Form No. 3405-283 Rev A Windshield Washer Fluid Kit 2015 and after Workman® GTX/HDX/MD/HD Series Utility Vehicle Model No. 130-5615 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. Installation Loose Parts Use the chart below to verify that all parts have been shipped.
Description Washer-fluid tank Tank-support bracket (216 x 95 mm (8-1/2 x 3-3/4) with 90° flange) Carriage bolt (5/16 x 3/4 inch) Flanged locknut (5/16 inch) Hose (3/16 inch) Barbed hose connector Wire harness Push fastener Cable tie Use Qty. 1 1 2 2 1 1 1 3 1 Install the windshield washer fluid kit (MD-series models). Installing the Windshield Washer Fluid Kit Preparing the Machine 1. Park the machine on a level surface and set the parking brake. For GTX-Series Models 2.
Installing the Washer-Fluid Tank Routing and Connecting the Hose For Machine without the Storage Box Kit Installed 1. Raise the machine with jack stands. 1. Install the washer-fluid tank to the washer-fluid-tank bracket with the 4 carriage bolts (5/16 x 3/4 inch) and 4 flange nuts (5/16 inch) as shown in Figure 2. 2. Connect the female straight fitting to the cab hose and the male straight fitting to the kit hose (Figure 4). Figure 4 1. Cab hose 3. Male straight fitting 2.
Connecting the Hose to the Pump 1. At the washer-fluid tank, align the end of the hose to the barbed fitting in the washer pump (Figure 8). Figure 6 1. Frame channel 2. Floor-channel plate 3. Kit hose Figure 8 5. Route the kit hose through the opening in the top of the frame channel (Figure 7). 1. Hose 3. Washer-pump motor 2. Barbed fitting 2. Push the hose onto the fitting until the hose fully seats onto the fitting (Figure 8). Note: If the hose is too long, shorten it.
Connecting the Kit Wire Harness to the Washer Pump 1. Align the 2-socket connector of the wire harness to the 2-blade connector of the washer pump (Figure 12). 2. Push the wire-harness connector onto the pump until the connector fully seats (Figure 12). Figure 10 1. Frame channel 3. Floor-channel plate 2. Kit wire harness 3. Route the kit wire harness through the opening in the top of the frame channel (Figure 11). Figure 12 1. 2-socket connector (wire harness) 2.
Installing the Windshield Washer Fluid Kit For HD-Series Models Removing the Roof Panel Roof panel weight: 9.5 kg (21 lb) 1. Remove the 10 bolts (1/4 x 1 inch) and 10 sealing washers (1/4 inch) that secure the roof panel to the roof-support brackets of the cab (Figure 13). Figure 14 2. Plug 1. Overhead console Note: Retain the bolts and washers for installation of the roof panel in Installing the Overhead Console Plug and the Roof Panel (page 11). Installing the Washer-Fluid Tank 1.
Figure 18 Figure 16 1. Holes—6.3 mm (1/4 inch) 4. Use an awl or punch to open a hole through the interior foam panel (Figure 17) at the hole locations that you identified in step 3. 1. Carriage bolt (1/4 x 1-1/4 inches) 3. Spacer (1/4 inch) 2. Strap 4. Hole location 6.3 mm (1/4 inch)—interior foam panel 6. Assemble the tank-support bracket and washer-fluid tank (Figure 19) onto the 2 carriage bolts (1/4 x 1-1/4 inches) with the 2 flanged locknuts (1/4 inch).
Connecting the Hose to the Wiper 3. Route the free end of the hose into the opening at the top of the driver’s side pillar B of the cab frame, and down through the frame (Figure 22). 1. At the overhead console, route 1 end of the hose (3/16 inch) through the hole in the overhead console (Figure 20). Note: Use a stiff piece of wire, about 173 cm (68 inch) long, to pull (fish) the hose through pillar B of the cab frame. Figure 20 1. Hole (overhead console) 4. Barbed hose fitting 2. Bulb seal 5.
Connecting the Wire Harness at the Overhead Console Connecting the Hose to the Pump 1. At the washer-fluid tank, align the end of the hose to the barbed fitting in the washer pump (Figure 24). 1. At the overhead console, route the 2-pin connector end of the wire harness for the washer pump through the hole in the overhead console (Figure 25). Figure 24 1. Washer-pump motor 3. Hose 2. Barbed fitting 2. Push the hose onto the fitting until the hose fully seats onto the fitting (Figure 24).
Routing the Wire Harness 4. Route the wire harness for the washer pump across the back of the cab, and aligned to the 2-blade connector in the washer-pump motor (Figure 28). 1. At the overhead console, route the wire harness for the washer pump (Figure 26) to the left and along side of the hose installed in Routing the Hose (page 8). Figure 26 1. Washer pump wire harness 2. Hole (overhead console) 4. Pillar B (cab frame) Figure 28 5. Front of the machine 3. Bulb seal 2.
Securing the Wire Harness and Hose 5. Install 3 push fasteners at the location where you removed the push fasteners in step 4 (Figure 30 and Figure 31). 1. Remove the 2 harness clips that secure the cab wire harness to the front, left cab frame (Figure 30). 6. Secure the washer-pump harness and hose with the cable-tie portion of the push fasteners. 7. At the back of the cab, install 3 push fasteners into the 3 hole across the back panel of the cab (Figure 32). Figure 30 1. Push fasteners 2.
Installing the Windshield Washer Fluid Kit Installing the Washer-Fluid Tank 1. Assemble the washer-fluid tank to the tank-support bracket with the 2 carriage bolts (5/16 x 3/4 inch) and 2 flanged locknuts (5/16 inch) as shown in Figure 35. For MD-Series Models Removing the Roof Panel Roof-panel weight: 9.5 kg (21 lb) 1. Remove the 10 bolts (1/4 x 1 inch) and 10 sealing washers (1/4 inch) that secure the roof panel to the roof-support brackets of the cab (Figure 33).
Connecting the Hose to the Wiper 1. At the overhead console, route 1 end of the hose (3/16 inch) through the hole in the overhead console (Figure 38) Figure 38 Figure 36 1. Left headlight 3. Lower headlight support 2. Flanged-head bolts (1/4 x 5/8 inch) 4. Front of the machine 1. Hole (overhead console) 4. Barbed hose fitting 2. Bulb seal 5. Hose (wiper arm) 3. Hose (3/16 inch) 2.
Connecting the Hose to the Pump down to the hole at the bottom of the pillar (Figure 39 and Figure 40). 1. At the washer-fluid tank, if needed, cut the hose to remove excess hose length. Note: The hole is about level with the midpoint in the dash 2. Align the end of the hose to the barbed fitting in the washer pump (Figure 42). Note: Use a stiff piece of wire, about 130 cm (51 inch) long, to pull the hose through pillar A of the cab frame. 3.
Routing the Wire Harness Connecting the Wire Harness at the Overhead Console 1. At the overhead console, route the wire harness for the washer pump (Figure 44) to the left and along side of the hose installed in Routing the Hose (page 13). 1. At the overhead console, route the 2-pin connector end of the wire harness for the washer pump through the hole in the overhead console (Figure 43). Figure 44 1. Overhead console 3. Pillar A (driver’s side) 2. Washer pump wire harness 2.
Figure 45 1. Hole—pillar A (driver’s side) 3. Fender 2. Washer pump wire harness 4. Electrical mounting plate Figure 46 1. 2-socket connector (washer pump wire harness) 4. Electrical mounting plate 2. Washer pump wire 5. Fender harness 3. 2-blade connector (washer 6. Front of the machine pump) 3. Route the wire harness forward, between the electrical mounting plate and the fender to the machine (Figure 45 and Figure 46). 4.
Securing the Wire Harness 1. Remove the 2 harness clips that secure the cab wire harness to the front, left cab frame (Figure 48). Figure 48 1. Harness clips 2. Cab frame 2. Install 2 push fasteners at the location where you removed the harness clips in step 1 (Figure 48 and Figure 49). Figure 50 1. Harness clip 4. Wire harnesses (cab harness and washer-pump harness) 2. Hose 3. Hole (lower, forward cab panel) 5. Push fastener 5.
Installing the Overhead-Console Plug and the Roof Panel 1. Align the plug that you removed in step 3 of Removing the Roof Panel (page 12) with the top opening of the overhead console (Figure 34). 2. Push the plug down into the overhead console until it fully seats (Figure 34). 3. Align the holes in the roof panel with the clip nuts on the brackets of the cab frame (Figure 33). 4.
Operation Using the Windshield Washer Using the Wiper/Washer Control • Push the wiper/washer switch up to run the windshield wipers (Figure 52). Figure 53 Figure 52 1. Wiper On 4. Wiper/washer switch 2. Washer On (momentary) 5. Overhead console 1. Cap 3. 25 mm (1 inch) fill level 2. Filler neck (washer tank) 4. Water or windshield-washer fluid 3. Add water or windshield-washer fluid through the filler neck of the tank to within 25 mm (1 inch) of the top of the tank (Figure 53). 3.
Declaration of Incorporation Model No. 130-5615 Serial No. Product Description Invoice Description General Description Directive None and Up Windshield Washer Fluid Kit, 2015 and after Workman GTX/HDX/MD/HD Series Utility Vehicle WASHER FLUID KIT [WORKMAN] 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.
