Form No. 3420-758 Rev A Ball Cage Kit Workman® GTX Utility Vehicle Model No. 07161—Serial No. 400000000 and Up 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. Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Use the chart below to verify that all parts have been shipped.
Procedure Description Qty.
Procedure 14 15 16 Description Qty. Latch pin Thrust washer Pin guard Jam nut Sunshade Clip Sealing washer Hex-flange bolt (1/4 x 1 inch) Friction washer Plastic washer Flange bushing 2 4 2 2 1 2 4 4 2 4 2 No parts required – Use Assemble the latch pin. Install the canopy. Complete the installation. 1 Preparing the Machine No Parts Required Procedure 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key.
2 Removing the Seat Assembly, Handholds, Side Panels, and Rubber Covers No Parts Required Removing the Seat Assembly g036760 1. Push the seat assembly forward to the raised position. 2. Slide the seat assembly to the side out of the pins, and lift the seat assembly upward (Figure 2). Figure 3 Left Handhold Shown 1. Left handhold 3. Flange nut (5/16 inch) 2. Flange bolt (5/16 x 3/4 inch) g190187 Figure 2 1. Pins g036761 Figure 4 Right Handhold Shown Removing the Handholds 1.
Removing the Side Panels For Electric Machines 1. Disconnect the batteries; refer to your machine Operator’s Manual. Note: Correctly follow the procedure for disconnecting the batteries. Disconnect the main negative-battery cable (black), then disconnect the main positive-battery cable (red). 2. Remove the charger and the charger cable from the charger bracket (Figure 5). g193101 Figure 6 Left Side Shown (Top View) 1. Left side panel 2. Charger bracket g191363 Figure 5 Left Side Shown 1. Charger 3.
4. Removing the Side Panels Remove the 4 torx-head screws (M6.0 x 22 mm) from the left side panel and remove it (Figure 7). For Gasoline Machines 1. Disconnect the vent tube and fuel line from the fuel tank (Figure 8). DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Drain fuel from the fuel tank when the engine is cold. Do this outdoors and in an open area. Wipe up any fuel that spills.
4. and the 4 torx-head screws (M6.0 x 22 mm) that secure the right side panel, and remove the right side panel (Figure 11). Remove the 6 torx-head screws (M6.0 x 22 mm) from the left side panel and remove the side panel (Figure 9). Note: The battery comes off with the right side panel as shown in Figure 11. g199036 g033999 Figure 9 Left Side Shown (Top View) 1. Side panel 5. Figure 11 Right Side Shown (Top View) 2. Torx-head screw (M6.0 x 22 mm) 1. Flange-head bolt (5/16 x 3/4 inch) 3.
g217566 Figure 13 Left Side Shown 1. Plastic rivet (10) 3. Cable tie g237471 Figure 15 Marking the forward floor channel 2. Rubber cover 1. Front of the machine 2. Forward floor channel 3. Floor brace 3 Installing the Floor Braces Parts needed for this procedure: 2 Floor brace 20 Flange-head bolts (5/16 x 1 inch) 20 Flange locknut (5/16 inch) 4. Side frame channel 5. Rear floor channel 2. Clamp the floor brace to the side frame channel and floor channels. 3.
6. Drill the side and floor channels at the centerpunch marks with a 8 mm (5/16 inch) drill bit (Figure 18). 7. Repeat steps 1 through 6 for the floor brace at the other side of the machine. Assembling the Floor Braces to the Machine 1. Align the holes in the floor brace with the holes that you drilled in the side and floor channels (Figure 19). g237472 Figure 17 Marking the rear floor channel 1. Front of the machine 4. Side frame channel (left) 2. Forward floor channel 3. Floor brace 5.
4 Installing the ROPS Assembly 2. Using a clamp, secure the ROPS bracket in place. 3. Mark the hole locations on the ROPS bracket (Figure 20). 4. Using a ROPS bracket as a guide, drill 3 holes (13.5 mm or 17/32 inch) into the frame (Figure 21).
Cutting and Installing the Rubber Covers 1. Cut the rubber covers using the measurements shown in Figure 22. Note: The cuts in the rubber cover allow for space to install the ROPS brackets. g217562 Figure 22 1. Location of cut 2. Install each rubber cover using the previously removed 10 plastic rivets and a cable tie (Figure 23). Note: If the previously removed rivets are damaged or missing, replace them with the rivets provided in this kit. g217602 Figure 23 Left Side Shown 1.
Trimming the Side Panels Trim the side panels using the measurements shown in Figure 24. g217567 Figure 24 1. Trim to this line. 2. Trim to this corner.
Installing the Roll Bar Installing the ROPS Brackets 1. 1. Install a ROPS bracket using 3 flange-head bolts (1/2 x 3 inches), 5 flat washers (1/2 inch), and 3 locknuts (1/2 inch) as shown in Figure 25. Secure 1 side of the roll bar to a ROPS bracket using 2 flange-head bolts (1/2 x 3-1/2 inches) and 2 locknuts (1/2 inch) as shown in Figure 26. Note: Ensure that you install the 2 flat washers (1/2 inch) on the outside as shown in Figure 25.
5 Installing the Side Panels, Handholds, and Seat Belts Parts needed for this procedure: 2 Seat belt 2 Seat latch 4 Hex-head bolt (7/16 x 1 inch) 8 Flat washer (7/16 inch) 4 Locknut (7/16 inch) g204767 Figure 27 Installing the Side Panels For Electric Machines 1. Install the left side panel using the previously removed 4 torx-head screws (M6.0 x 22 mm) as shown in Figure 7. 2. Secure the charge bracket to the left side panel using the previously removed 4 torx-head screws (M6.
Procedure 6 Note: Do not tighten any fasteners except when instructed. 1. Installing the ROPS Extension Using the dimensions shown in Figure 29, drill 2 holes (5/16 inch) into the outside of the floor plate on the left and right sides of the machine.
g214689 Figure 31 g214618 1. Windshield support 3. Nut—inside dash frame (5/16 inch) Figure 33 2. Hex-flange bolt (5/16 x 1 inch) 4. Secure the lower bracket of the left and right windshield supports to the machine using 4 carriage bolts (5/16 x 1 inch) and 4 flange nuts (5/16 inch) in the holes you drilled in step 1 (Figure 32). 1. Carriage bolt (5/16 x 2-3/4 inches) 3. Rear screen 2. Flange nut (5/16 inch) 4. Rear canopy support 6.
8. Loosely install the crosslink tubes to the rear mount brackets and rear corner gussets using 4 carriage bolts (5/16 x 1-3/4 inches) and 4 flange nuts (5/16 inch) as shown in Figure 35. g214868 Figure 37 1. Front crosslink 3. Nut (1/4 inch) 2. Front support 4. Hex-head flange bolt (1/4 x 1-1/2 inches) g231407 Figure 35 1. Carriage bolt (5/16 x 1-3/4 inches) 5. Rear mount bracket 2. Front mount bracket 3. Corner gusset 6. Crosslink tube 7. Windshield support 12. 4. Flange nut (5/16 inch) 9.
7 8 Installing the Seat Assembly Installing the Doors Parts needed for this procedure: No Parts Required Procedure Slide the seat assembly onto the pins and lower the seat assembly (Figure 65). 1 Right door assembly 1 Left door assembly 2 Door tether 2 Right door hinge 2 Left door hinge 4 Carriage bolt (5/16 x 2-3/4 inches) 4 Shoulder bolt (5/16 x 1/2 inch) 4 Spacer 8 Flange nut (5/16 inch) Procedure Refer to Figure 39 as you perform the following steps. 1.
g214744 Figure 39 1. Right door assembly 6. Shoulder bolt (5/16 x 1/2 inch) 2. Left door assembly 7. Carriage bolt (5/16 x 2-3/4 inches) 3. Right door hinge 8. Flange nut (5/16 inch) 4. Left door hinge 9. Spacer 5.
9 Removing the Hood and Bumper No Parts Required Removing the Hood from the Machine 1. Lift up the handle of the rubber latches at each side of the hood (Figure 40). g237474 Figure 41 1. Pivot latch g034045 Figure 40 2. Rotate the hood forward. 3. While supporting the hood, push the pivot latch inward and move the hood rearward until the clevis pin of the hood clears the latch (Figure 41). 20 2. Clevis pin 4. Repeat step 3 at the other side of the hood. 5. Remove the hood from the machine.
Removing the Bumper from the Machine 1. 10 While supporting the bumper, remove the 8 flange-head bolts that secure the bumper to the bumper mounts and headlight brackets (Figure 42) Installing the Headlight Guards Parts needed for this procedure: 2 Headlight guard 4 Flange bolt (5/16 x 5/8 inch) Installing the Headlight Guards 1. Remove the 2-socket connector of the machine wire harness from the 2–pin connector at the back of the head light (Figure 43). Note: Retain the clips for assembly.
5. Align the 3 headlight-adjusting nuts through the holes in the headlight mounting bracket and secure the nuts with the clips (Figure 43) that you removed in step 2 . g237537 Figure 46 1. Headlight-adjusting nut 3. Clip 2. Headlight bracket 4. 2-socket connector (machine wire harness) 6. Connect the 2-socket connector of the machine wire harness to the 2-pin connecto at the back of the headlight (Figure 46). 7.
2. 11 Loosely assemble the bottom bracket onto the ball-picker mount (Figure 49) with 4 flange bolts (3/8 x 1 inch) and 4 flange locknuts (3/8 inch). Installing the Ball-Picker Mount Parts needed for this procedure: 1 Ball-picker mount 1 Bottom bracket 14 Flange bolt (3/8 x 1 inch) 14 Flange locknut (3/8 inch) Drilling the Center-Channel Plate 1. g237671 Assemble the ball-picker mount onto the bumper support as shown in Figure 48. Figure 49 1. Bottom bracket 3. Ball-picker mount 2.
6. Centerpunch the 4 marks that you made on the center-channel plate in step 4. 7. Drill 4 holes 10 mm (3/8 inch) in the center-channel plate at the centerpunch marks that you made in step 6 (Figure 51). g237674 Figure 53 1. Hole (Ball-picker mount) 2. Front frame channel g237672 Figure 51 1. Center-channel plate 2. Drill bit 10 mm (3/8 inch) Drilling the Front Frame Channel 1.
Assembling the Ball-Picker Mount to the Machine 1. Assemble the ball-picker mount and the bottom bracket to the front frame channel and center-channel plate (Figure 57, Figure 58, and Figure 59) with 14 flange bolts (3/8 x 1 inch) and 14 flange locknuts (3/8 inch). g237675 Figure 55 1. Front frame channel 3. Hole (Ball-picker mount) 2. Right side of the machine 3.
g237868 Figure 60 1. Area to trim 2. 2. 1 inch from the bottom Cut out the area marked to create clearance for the ball-picker mount. Assembling the Bumper to the Machine 1. Support the bumper so that it aligns with the bumper and headlight mount as shown in Figure 42. 2. Install the bumper with the 8 flange-head bolts removed in 9 Removing the Hood and Bumper (page 20). g237837 Figure 59 1. Flange bolt (3/8 x 1 inch) 3. Flange locknut (3/8 inch) 2. Ball-picker mount 4. Top of the machine 2.
Procedure 13 1. Installing the Windshield Use 1 hex-head flange bolt (1/4 x 1-1/2 inches) and 1 nut (1/4 inch) to secure the windshield bracket to the windshield support assembly (Figure 61). Parts needed for this procedure: 1 Windshield 8 Shoulder bolt (5/16 x 1-1/4 inches) 5 Hex-head flange bolt (1/4 x 1-1/2 inches) 16 Rubber bushing 8 Backup washer 1 Windshield support assembly 1 Windshield bracket 8 Nut (5/16 inch) 5 Nut (1/4 inch) g214632 Figure 61 1.
14 15 Assembling the Latch Pin Installing the Canopy Parts needed for this procedure: Parts needed for this procedure: 2 Latch pin 1 Sunshade 4 Thrust washer 2 Clip 2 Pin guard 4 Sealing washer 2 Jam nut 4 Hex-flange bolt (1/4 x 1 inch) 2 Friction washer 4 Plastic washer 2 Flange bushing Procedure 1. 2. Align the latch pin and the pin guard with the opening at the mount bracket as shown in Figure 63.
Important: Apply thread-locking compound 16 to the hex-flange bolts before installing. Important: Ensure that the plastic washers are installed onto the top and bottom of the sunshade, as this prevents damaging the sunshade. Completing the Installation No Parts Required Procedure For Electric Machines Connect the battery; refer to your machine Operator’s Manual. Note: Correctly follow the procedure for connecting the batteries.
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