installation guide for the mule™ 3000 trans enclosure files/instructions... · slide the...

INSTALLATION GUIDE FOR THE MULE™ 3000 TRANS ENCLOSURE P. 1

INSTALLATION OF THE ENCLOSURE FOR THE MULE™ 3010 TRANS

www.essexmfg.com PO Box 92864 Southlake, TX 76092 Ph:888-643-7739

Sept ‘07


Preparation The passenger side grab handle and mounting brackets-must be removed for the cab to install. They can be sawed or ground off. The Essex cab is installed behind the roll cage. Remove the battery cover from under the drivers seat and set it aside. Loosen the cover under the passenger seat to allow the right floorboard to slide under it. Remove the lower frame bolt on each side of the middle & rear rollbar. Install the “Z” support brackets for the extended floorboards and loosely secure with the original 8mm bolt.

Floorboards & Mounting Brackets Position the left and right treadplate floorboards. The notch should be located around the vinyl front wheel well boot. Re-move the bolt from the rubber boot and use it to secure the floorboard. Align the floorboards along each side and install two 8mm bolts in the holes for each of the support brackets. Drill two 5/16” holes in the treadplate floor thru the floorboard holes in front of each seat for both the left & right sides. In-stall 5/16” carriage bolts and tighten. If planned, install the heavy duty battery at this time before the rear quarter panels are installed. Loosen the 19mm front rollbar bolts to provide a gap for the front quarter panel brace and the lower windshield brace to fit alongside the frame. Remove the two screws on the back of each front wheel well and install the left & right side mounting brackets using the cap headed 6mm bolt.

The enclosure is shipped with all trim and doors pre-assembled. All hardware is included. The fasteners for the body panels are 10mm serrated flange nuts and 6mm bolts. Use the black wash-ers provided under the heads of the external bolts. The extended floorboards are secured with 8mm Hex head and 5/16” carriage bolts. You will need the following tools to complete the installation:

• Metric Sockets, 10, 12 ,14 & 19mm, SAE 3/8, 7/16, 1/2 & 9/16

2

Stow the rear seat in the foot well and raise the bed. Center and install the 32” bulb gasket on the top edge of the plastic seat skirt under the front of the bed. The rubber flap should be on the back side with the slit lined up for ac-cess to the oil dipstick. On the drivers side, snap the pvc clamp to the short tube of the seat frame and fit the rubber flap around the air tube on the outside leg of the rear rollbar On the passenger side; remove the air cleaner cover. Fit the gasket piece with the 5” dia cutout over it and reinstall the cover.

Underseat Closeouts


Trans Hardtop Installation Attach the visor to the roof using six 6mm bolts. Install the top bolts on each side first, then rotate to a 45 de-gree position for the others. Use the black washers un-der the outside bolt heads. The front half of the Trans top mounts the same as the standard hardtop with the exception of the back brackets. With the top positioned on the unit, Bolt the short leg of the L brackets in the larger rear holes near the back of the main top. Install the left mid quarter panel with the door post against the roll bar. Secure the bottom brackets with 8mm bolts thru the floorboards. Use the allen head M6 bolt/washer to join the top of the door post to the main roof. Leave fasteners loose until doors are fitted. [Fig 1] Install the slide assemblies in the other holes on each side. Use a square to align them 90 degrees and tighten them securely. Note: Put only the screw on the top side. All the washers and nuts will be on the inside of the roof. Connect the short leg of the L brackets to the bolt in the back of the slides. The long leg of the bracket is bolted to the roll bar frame using the oem Bolt. [Fig 2] At this point; adjust the L brackets so the slide assembly and top of the roof are level with each other. Pull the inner slide all the way out on each slide. Position the back section over the roll bars and feed it onto the mating slides on the main top. When they are connected, slide the back section all the way forward. The hole in each side should line up with the riveted nut on the side of the front section. Install knobs in the extended position

INSTALLATION GUIDE FOR THE MULE™ 3000 TRANS ENCLOSURE P. 4 WINDSHIELD AND FRONT PANELS

Inside Latch Handle Swell Latch Parts Outside Latch view Install the "swell" latches into the aligned holes of the windshield and lower closeout panel. The pivot handle is on the inside; washer, rub-ber sleeve and nut to the outside. Position the lower windshield as-sembly on the hood so that it fits on the rubber sleeves of the upper corner latches and lies flush against the hood as shown. ADJUST IT AND CENTER THE WINDSHIELD PANEL BEFORE DRILLING THE MOUNTING HOLES. Drill 1/4" holes for the mount-ing bolts on the front side of the lower window assembly. Raise the hood and fasten it with M6 bolts and the inside squeeze plate as shown. Drill the two rear 1/4" holes from the inside and install M6 bolts. Pull the gasket tight and fold it around the lower edge of the hood. Install the plastic clip to secure it as shown. Adjust the swell latches for smooth closure by tightening, or loosening the nut on the front side. Once adjusted for proper closure, we sug-gest that you secure the nut with LocTite or teflon tape to keep it from coming loose.

Slide the windshield assembly across the front of the Mule behind the roll cage. Once it is in position, push the top forward against the top roll bar frame and start the 6mm bolts in the top of the windshield to attach it to the nuts welded in the roof. Leave them loose until the quarter panels and doors are adjusted Assemble the quarter panels to the frame by aligning the side holes with the mounting bracket and with the hole in the side of the roof. Install the lower closeout bracket in the rollbar bolt slot and the flange into the seam of the corner beam. Slide the upper windshield panel into position aligning it with the nuts in the roof beam. Start M6 bolts to hold it in place. Seat the tongue of the

windshield panel fully into the side seams in the corner beams. Install the M6 bolts to secure the windshield to the corner beams. Install the T handles for the upper window and adjust the nylock nuts for smooth operation. The inside tongue fits in the track of frame.

LOWERWINDSHIELD PANEL


SETTING THE DOORS

1 Note: Leave the cab bolts loose to permit adjstment of the margins for the doors.

2 Install the door headers and fit the gasket to them. 3 Install the hinges on each side and leave them finger tight

to permit adjustment of the gap on the edges of the doors. 4 Set the doors on the hinges to check for height and clear-

ance. There should be 1/8” clearance around the door. A paint stick works well as a spacer dur-ing adjustment.

5 Adjust the hinges and rear post as needed. The hinge plates have adjustment range in each di-rection. Adjust the rear post and tighten the bolt to the floorboard. The door strike can also be ad-justed by bending it open to meet the latch.

6 Once the door is aligned in the frame, tighten the hinge plates.

Vinyl Closeout Installation

Install the rollup rear window behind the front seat. It is secured by velco to the top and sides. Straps at the lower corners secure it to the grabrail. It can be rolled up to the inside of the front compartment or removed when not in use. Lower the seatback and slide the top of the rear closeout into the channel at the back of the roof. Snap it around the air vents on each roll bar and around the grab handles under the bed. Position the side panels inside the seatbelts and secure with the pvc clamps around the diagonal roll bars. Pull the seatbelt through the flap. Remove when the unit is configured with a long bed.


Finishing the Installation • Replacew the battery cover • Check and tighten all fasteners • Install roll cage gaskets, oval shaped holes, at the top of the windshield on the inside. • Install the windshield wiper with the arm aligned with the top left of rthe upper window.

This will allow the window to open without deflecting the arm. • See page 7 for additional accessory installation


COOLING DEFROST FAN Mount the fan to the top passenger wind-shield. Ground the ring terminal to the cab and connect the +12v lead to the roof har-ness. Alternatively, the fan can be mounted on top of the dash on either the driver ./or passenger side.

STANDARD CAB ACCESSORIES

Optional Cab Accessories: The following section includes installation instructions for accessories that may have been included in your Cab enclosure package.

REARVIEW MIRROR The heavy duty wide angle mirror can be bolted to the channel inside the roof with the self tapping Tek screws provided; Or, it can be mounted to the windshield frame above the Driver’s side

BREAKAWAY EXTERIOR MIRRORS

Using the mounting template, Drill two 1/4” holes in front of the hinge on the driver’s quarterpanel and fasten the arm with the M6 bolts. DO NOT OVER-TIGHTEN. Mount the right mirror arm on the door as shown. Drill two 1/4” holes with the tem-plate and fasten to the door.

MOLDED FLOORMAT The one piece molded floor-mat features a non skid sur-face and 1/2” thickness for comfort and insulation. I

ACCESSORY HARNESS The roof has a wiring harness preinstalled at the factory. Together with the fuse panel this will save time in installa-tion and servicing of powered accessories. • Connect the 4-way female connector to the male con-

nector in the headliner. Route the loom down the left rear post into the compartment under the seat. Secure with cable ties.

• Mount the fuse block to the side panel next to the bat-tery compartment, with the Tek screws provided. Insert the male bullet connector to the brown wired female bullet. , This +12v is keyed to the ignition switch. Attach the ring terminal to + battery terminal for a constant power source.

WINDSHIELD WIPER • Install the windshield wiper through the hole provided in the windshield for the shaft and with the #10 screw and bolt. The small bolt makes the ground for the motor; be sure it is tightened to make contact. Attach the roof har-ness spade connector to the motor. • Operate the motor and turn it off in the left most posi-tion of travel. • With the shaft in the left most position, set the arm along the top left edge of the window. • The arm is adjustable in length. Pivot the lever under the joint in the arm and

to set the arm length to best cover the windshield. The wiper s set for 120 degree sweep. • To permit the windshield to open without wiper interference, stop the motor when the arm is at the full left

sweep position. The arm will then be out of the way when the lift windshield is opened


CAB CARTON #1 HARDTOP & WLT

FRONT QTR PANELS, LEFT & RIGHT FRONT QTR MOUNTING BRACKETS, L & R MAIN HARDTOP WITH DOME LIGHT SLIDING REAR HARDTOP, DRAWER SLIDES FRONT VISOR LOWER WINDSHIELD ASSEMBLY LOWER WINDSHIELD CLOSEOUT BRACKETS LIFT WINDSHIELD PANEL W/GAS PROPS

3000T1/2CAB SMALL PARTS BAG #1 • HARDTOP/ WLT BOLT KIT 21 - 6MM X 12MM HEX SERRATED BOLTS & FLAT WASHERS 12 - 6MM HEX FLANGE NUTS FOUR 6 X 25 MM CAP HEAD BOLTS FOR THE FRONT MOUNTING BRACKETS 2 "SWELL" CAM LATCHES FOR SECURING THE LOWER WINDSHIELDPANEL TO THE UPPER FRAME 2 PLASTIC “U” CLIPS FOR SECURING THE ENDS OF THE LOWER HOOD GASKET • ACCESSORY HARNESS & 4 FUSE BLOCK • 2 DRAWER SLIDES FOR THE REAR SECTION • 2 WEB STRAPS W/WING BOLTS FOR SLIDER HOLD

DOWN • 2 ADHESIVE GASKETS (OVAL) FOR WINDSHIELD TO

ROLL CAGE CLOSEOUT • SPARE PARTS KIT, FASTENERS AND FUSES • T HANDLES FOR THE SAFARI LIFT WINDSHIELD

CAB CARTON #2 CABUPGD

FRONT DOOR HEADER PANELS, L & R MID QTR PANELS, LEFT & RIGHT FLOORBOARDS, L & R REAR CLOSEOUT PANEL, BLACK VINYL REAR VINYL ROLLUP WINDOW THREE REAR SEAT CLOSEOUT PANELS

3000TCABUPGD SMALL PARTS BAG #2 ⇒ WINDSHIELD WIPER KIT{MOTOR, ARM, BLADE & FASTENE R

⇒ 4 MOUNTING BRACKETS FOR THE EXTENDED FLOOR

BOARDS ⇒ TWO “L” BRACKETS FOR SECURING THE BOTTOM OF THE

MID DOOR PANELS ♦ 10 - 8MM HEX BLOTS & NUTS AND 4 - 5/16” CARRIAGE

BOLTS & NUTS FOR FLOOR BOARDS. ♦ TEN 6MM NUTS, BOLTS & WASHERS FOR DOOR HEADERS

AND QTR PANELS ♦ FOUR 6MM TRUSS HEAD BOLTS, NUTS AND WASHERS

FOR THE TOP OF THE MID DOOR PANELS. NOTE RE-CESSED ALLEN DRIVE

OPTIONAL ACCESSORIES DOORS, L & R W/ 2 KEYS AND HINGES

⇒ FRONT AND REAR STEEL DOORS W/SLIDER WINDOW ⇒ MARINE VINYL COVERED DOORS W/ZIPPERED WINDOW

FONT & REAR

CAB PACKAGE: ♦ DEFROSTER FAN ♦ FLOORMAT ♦ EXTERNAL MIRRORS, LEFT - RIGHT ♦ REAR VIEW MIRROR

ROOF MOUNT DIGITAL RADIO, CASSETTE OR CD, SPEAKERS GAUGE PKG - OIL & VOLTMETER TURN SIGNALS – 2 & 4 WAY BACKUP ALARM STROBE LIGHT, 70 FPM BEACON 70 AMP ALTERNATOR, GUN RACKS VISOR LIGHTBAR, SPOTLIGHT & BEDLIGHTS

P .O . B o x 9 2 8 6 4 S o u th la k e , T X 7 6 0 9 2

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