Form No. 3415-304 Rev A Hand Throttle Kit Serial Number 400000000 and After Workman® HDX Utility Vehicle Model No. 07408 Installation Instructions Safety 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. Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger.
Installation Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 2 3 No parts required – Prepare to install the kit. No parts required – Remove the hood. No parts required – Remove the center console panel and seats. 4 No parts required – Remove the coolant tank, ROPS shield, and seat shroud.
1 Preparing to Install the Kit No Parts Required Procedure 1. Park the machine on a level surface. 2. Engage the parking brake. 3. For machine models with a utility bed, perform the following: g009164 Figure 2 A. Remove the bed from the vehicle. Refer to the vehicle Operator’s Manual for the removal procedure. 1. Bed support 3. Bed 2. Cylinder barrel B. Remove the bed support from the storage brackets on the back of the ROPS panel (Figure 1). 4. Shut off the engine and remove the key. 5.
1 2 4 3 G022071 g022071 Figure 4 1. Terminal cover 3. Battery post 2. Positive terminal 4. Battery g010314 Figure 5 2 1. Hood Removing the Hood 2. Pivot the bottom of the hood upward until the top mounting tabs can be pulled from the frame slots (Figure 5). No Parts Required 3. Pivot the top of hood forward and unplug the wire connectors from the headlights (Figure 5). 4. Remove the hood. Procedure 1.
3 Removing the Center Console Panel and Seats No Parts Required Procedure 1. Unscrew and remove all knobs from console levers and from the gear shift lever (Figure 6). g023165 1 2 3 4 5 4 Figure 7 5 1. Screw 2. Cover plate 4. Remove the 8 socket-head bolts that secure the seat rails of the seat to the chassis and remove the seats (Figure 8). G023161 g023161 Figure 6 1. Shifter rod 2. Jam nut 3. Shifter handle 4. Control rod 5. Control knob 2.
4 Removing the Coolant Tank, ROPS Shield, and Seat Shroud No Parts Required Removing the Coolant Tank 1. Lift the coolant tank up and out of the support bracket on the back of the ROPS shield (Figure 9). g023167 Figure 10 1. Nuts 3. ROPS panel 2. Mounting bracket (ROPS bar) 4. Carriage bolts 2. Remove the ROPS panel from the machine (Figure 10) Removing the Seat Shroud 1. Ensure that the parking brake is set (Figure 11). g023166 Figure 9 1. Coolant tank 3. Support bracket 2.
3. Lift the seat shroud up and remove it from the machine (Figure 12). g023210 Figure 13 1. Lower-dust boot 3. Parking brake 2. Brake switch 4. Hex-washer head screw g023169 2. Align the holes in the parking-brake switch with the holes in the left side of the parking brake (Figure 13). Figure 12 1. Seat shroud 3. Secure the switch to the brake with the 2 hex-washer head screws (Figure 13).
g023216 Figure 15 1. Relay (back-to-back location) 3. Bolt (1/4 x 5/8 inch) 2. Dash-support tube 7. Align the 2 relays back-to-back (Figure 15). g023211 8. Secure the 2 relays to the dash-support tube with the bolt (1/4 x 5/8 inch) at the hole that you drilled in the left location (Figure 15). Figure 14 1. 38 mm (1-1/2 inch) 4. 13 mm (1/2 inch) 2. 106 mm (4-3/8 inch) 5. Dash-support tube 3. Center-support bracket 6. Drill bit—6 mm (7/32 inch) 7 2. Mark the location with a center punch. 3.
4. Mark the outline of the upper-right hole in the hand-throttle bracket onto the dash panel (Figure 17). 5. Remove the bolts and nuts that secure the hand throttle bracket to the dash panel and remove the bracket. 6. Locate the center of the outline that you marked in step 4, and mark the location with a center punch. (Figure 18). g023217 Figure 16 1. Dash support 3. Dash panel 2. Flange nut 4. Flange bolt g023219 Figure 18 2.
2. Align the lever hand throttle to the slot in the hand-throttle bracket, and align the holes in the mounting bracket that is attached to the hand throttle to the hand-throttle bracket (Figure 19). 8 Installing the Hand Throttle and Mode Switch 3. Secure the hand throttle to the hand-throttle bracket with the 2 bolts (10–32 x 5/8) and 2 nuts (Figure 19). Installing the Mode Switch Parts needed for this procedure: 1 Hand throttle 2 Bolt (10–24 x 5/8 inch) 2 Serrated nut (10–32) 1 Mode switch 1.
2. Disconnect the 31-pin and 31-socket connectors for the front and rear wire harnesses (Figure 21). 9 3. Locate the 31-pin and 31-socket connectors located on the throttle kit harness (Figure 22). Installing the Wire Harness Parts needed for this procedure: 1 Wire harness 5 Cable tie Connecting to the Main Harness Interconnections 1.
Routing the Harness and Connecting the Relay Connectors 3. Remove the resistor from the 6-pin connector for the hand throttle up circuit (Figure 23). Note: Retain the resistor and install it in the 1. Route the branch of the wire harness with the 3 connectors with 5 sockets each (Figure 23) up to the relays that you installed in 6 Installing the Relays (page 7). 6-pin connector if the hand throttle kit is removed from the machine. 4.
Routing the Wire Harness 5. Continue routing the wire harness of the kit along the lower-frame tube and then up behind the upper-control arm and the rear-support channel for the seat (Figure 26, Figure 27, and Figure 28). 1.
g023374 Figure 29 1. Parking-brake switch 4. Cable tie (kit) 2. 2-pin connector (parking-brake switch) 5. Rear-main harness (machine) 3. 2-pin socket connector (wire harness—kit) 6. Wire harness (kit) g023373 Figure 28 1. Seat-support channel (rear) 4. Wire harness (kit) 2. Rear-main harness (machine) 5. Cable tie (kit) 2. Connect the 2-pin socket connector of the wire harness of the kit to the 2-pin connector of the wire harness of the parking-brake switch (Figure 29). 3.
Installing the ROPS Shield 12 1. Align the holes in the ROPS shield with the hole in the brackets on the rollbar (Figure 10). 2. Secure the ROPS shield to the rollbar with the 6 carriage bolts and 6 nuts (Figure 10) that you removed in step 1 of Removing the ROPS Panel (page 6). Connecting the Battery No Parts Required Installing the Coolant Tank Procedure 1. Align the left and right flanges of the coolant-tank bracket with the coolant tank support on the ROPS shield (Figure 9). 1.
13 Lowering the Bed No Parts Required Procedure 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). 2. Insert the bed support into the brackets on the back of the ROPS panel (Figure 1). 3. Install the bed; refer to the Operator’s Manual. 14 Installing the Hood No Parts Required Procedure 1. Align the bottom of the hood to the top of the bumper (Figure 5). 2. Connect the lights. 3.
6. Move the hand throttle to the SLOW position (Figure 30). 15 7. Place your foot on the service brake. 8. Release the parking brake. Testing the Hand Throttle Kit 9. Move the hand throttle toward the FAST position (Figure 30). Note: The engine speed should remain at idle. No Parts Required 10. Set the parking brake and shut off the machine. Testing the Accessory Mode Testing the Normal Ground-Speed Mode 1. Move the machine to a clear level surface. 2.
Product Overview Operation Controls Using the Limit Ground-Speed Mode Hand Throttle Setting the maximum engine speed 1. Move the machine to a clear level surface. 2. Move the hand throttle to the Slow position (Figure 31). 3. Press the mode switch up to the limit ground-speed position (Figure 31). 4. Move the gear selector to the gear for the desired ground speed. 5. Fully press down the throttle pedal. 6.
Troubleshooting Accessory Operation Problem The engine is not controlled by the hand throttle when in the accessory mode. Possible Cause Corrective Action 1. The parking brake is not engaged. 1. Engage the parking brake. 2. The parking-brake switch is damaged. 2. Replace the parking-brake switch. The engine power is too low for the accessory. 1. The hand throttle is set to a slow position. 1. Increase the engine power by moving the hand throttle to the desired engine-speed position.
