Windshield Washer Fluid Kit

If you have the Storage Box Kit installed, discard the washer bottle bracket mount.

1. Install the washer-fluid tank to the storage box with the 4 flange-head screws (1/4 x 5/8 inch) and the 4 locknuts (1/4 inch) as shown in Figure 1.

   

   Figure 1

   1. Storage box
   2. Flange-head (1/4 x 5/8 inch)
   3. Locknut (1/4 inch)
   4. Washer-fluid tank

2. Torque the locknuts to 1017 to 1243 N∙cm (90 to 110 in-lb).

1. Install the washer-fluid tank to the washer bottle bracket mount with the 4 carriage bolts (5/16 x 3/4 inch) and 4 locknuts (5/16 inch) as shown in Figure 2.

   

   Figure 2

   1. Locknut (5/16 inch)
   2. Washer-fluid tank
   3. Washer bottle bracket mount
   4. Carriage bolt (5/16 x 3/4 inch)

2. Torque the flange nuts (5/16 inch) to 1,987 to 2,542 N∙cm (175 to 225 in-lb).

3. Install the washer bottle bracket mount to the dash reinforcement with the 2 flange-head screws (1/4 x 5/8 inch) and 2 locknuts (1/4 inch) as shown in Figure 3.

   

   Figure 3

   1. Washer bottle bracket mount
   2. Dash reinforcement
   3. Flange-head screw (1/4 x 5/8 inch)
   4. Locknut (1/4 inch)

4. Torque the locknuts (1/4 inch) to 1,017 to 1,243 N∙cm (90 to 110 in-lb).

1. Raise the machine with jack stands.

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
   2. Female straight fitting
   3. Male straight fitting
   4. Kit hose

3. Connect the female straight fitting on the kit hose to the male straight fitting on the cab hose (Figure 5).

   

   Figure 5

   1. Female straight fitting
   2. Male straight fitting

4. Route the kit hose along the floor-channel plate and through the opening in frame channel (Figure 6).

   

   Figure 6

   1. Frame channel
   2. Floor-channel plate
   3. Kit hose

5. Route the kit hose through the opening in the top of the frame channel (Figure 7).

   

   Figure 7

   1. Frame channel
   2. Kit hose

6. Secure the kit hose along the frame channel and as necessary.

7. Connect the kit to the pump; refer to 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 8

   1. Hose
   2. Barbed fitting
   3. Washer-pump motor

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.

1. Connect the male connector on the kit wire harness to the female connector on the cab wire harness (Figure 9).

   

   Figure 9

   1. Cab wire harness
   2. Female connector
   3. Male connector
   4. Kit wire harness

2. Route the kit wire harness along the floor-channel plate and through the opening in frame channel (Figure 10).

   

   Figure 10

   1. Frame channel
   2. Kit wire harness
   3. Floor-channel plate

3. Route the kit wire harness through the opening in the top of the frame channel (Figure 11).

   

   Figure 11

   1. Frame channel
   2. Kit wire harness

4. Secure the kit wire harness along the frame channel and as necessary.

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 12

   1. 2-socket connector (wire harness)
   2. 2-blade connector (washer pump)

1. Connect the negative-battery cable; refer to your Operator’s Manual.

2. Lower the cargo box and close the hood; refer to your Operator’s Manual.

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).

   Note: Retain the bolts and washers for installation of the roof panel in Installing the Overhead Console Plug and the Roof Panel.

   

   Figure 13

   1. Bolt (1/4 x 1 inch)
   2. Sealing washer (1/4 inch)
   3. Roof-support bracket
   4. Roof panel

2. Lift the roof panel straight up and remove it from the cab of the machine.

   Note: Be careful when you set the roof panel down to avoid damaging the surface and edges of the panel.

3. Remove the plug from the overhead console (Figure 14).

   

   Figure 14

   1. Overhead console
   2. Plug

1. Assemble the washer-fluid tank to the washer bottle bracket-mount with the 2 carriage bolts (5/16 x 3/4 inch) and 2 locknuts (5/16 inch) as shown in Figure 15.

   

   Figure 15

   1. Carriage bolt (5/16 x 3/4 inch)
   2. Hole—square (tank support bracket for HD-series)
   3. Hole (washer fluid tank)
   4. Locknut (5/16 inch)

2. Torque the locknuts to 1,987 to 2,542 N∙cm (175 to 225 in-lb).

3. Locate the 2 holes 6.3 mm (1/4 inch) at the center of the rear panel of the cab (Figure 16).

   Note: The holes are spaced apart 178 mm (7 inches).

   

   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.

   Note: Use caution when working with sharp awl or punch.

   

   Figure 17

   1. Hole locations 6.3 mm (1/4 inch)—interior foam panel
   2. Awl or punch

5. Assemble the 2 carriage bolts (1/4 x 1-1/4 inches), strap, and 2 spacers (1/4 inch) to the holes that you made in the interior foam panel (Figure 18).

   

   Figure 18

   1. Carriage bolt (1/4 x 1-1/4 inches)
   2. Strap
   3. Spacer (1/4 inch)
   4. Hole location 6.3 mm (1/4 inch)—interior foam panel

6. Assemble the washer bottle bracket mount and washer-fluid tank (Figure 19) onto the 2 carriage bolts (1/4 x 1-1/4 inches) with the 2 locknuts (1/4 inch).

   

   Figure 19

   1. Carriage bolt (1/4 x 1-1/4 inches)
   2. Hole (washer bottle bracket mount)
   3. Locknut (1/4 inch)

7. Torque the flanged locknuts to 1,017 to 1,243 N∙cm (90 to 110 in-lb).

1. At the overhead console, route 1 end of the hose through the hole in the overhead console (Figure 20).

   

   Figure 20

   1. Hole (overhead console)
   2. Bulb seal
   3. Hose
   4. Barbed hose fitting
   5. Hose (wiper arm)

2. Insert the small end of the barbed hose fitting into the end of the hose from the wiper arm until the fitting fully seats (Figure 20).

3. Insert the large end of the barbed hose fitting to the end of the hose until the fitting fully seats (Figure 20).

1. Route the hose to the left of the overhead console along the bulb seal at the front of the cab frame (Figure 21).

   

   Figure 21

   1. Hose
   2. Hole (overhead console)
   3. Bulb seal
   4. Pillar B (cab frame)
   5. Front of the machine

2. Route the hose rearward along the left frame channel of the cab (Figure 21).

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).

   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 22

   1. Hose
   2. Pillar B (cab frame)

4. Route the free end of the hose across the back of the cab, and align the hose with the barbed fitting in the washer pump (Figure 23).

   

   Figure 23

   1. Front of the machine
   2. Hose
   3. Barbed fitting (washer pump)

1. At the washer-fluid tank, align the end of the hose to the barbed fitting in the washer pump (Figure 24).

   

   Figure 24

   1. Washer-pump motor
   2. Barbed fitting
   3. Hose

2. Push the hose onto the fitting until the hose fully seats onto the fitting (Figure 24).

   Note: If the hose is too long, shorten it in step 9 of Securing the Wire Harness and Hose.

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 25

   1. Hole (overhead console)
   2. 2-socket connector (cab wire harness)
   3. Washer pump wire harness
   4. 2-pin connector (washer pump wire harness)

2. Align the 2-pin connector of the washer pump wire harness to the 2-socket connector of the cab wire harness (Figure 25).

3. Push the 2 connectors together until the connector lock snaps secure (Figure 25).

4. Route the 2-socket connector of the wire harness for the washer pump to the left of the overhead console along the bulb seal at the front of the cab frame (Figure 25).

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.

   

   Figure 26

   1. Washer pump wire harness
   2. Hole (overhead console)
   3. Bulb seal
   4. Pillar B (cab frame)
   5. Front of the machine

2. Route the wire harness rearward along the left frame channel of the cab (Figure 26).

3. Route the 2-socket connector of the wire harness into the opening at the top of the driver’s side pillar B of the cab frame and down through the frame (Figure 27).

   Note: Use a stiff piece of wire, about 173 cm (68 inch) long, to pull the wire harness through pillar B of the cab frame.

   

   Figure 27

   1. Washer pump wire harness
   2. Pillar B (cab frame)

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).

   

   Figure 28

   1. Front of the machine
   2. Pillar B (cab frame)
   3. Washer pump wire harness
   4. 2-blade connector (washer-pump motor)
   5. 2-socket connector (washer pump wire harness)

1. Align the 2-socket connector of the wire harness to the 2-blade connector of the washer pump (Figure 29).

   

   Figure 29

   1. 2-blade connector (washer pump)
   2. 2-socket connector (washer pump wire harness)

2. Push the wire-harness connector onto the pump until the connector fully seats (Figure 29).

1. Remove the 2 harness clips that secure the cab wire harness to the front, left cab frame (Figure 30).

   

   Figure 30

   1. Push fasteners
   2. Harness clips
   3. Bulb seal

2. Install 2 push fasteners at the location where you removed the harness clips in step 1 (Figure 30 and Figure 31).

   

   Figure 31

   1. Hole (seal mount)
   2. Push fasteners

3. Secure the cab harness, washer-pump harness, and hose with the cable tie portion of the push fasteners (Figure 31).

   Note: Tighten the cable tie only snug. Do not pinch or collapse the hose.

4. Remove the 3 push fasteners above the driver’s door frame (Figure 30).

5. Install 3 push fasteners at the location where you removed the push fasteners in step 4 (Figure 30 and Figure 31).

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 32

   1. Hole (back cab panel)
   2. Push fasteners

8. Secure the washer-pump harness and hose with the cable tie portion of the push fasteners.

9. If needed, shorten the hose as follows:

   1. At the washer fluid tank, remove the hose from the barbed fitting at the pump (Figure 24).

   2. Cut the hose to remove the excess hose length.

   3. Push the hose onto the fitting until the hose fully seats onto the fitting (Figure 24).

1. Align the plug that you removed in step 3 of Removing the Roof Panel with the top opening of the overhead console (Figure 14).

2. Push the plug down into the overhead console until it is seated (Figure 14).

3. Align the holes in the roof panel with the clip nuts at the brackets of the cab frame (Figure 13).

4. Assemble the roof panel to the cab frame with the 10 bolts (1/4 x 1 inch) and 10 sealing washers (1/4 inch) as shown in Figure 13 that you removed in step 1 of Removing the Roof Panel.

5. Torque the bolts to 520 to 678 N∙cm (41 to 55 in-lb).

1. Connect the negative-battery cable; refer to your Operator’s Manual.

2. Lower the cargo box; refer to your Operator’s Manual.

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).

   Note: Retain the bolts and washers for installation of the roof panel in Installing the Overhead-Console Plug and the Roof Panel.

   

   Figure 33

   1. Bolt (1/4 x 1 inch)
   2. Sealing washer (1/4 inch)
   3. Roof-support bracket
   4. Roof panel

2. Lift the roof panel straight up and remove it from the cab of the machine.

   Note: Be careful when you set the roof panel down to avoid damaging the surface and edges of the panel.

3. Remove the plug from the overhead console (Figure 34).

   

   Figure 34

   1. Overhead console
   2. Plug

1. Assemble the washer-fluid tank to the washer bottle mount bracket with the 2 carriage bolts (5/16 x 3/4 inch) and 2 locknuts (5/16 inch) as shown in Figure 35.

   

   Figure 35

   1. Carriage bolt (5/16 x 3/4 inch)
   2. Hole—square (tank support bracket for MD-series models)
   3. Hole (washer bottle mount bracket)
   4. Locknut (5/16 inch)

2. Torque the locknuts to 1,987 to 2,542 N-cm (175 to 225 in-lb).

3. At the lower headlight support, remove the 2 hex washer head bolts (1/4 x 7/8 inch), inboard of the right headlight, that secures the headlight brackets to the headlight (Figure 36).

   Note: Retain the 2 hex washer head bolts (1/4 x 7/8 inch) for installation of the washer-fluid tank and washer bottle mount bracket.

   

   Figure 36

   1. Bumper support bracket
   2. Hex washer head bolts (1/4 x 7/8 inch)
   3. Front of machine
   4. Right headlight

4. Align the holes in the washer bottle mount bracket with the holes in the lower headlight support (Figure 37).

   

   Figure 37

   1. Hex washer head bolts (1/4 x 7/8 inch)
   2. Hole (tank-support bracket—MD-series models)
   3. Hole (lower headlight support)

5. Assemble the tank-support bracket to the lower headlight support with the 2 hex washer head bolts (1/4 x 7/8 inch) that were removed in step 3 (Figure 37).

6. Torque the 2 bolts to 79 to 147 N∙cm (7 to 13 in-lb).

1. At the overhead console, route 1 end of the hose through the hole in the overhead console (Figure 38)

   

   Figure 38

   1. Hole (overhead console)
   2. Bulb seal
   3. Hose
   4. Barbed hose fitting
   5. Hose (wiper arm)

2. Insert the small end of the barbed hose fitting into the end of the hose from the wiper arm until the fitting fully seats (Figure 38).

3. Insert the large end of the barbed hose fitting to the end of the hose until the fitting fully seats (Figure 38).

1. Route the hose to the left of the overhead console along the bulb seal at the front of the cab frame (Figure 39).

   

   Figure 39

   1. Hose
   2. Hole (overhead console)
   3. Bulb seal
   4. Pillar A (driver’s side)
   5. Front of the machine

2. Route the free end of the hose into the opening at the top of pillar A (driver’s side) of the cab frame and down to the hole at the bottom of the pillar (Figure 39 and Figure 40).

   Note: The hole is about level with the midpoint in the dash

   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. Route the free end of the hose forward, between the fender and the steering column (Figure 40 and Figure 41).

   

   Figure 40

   1. Hole—pillar A (driver’s side)
   2. Hose
   3. Fender
   4. Steering column
   

   Figure 41

   1. Steering column
   2. Washer-fluid tank
   3. Master cylinder
   4. Hose
   5. Fender

4. Route the free end of the hose inboard toward the washer-fluid tank (Figure 41).

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 42).

   

   Figure 42

   1. Hole (overhead console)
   2. 2-socket connector (cab wire harness)
   3. Washer pump wire harness
   4. 2-pin connector (washer pump wire harness)

2. Align the 2-pin connector of the washer pump wire harness to the 2-socket connector of the cab wire harness (Figure 42).

3. Push the 2 connectors together until the connector secures (Figure 42).

4. Route the 2-socket connector of the wire harness for the washer pump to the left of the overhead console along the bulb seal at the front of the cab frame (Figure 42).

1. At the overhead console, route the wire harness for the washer pump (Figure 43) to the left and along side of the hose installed in Routing the Hose.

   

   Figure 43

   1. Overhead console
   2. Washer pump wire harness
   3. Pillar A (driver’s side)

2. Route the 2-socket connector of the wire harness into the opening at the top of pillar A (driver’s side) of the cab frame and down to the hole at the bottom of the pillar (Figure 44).

   Note: Use a stiff piece of wire, about 130 cm (51 inch) long, to pull the wire harness through pillar A of the cab frame.

   

   Figure 44

   1. Hole—pillar A (driver’s side)
   2. Washer pump wire harness
   3. Fender
   4. Steering column

3. Route the wire harness forward, between the fender and the steering column (Figure 44 and Figure 45).

4. Route the wire harness for the washer pump inboard toward the washer-fluid tank, and align the harness with the 2-blade connector on the washer-pump motor (Figure 45).

   

   Figure 45

   1. 2-socket connector (washer pump wire harness)
   2. Washer pump wire harness
   3. Steering column
   4. Fender
   5. Master cylinder
   6. 2-blade connector (washer pump)

1. Align the 2-socket connector of the wire harness for the washer pump to the 2-blade connector of the washer pump (Figure 46).

   

   Figure 46

   1. 2-blade connector (washer pump)
   2. 2-socket connector (washer pump wire harness)

2. Push the wire-harness connector onto the pump until the connector fully seats (Figure 46).

1. Remove the 2 harness clips that secure the cab wire harness to the front, left cab frame (Figure 47).

   

   Figure 47

   1. Harness clips
   2. Cab frame

2. Install 2 push fasteners at the location where you removed the harness clips in step 1 (Figure 47 and Figure 48).

   

   Figure 48

   1. Push fastener
   2. Hole (cab frame)

3. Secure the cab harness, washer-pump harness, and hose with the cable tie portion of the push fasteners (Figure 48).

   Note: Tighten the cable tie only snug. Do not pinch or collapse the hose.

4. Remove the harness clip that secures the cab wire harness to the lower forward-cab panel at the driver’s side of the machine (Figure 49).

   

   Figure 49

   1. Harness clip
   2. Hose
   3. Hole (lower, forward cab panel)
   4. Wire harnesses (cab harness and washer-pump harness)
   5. Push fastener

5. Install a push fastener at the location where you removed the harness clip in step 4 (Figure 49).

6. Secure the cab harness, washer-pump harness, and hose with the cable tie portion of the push fastener (Figure 49).

7. Coil the excess washer-pump harness (Figure 50), and secure the coiled harness and hose with a cable tie.

   

   Figure 50

   1. Hose
   2. Washer pump harness (coiled)
   3. Cable tie
   4. Fender
   5. Master cylinder

1. Align the plug that you removed in step 3 ofRemoving the Roof Panel 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. Assemble the roof panel to the cab frame with the 10 bolts (1/4 x 1 inch) and 10 sealing washers (1/4 inch) as shown in Figure 33 that you removed in step 1 of Removing the Roof Panel.

5. Torque the bolts to 520 to 678 N∙cm (41 to 55 in-lb).

1. Connect the negative-battery cable; refer to your Operator’s Manual.

2. Lower the cargo box and close the hood; refer to your Operator’s Manual.

• Push the wiper/washer switch up to run the windshield wipers (Figure 51).

  

  Figure 51

  1. Wiper On
  2. Washer On (momentary)
  3. Wiper Off
  4. Wiper/washer switch
  5. Overhead console

• Push the wiper/washer switch down to stop the windshield wipers (Figure 51).

• Momentarily push in the upper half of the wiper/washer switch to spray the washer fluid onto the windshield (Figure 51).

1. Access the washer tank as follows:

   • For HD-series Workman machines, raise the cargo bed and place the safety support on the lift cylinder; refer to your Operator’s Manual.

   • For GTX-series and MD-series Workman machines, raise the hood; refer to your Operator’s Manual.

2. Remove the cap from the washer tank (Figure 52).

   

   Figure 52

   1. Cap
   2. Filler neck (washer tank)
   3. 25 mm (1 inch) fill level
   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 52).

   Note: In climates where freezing temperatures occur, use all season (ethanol type) windshield-washer fluid.

4. Install the cap onto the filler neck securely (Figure 52).

5. Prepare the machine for operation as follows:

   • HD-series Workman machines— Remove the safety support from the bed lift cylinder, stow the safety support, and lower the bed; refer to your Operator’s Manual.

   • GTX-series and MD-series Workman machines—Lower the hood and secure it with the hood latches; refer to your Operator’s Manual.