Form No. 3392-715 Rev A 4-Wheel Drive Kit Workman® HDX-Auto Utility Vehicle Model No. 07391 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. Loose Parts Use the chart below to verify that all parts have been shipped. Description Use Qty. No parts required – Prepare to install the kit. No parts required – Remove the hood.
Description Use Qty. No parts required – Connect the battery. Interrupter switch Slotted hex-head bolt (6-32 x 1 inch) Locknut (6–32 inch) 1 2 2 Install the interrupter switch. No parts required – Lower the bed. No parts required – Install the hood. No parts required – Adjust the 4-wheel drive engagement. Preparing to Install the Kit 1. Move the machine to a level surface and set the parking brake. 2. For machine models with a utility bed, perform the following: A.
Figure 5 1. Forward 3. Lift control (cargo box) 2. Backward Figure 3 Removing the Hood 1. Battery cover B. Remove the battery cover from the battery base (Figure 3). C. Remove the terminal of the positive battery cable from the battery post (Figure 4). 1. While grasping the hood in the headlight openings, lift up on the hood to release the lower mounting tabs from the slots in the bumper (Figure 6). Note: Ensure that the terminal positive battery cable does not touch the battery post.
Removing the Seats Removing the Center-Console Covers 1. Ensure that the parking brake is set (Figure 7). Figure 8 1. Indicator connector 2. Shift-indicator cover 4. Control cover 5. Machine-harness connector 3. Hex-head screws 7. Lift shift indicator assembly up, disconnect electrical connectors of the machine harness and indicator, and remove the indicator from the machine. (Figure 8). 8.
Removing the ROPS Panel and Seat Shroud Removing the Coolant Tank, ROPS Shield, and Seat Shroud 1. Remove the 6 carriage bolts and 6 nuts that secure the ROPS panel to the mounting brackets on the ROPS bar (Figure 12). Removing the CVT Cooling Duct and Coolant Tank 1. Remove the hose clamp that secures the CVT cooling duct to the flange of the CVT intake at the back of the ROPS panel on the passenger side (Figure 10). Figure 12 Figure 10 1. CVT intake 3. CVT cooling duct 2. Hose clamp 1. Nuts 3.
Jacking Up the Machine DANGER A vehicle on a jack may be unstable and slip off of the jack, injuring anyone beneath it. • Do not start the vehicle while the vehicle is on a jack. • Always remove the key from the switch before getting off of the vehicle. • Block the tires when the vehicle is on a jack. • Do not start the engine while the vehicle is on a jack, Figure 15 because the engine vibration or wheel movement could cause the vehicle to slip off of the jack. 1.
Removing the Front Brakes Removing the Brake Calipers and Rotors 1. Remove the 2 flange bolts that secure the brake caliper to the steering knuckle (Figure 17). Figure 18 1. Spindle bolt 5. Washer (1 x 2 inch) 2. Washer (1 x 2-5/8 inch) 6. Spindle nut 3. Bearing 7. Rotor 4. Wheel hub Figure 17 1. Flange bolt 2. Remove the spindle nut and washer (1 x 2 inch) that secures the brake rotor to the bearing in the wheel hub (Figure 18). 3. Brake caliper 2.
4. Remove the cotter pin that secures the slotted nut to the forward-ball joint of the steering cylinder (at the pitman arm), and remove the slotted nut (Figure 21). Note: Retain the slotted nut and cotter pin for installation in Installing the Steering Cylinder (page 10). Figure 19 1. Steering knuckle 3. Wheel hub 2. Hole (wheel flange) 4. Hex-head bolt 2. Remove the wheel hub from the steering knuckle (Figure 19). 3. Repeat steps 1 and 2 for the wheel hub on the other side of the machine.
Figure 23 1. Cylinder-mount plate 4. Forward-ball joint 2. Rear-ball joint 5. Steering cylinder 3. Pitman arm Figure 22 1. Slotted nut 4. Cotter pin 2. Rear-ball joint (steering cylinder) 5. Cylinder-mount plate 7. Remove the rear-ball joint of the steering cylinder from the cylinder-mount plate (Figure 23). 8. Remove the steering cylinder from the machine. 3. Inboard-seat support (diver’s side) Installing the Hydraulic Fittings and Grease Fittings 6.
Preparing to Install the Front Differential 4. Remove the 90°-hydraulic fitting from the retract port of the old-steering cylinder (Figure 24). Note: Notice the position of the 90°-hydraulic fitting before you remove it from the old-steering cylinder. Checking the Oil Level in the Front Differential 5. Install the 90°-hydraulic fitting into the retract port of the new-steering cylinder (Figure 24).
Installing the Isolator Mount and Aligning Differential 1. Insert the 4 isolators through the holes in the forward and rear differential-support plates (Figure 26). Note: Ensure that the flange of the isolators are up and above the differential-support plates. Figure 27 1. Up 3. Differential 2. Forward 4. Hole (isolator and mounting plate) Installing the Front-Drive Shaft Lubricant Type: No. 2 General Purpose Lithium Base Grease 1.
9. Torque the bolt and nut to 1998 to 2542 N-cm (175 to 225 lb-in). 10. Lubricate the grease fittings at the sliding yoke and 2 universal joints with the specified grease. Installing the Differential 1. Secure the differential to the differential supports with 1 mount plate and 4 hex-head bolts (3/8 x 1-1/2 inch) as shown in Figure 31. Note: Ensure that the strap that connects two sets of holes in the mount plate is toward the passenger side of the vehicle.
Installing the Front Axles 1. Wipe clean the splines at each end of the 2 front axles (Figure 32). Figure 33 1. Steering knuckle 3. Hex-head bolt (3/8 x 1 inch) 2. Wheel hub 2. Secure the wheel hub to the steering knuckle with the 4 hex-head bolts (3/8 x 1 inch) that you removed in step 1 of Removing the Wheel Hubs (page 7). Figure 32 1. Steering knuckle 4. Spacer 2. Inboard-axle stub (short spines end) 5. Differential-drive socket 3. Outboard-axle stub (long splines and threaded end) 6.
4. Separate the brake pads in the caliper slightly so the caliper and pads will slip over the brake rotor. 2. Slip the wheel over the studs until the wheel is flush with the brake rotor. Note: Ensure that the wheel is centered on the wheel hub. 3. Thread the lug nuts onto the studs, and hand tighten the nut. 4. Repeat steps 1 through 3 to the wheel at the other side of the machine. 5. Lower the machine to the ground and remove the jack stands. 6. Torque the lug nuts to 94 to 122 N-m (70 to 90 lb-ft). 7.
Installing the Coolant Tank and the CVT Cooling Duct Installing the Front-Differential Relay 1. Align the left and right flanges of the coolant-tank bracket with the slots in the seat shroud (Figure 11); refer to Removing the Coolant Tank, ROPS Shield, and Seat Shroud. Installing the Relay and Connecting the Harness 1. Align the hole in the front-differential relay with the hole in the dash-support tube that is outboard of the existing relay of the machine (Figure 37). 2.
Adjusting the Fast Idle for the Engine Connecting the Battery 1. Connect the positive battery cable to the battery (Figure 4); refer to Preparing to Install the Kit (page 2). 1. Start the engine and run it until the engine is at normal operating temperature (approximately 5–10 minutes). 2. Squeeze the battery cover, align the tabs to battery base, and release battery cover (Figure 3); refer to Preparing to Install the Kit (page 2). 2.
Adjusting the Accelerator Pedal Position Use another person to help adjust the accelerator pedal. 1. Move the bellcrank against the fast-idle stop and hold it against the stop (Figure 40). 2. Measure the gap between the accelerator pedal and the floor beneath the pedal (Figure 41). Note: The gap between the accelerator pedal and the floor should measure 6.35 mm (1/4 inch). Note: If the gap between the accelerator pedal and the floor is 6.
Installing the Interrupt Switch 2. Gently move the throttle pedal down until the free play is removed from between the accelerator pedal and the throttle cable (Figure 43). 3. While holding the pedal in position to remove the free play, measure the distance from the rearward bottom corner of the accelerator-pedal arm to the floor (Figure 43). 1. Align the interrupt switch to the inner face of the right flange of the accelerator-pedal bracket with the wire harness of the switch forward (Figure 45).
Figure 46 1. Bracket slot 2. Slotted hex-head bolt Figure 48 1. 2 pin connector (machine-forward harness) 2. 2 socket connector (interrupt-switch harness) 2. Remove the cable tie that secures the 2 pin connector against the harness. 3. Plug 2 pin connector of the machine harness into the 2 socket connector of the interrupt-switch harness(Figure 48). Testing the Wiring Harness and Switches Figure 47 1. Interrupter switch Note: This procedure requires 2 people to test the harness and switch. 3.
Figure 50 1. Accelerator pedal pressed (11.5 to 14 volts) Figure 49 1. 2-socket connector (machine harness) 3. Release the accelerator pedal (Figure 50). 2. Passenger side of the machine B. Set the volt/ohm meter to read a 11–14 volt range. C. Insert the leads of the volt/ohm meter into the 2-socket connector for the machine (Figure 49). Note: The volt/ohm meter should indicate 0 volts. 4. Rotate the key switch to the Off position and remove the key. 5.
Lowering the Bed Note: If the 4-wheel drive system engages with too much sensitivity, you will experience the sensation of binding in the machine’s handling or hear a grinding noise after a changing the travel direction of the machine—such as from forward to reverse or from reverse to forward. For machine models with a utility bed, perform the following: 1. Pull the bed support from the cylinder rod and remove the support (Figure 2); refer to Preparing to Install the Kit (page 2). 1.
Maintenance Preparing to Maintain the 4 Wheel Drive System 1. Move the machine to a level surface. 2. Shut off the machine, and remove the key from the ignition switch. 3. Allow the engine and exhaust system components to cool off. Lubrication Grease type: No. 2 General Purpose Lithium Base Grease Figure 53 Greasing the Steering Cylinder Service Interval: Every 100 hours Servicing the Differential 1. Wipe clean the grease fittings at the front and rear ball joints of the steering cylinder (Figure 52).
Changing the Differential Oil Service Interval: Every 800 hours 1. Align a drain pan beneath the drain plug of the differential (Figure 55). Figure 55 1. Drain-plug port 2. Drain plug 2. Remove the sight plug and drain plug from the differential (Figure 54). Note: Allow the oil to drain completely. 3. Install the drain plug (Figure 55). 4. Add the specified oil into the sight-plug port until the oil level is at the bottom of the threads of the port (Figure 54). 5. Install the sight plug (Figure 54).
Declaration of Incorporation Model No. 07391 Serial No. None and Up Product Description Invoice Description 4-Wheel Drive Kit, Workman HDX AUTOMATIC 4WD KIT HDX-Auto Utility Vehicle General Description Directive Utility Vehicle 2006/42/EC, 2004/108/EC Relevant technical documentation has been compiled as required per Part B of Annex VII of 2006/42/EC. We will undertake to transmit, in response to requests by national authorities, relevant information on this partly completed machinery.
