
3.Hold-down6.Flangebolt
6

4.Removethe6torx-headscrews(M6.0x22mm)
fromtheleftsidepanelandremovetheside
panel(Figure9).
g199036
Figure9
LeftSideShown(T opView)
1.Sidepanel2.Torx-headscrew(M6.0x
22mm)
5.Disconnectthenegative(–)batterycablefrom
thebatteryandthenthepositive(+)battery
cableasshowninFigure10.
g034125
Figure10
RightSideShown(TopView)
1.Nut3.Bolt
2.Positive(+)batterycable4.Negative(–)batterycable
6.Removethe2ange-headbolts(5/16x3/4
inch)thatsecurethebatterytraytotheframe
andthe4torx-headscrews(M6.0x22mm)that
securetherightsidepanel,andremovetheright
sidepanel(Figure11).
Note:Thebatterycomesoffwiththerightside
panelasshowninFigure11.
g033999
Figure11
RightSideShown(TopView)
1.Flange-headbolt(5/16x
3/4inch)
3.Rightsidepanel
2.Torx-headscrew(M6.0x
22mm)
RemovingtheRubberCovers
g237477
Figure12
Removethe10plasticrivetsandthecabletiefrom
eachrubbercoverandremovetherubbercovers
(Figure13).
7

g217566
Figure13
LeftSideShown
1.Plasticrivet(10)3.Cabletie
2.Rubbercover
3
InstallingtheFloorBraces
Partsneededforthisprocedure:
2Floorbrace
20Flange-headbolts(5/16x1inch)
20Flangelocknut(5/16inch)
DrillingtheFrameChannels
g237478
Figure14
1.Aligntheoorbracetothemachineasfollows:
•Aligntheangesoftheoorbraceush
tothesideframechannel,forwardoor
channel,andrearframechannelofthe
machine(Figure15).
•Aligntheoorbraceparalleltotheoor
(Figure15).
g237471
Figure15
Markingtheforwardoorchannel
1.Frontofthemachine4.Sideframechannel
2.Forwardoorchannel5.Rearoorchannel
3.Floorbrace
2.Clamptheoorbracetothesideframechannel
andoorchannels.
3.Usingtheoorbraceasatemplate,markthe
holelocationsonthesideframechanneland
oorchannels(Figure15,Figure16,andFigure
17).
g237473
Figure16
Markingthesideframechannel
1.Frontofthemachine4.Sideframechannel
2.Forwardoorchannel5.Rearoorchannel
3.Floorbrace
8

g237472
Figure17
Markingtherearoorchannel
1.Frontofthemachine4.Sideframechannel(left)
2.Forwardoorchannel5.Rearoorchannel
3.Floorbrace6.Sideframechannel(right)
4.Removetheoorbracefromthemachine.
5.Centerpunchthe10marksthatyoumadein
step3ofDrillingtheFrameChannels(page8).
g237469
Figure18
1.Rearoorchannel4.Forwardoorchannel
2.8mm(5/16inch)drillbit5.Frontofthemachine
3.Sideframechannel
6.Drillthesideandoorchannelsatthe
centerpunchmarkswitha8mm(5/16inch)drill
bit(Figure18).
7.Repeatsteps1through6fortheoorbraceat
theothersideofthemachine.
AssemblingtheFloorBracesto
theMachine
1.Aligntheholesintheoorbracewiththeholes
thatyoudrilledinthesideandoorchannels
(Figure19).
g237470
Figure19
1.Floorbrace5.Flange-headbolts(5/16x
1inch)
2.Rearoorchannel6.Forwardoorchannel
3.Frontofthemachine7.Sideframechannel
4.Flangelocknut(5/16inch)
2.Assembletheoorbracetothesideandoor
channelswith10ange-headbolts(5/16x1
inch)and10angelocknuts(5/16inch)as
showninFigure19.
3.Torquetheange-headboltsandangelocknuts
to19.8to25.4N∙m(175to225in-lb).
4.Repeatsteps1through3fortheoorbraceat
theothersideofthemachine.
9

4
InstallingtheROPS
Assembly
Partsneededforthisprocedure:
1LeftROPSbracket
1RightROPSbracket
6Flange-headbolt(1/2x3inches)
10Flatwasher(1/2inch)
6Locknut(1/2inch)
1Rollbar
4Flange-headbolt(1/2x3-1/2inches)
4Locknut(1/2inch)
2Cabletie
4Plasticrivet
DrillingtheHolefortheROPS
Brackets
CAUTION
Usecautionwhendrillingtheholesintothe
rightsideoftheframeonanelectricmachine.
Ifyoudrilltoofar,youcoulddamagethe
batteriesorothercomponents.
1.AlignaROPSbracketwiththe2holesbehind
theseatbaseandtheholetowardthefrontof
theframerailasshowninFigure20.
g205374
Figure20
LeftSideShown
1.Holetowardthefrontof
theframerail
2.2holesbehindtheseat
base
2.Usingaclamp,securetheROPSbracketin
place.
3.MarktheholelocationsontheROPSbracket
(Figure20).
4.UsingaROPSbracketasaguide,drill3holes
(13.5mmor17/32inch)intotheframe(Figure
21).
g204644
Figure21
LeftSideShown
5.Repeatthisprocedureontheotherside.
10

CuttingandInstallingtheRubberCovers
1.CuttherubbercoversusingthemeasurementsshowninFigure22.
Note:ThecutsintherubbercoverallowforspacetoinstalltheROPSbrackets.
g217562
Figure22
1.Locationofcut
2.Installeachrubbercoverusingthepreviouslyremoved10plasticrivetsandacabletie(Figure23).
Note:Ifthepreviouslyremovedrivetsaredamagedormissing,replacethemwiththerivetsprovided
inthiskit.
g217602
Figure23
LeftSideShown
1.Plasticrivet(10)3.Cabletie
2.Rubbercover
11

TrimmingtheSidePanels
TrimthesidepanelsusingthemeasurementsshowninFigure24.
g217567
Figure24
1.Trimtothisline.2.Trimtothiscorner.
12

InstallingtheROPSBrackets
1.InstallaROPSbracketusing3ange-headbolts
(1/2x3inches),5atwashers(1/2inch),and3
locknuts(1/2inch)asshowninFigure25.
Note:Ensurethatyouinstallthe2atwashers
(1/2inch)ontheoutsideasshowninFigure25.
g217601
Figure25
LeftSideShown
1.Flatwasher(1/2inch)3.Flange-headbolt(1/2x3
inches)
2.Locknut(1/2inch)4.ROPSbracket
2.Torquethe3ange-headbolts(1/2x3inches)
to94to108N∙m(70to80ft-lb).
3.Repeatthisprocedureontheotherside.
InstallingtheRollBar
1.Secure1sideoftherollbartoaROPSbracket
using2ange-headbolts(1/2x3-1/2inches)
and2locknuts(1/2inch)asshowninFigure26.
g217565
Figure26
LeftSideShown
1.Rollbar3.ROPSbracket
2.Locknut(1/2inch)4.Flange-headbolt(1/2x
3-1/2inches)
2.Torquethe2ange-headbolts(1/2x3-1/2
inches)to94to108N∙m(70to80ft-lb).
3.Repeatthisprocedureontheotherside.
13

5
InstallingtheSidePanels,
Handholds,andSeatBelts
Partsneededforthisprocedure:
2Seatbelt
2Seatlatch
4Hex-headbolt(7/16x1inch)
8Flatwasher(7/16inch)
4Locknut(7/16inch)
InstallingtheSidePanels
ForElectricMachines
1.Installtheleftsidepanelusingthepreviously
removed4torx-headscrews(M6.0x22mm)
asshowninFigure7.
2.Securethechargebrackettotheleftsidepanel
usingthepreviouslyremoved4torx-head
screws(M6.0x22mm)asshowninFigure6.
3.Securethechargerandthechargercabletothe
chargerbracket(Figure5).
4.Repeatstep1ontherightside.
ForGasolineMachines
1.Installeachsidepanelusingthepreviously
removedtorx-headscrews(M6.0x22mm)as
showninFigure9andFigure11.
2.Securethefueltanktothefuel-tanktrayusing
thepreviouslyremovedangebolt(Figure8).
3.Securethehold-downtotheleftsidepanelusing
thepreviouslyremoved2screws(Figure8).
4.Connecttheventtubeandfuellinetothefuel
tank(Figure8).
InstallingtheHandholds
Installthe2handholdsusingthepreviouslyremoved
3angebolts(5/16x3/4inch)and3angenuts(5/16
inch)oneachside(Figure3andFigure4).
InstallingtheSeatBelts
1.Installaseatlatchusingahex-headbolt(7/16x
1inch),2atwashers(7/16inch),andalocknut
(7/16inch)asshowninFigure27.
g204767
Figure27
1.Hex-headbolt(7/16x1
inch)
3.Seatlatch
2.Flatwasher(7/16inch)4.Locknut(7/16inch)
2.Torquethehex-headbolt(7/16x1inch)to68to
81N∙m(50to60ft-lb).
3.Repeatsteps1and2toinstalltheotherseat
latch.
4.Installaseatbeltusingahex-headbolt(7/16x
1inch),2atwashers(7/16inch),andalocknut
(7/16inch)asshowninFigure28.
g204766
Figure28
1.Locknut(7/16inch)3.Seatbelt
2.Flatwasher(7/16inch)4.Hex-headbolt(7/16x1
inch)
5.Torquethehex-headbolt(7/16x1inch)to68to
81N∙m(50to60ft-lb).
6.Repeatsteps4and5toinstalltheotherseat
belt.
14

6
InstallingtheROPS
Extension
Partsneededforthisprocedure:
1Leftwindshieldsupport
1Rightwindshieldsupport
1Frontsupport
1Rearcanopysupport
1Left,frontmountbracket
1Right,frontmountbracket
1Left,rearmountbracket
1Right,rearmountbracket
1Left,rearcornergusset
1Right,rearcornergusset
1Left,frontcornergusset
1Right,frontcornergusset
1Frontcrosslink
2Crosslinktube
30Flangenut(5/16inch)
2Nut(1/4inch)
2Hex-headangebolt(1/4x1-1/2inches)
16Carriagebolt(5/16x1-3/4inches)
2Hex-angebolt(5/16x1inch)
6Carriagebolt(5/16x2-3/4inches)
4Carriagebolt(5/16x1inch)
Procedure
Note:Donottightenanyfastenersexceptwhen
instructed.
1.UsingthedimensionsshowninFigure29,drill
2holes(5/16inch)intotheoutsideoftheoor
plateontheleftandrightsidesofthemachine.
g036552
Figure29
2.UsingthedimensionsshowninFigure30,drill1
hole(5/16inch)intotheoutsideofthefootboard
ontheleftandrightsidesofthemachine.
g036553
Figure30
3.Securethemiddlebracketoftheleftandright
windshieldsupportstothemachineusing2
hex-angebolts(5/16x1inch)and2nuts(5/16
inch)intheholesyoudrilled(Figure31).
15

g214689
Figure31
1.Windshieldsupport3.Nut—insidedashframe
(5/16inch)
2.Hex-angebolt(5/16x1
inch)
4.Securethelowerbracketoftheleftandright
windshieldsupportstothemachineusing4
carriagebolts(5/16x1inch)and4angenuts
(5/16inch)intheholesyoudrilledinstep1
(Figure32).
g036554
Figure32
1.Carriagebolt(5/16x1
inch)
3.Lowerbracketof
windshieldsupport
2.Flangenut(5/16inch)
5.Use2carriagebolts(5/16x2-3/4inches)and
2angenuts(5/16inch)tosecuretherear
canopysupportandtherearscreentotheroll
bar(Figure33).
g214618
Figure33
1.Carriagebolt(5/16x2-3/4
inches)
3.Rearscreen
2.Flangenut(5/16inch)4.Rearcanopysupport
6.Use4carriagebolts(5/16x2-3/4inches)and
4nuts(5/16inch)tosecuretherearmount
bracketsandtherearcornergussetstotheroll
bar(Figure34).
g231406
Figure34
1.Rearcornergusset3.Carriagebolt(5/16x2-3/4
inches)
2.Rearmountbracket4.Flangenut(5/16inch)
7.Install2carriagebolts(5/16x2-3/4inches)and
2nuts(5/16inch)tosecuretherearscreento
therollbar(Figure34)
16

8.Looselyinstallthecrosslinktubestotherear
mountbracketsandrearcornergussetsusing4
carriagebolts(5/16x1-3/4inches)and4ange
nuts(5/16inch)asshowninFigure35.
g231407
Figure35
1.Carriagebolt(5/16x1-3/4
inches)
5.Rearmountbracket
2.Frontmountbracket6.Crosslinktube
3.Cornergusset7.Windshieldsupport
4.Flangenut(5/16inch)
9.Looselyinstallthefrontmountbracketsandfront
cornergussetstothecrosslinktubesandthe
windshieldsupportsusing8carriagebolts(5/16
x1-3/4inches)and8angenuts(5/16inch)as
showninFigure35.
10.Looselyinstallthefrontcrosslinktothefront
mountbracketsandcornergussetsusing4
carriagebolts(5/16x1-3/4inches)and4ange
nuts(5/16inch)asshowninFigure36.
g036759
Figure36
1.Carriagebolt(5/16x1-3/4
inches)
3.Frontcrosslink
2.Flangenut(5/16inch)
11.Use2hex-headangebolts(1/4x1-1/2inches)
and2nuts(1/4inch)tosecurethefrontsupport
tothefrontcrosslink(Figure37).
g214868
Figure37
1.Frontcrosslink3.Nut(1/4inch)
2.Frontsupport4.Hex-headangebolt(1/4
x1-1/2inches)
12.Tightenallloosefasteners.
17

7
InstallingtheSeat
Assembly
NoPartsRequired
Procedure
Slidetheseatassemblyontothepinsandlowerthe
seatassembly(Figure65).
g190186
Figure38
1.Pins
8
InstallingtheDoors
Partsneededforthisprocedure:
1Rightdoorassembly
1Leftdoorassembly
2Doortether
2Rightdoorhinge
2Leftdoorhinge
4Carriagebolt(5/16x2-3/4inches)
4Shoulderbolt(5/16x1/2inch)
4Spacer
8Flangenut(5/16inch)
Procedure
RefertoFigure39asyouperformthefollowingsteps.
1.Use4carriagebolts(5/16x2-3/4inches)and
4angenuts(5/16inch)tosecuretheleftand
rightdoorhingestotherollbar.
Note:Thishardwarealsosecurestherightand
leftsidesoftherearscreentotherollbar.
2.Placeaspacerontoeachdoorhinge.
3.Applyalightcoatingofgreaseontoeachdoor
hinge.
4.Installeachdoorassemblybyslidingthedoors
ontothedoorhinges.
Note:Ensurethateachdoorswingsfreely.
Adjustthedoorlatchpinsothatitiscenteredin
thedoorlatchhandle
5.Use4shoulderbolts(5/16x1/2inch)and4
angenuts(5/16inch)tosecurethedoortethers
tothedoorassembliesandthecrosslinktubes.
18

g214744
Figure39
1.Rightdoorassembly6.Shoulderbolt(5/16x1/2inch)
2.Leftdoorassembly7.Carriagebolt(5/16x2-3/4inches)
3.Rightdoorhinge8.Flangenut(5/16inch)
4.Leftdoorhinge9.Spacer
5.Doortether
19

9
RemovingtheHoodand
Bumper
NoPartsRequired
RemovingtheHoodfromthe
Machine
1.Liftupthehandleoftherubberlatchesateach
sideofthehood(Figure40).
g034045
Figure40
2.Rotatethehoodforward.
3.Whilesupportingthehood,pushthepivotlatch
inwardandmovethehoodrearwarduntilthe
clevispinofthehoodclearsthelatch(Figure
41).
g237474
Figure41
1.Pivotlatch2.Clevispin
4.Repeatstep3attheothersideofthehood.
5.Removethehoodfromthemachine.
20