Toro 137-1019 User manual

FormNo.3423-453RevA
WaterSealKit
Workman®HDXandHDX-AutoUtilityVehicleCabKit
ModelNo.137-1019
InstallationInstructions
Installation
MediaandAdditionalParts
DescriptionQty.Use
CVT-intakehoodassembly(Workman
HDX-Automachinesonly)1InstallingtheCVT-intakehoodassembly.
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Raiseorremovethebedfromthemachine(if
equipped).
Note:RefertothemachineOperator’sManual
formoredetailedinformationonraisingand
removingthebed.
4.Shutofftheengineandremovethekey.
5.Disconnectthebattery;refertotheOperator’s
Manual.
Note:Disconnectthenegativeterminalrst.
6.Whilegraspingthehoodintheheadlight
openings,liftuponthehoodtoreleasethelower
mountingtabsfromtheslotsinthebumper
(Figure1).
g010314
Figure1
1.Hood
7.Pivotthebottomofthehoodupwarduntilyou
canpullthetopmountingtabsfromtheframe
slots(Figure1).
8.Pivotthetopofthehoodforwardandunplugthe
wireconnectorsfromtheheadlights(Figure1).
9.Removethehood.
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8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3423-453*A

2
RemovingandPreparing
theCab
NoPartsRequired
Procedure
1.Holdthecabframeusingtheliftingpointsand
removethehardwaresecuringthecabtothe
machine.
g026247
Figure2
1.Liftingpoints
2.Liftthecaboffofthemachine.
3.Locatetheleftandrightframepanels.
g253023
Figure3
1.3/4inch2.3/4inch
4.Cuta3/4inchnotchoneachsideofthepanel
asshowninFigure3).
5.Removetheroofofthecabandremovethe
partsofthewiperassembly(Figure4).
Note:Savethesepartstobeinstalledagain
later.
g253075
Figure4
6.Addsealanttotheseamsofthecab(Figure5).
g253027
Figure5
7.Addsealanttotheseamsofthewipermount
(Figure6andFigure7).
2

g253028
Figure6
g253029
Figure7
3
InstallingtheWiperMount
Assembly
Partsneededforthisprocedure:
1Wipermountassembly
1Wipermountassemblyfoam
2Carriagebolt(5/16-18x3/4inch)
2Nut(5/16inch)
3Hex-headbolt(5/16-18x3/4inch)
2Bolt(1/4-20x1/2inch)
2Nut(1/4inch)
Procedure
1.Installthewipermountontothecabframeusing
2carriagebolts(5/16-18x3/4inch),2nuts(5/16
inch),and3hexheadbolts(5/16-18x3/4inch)
asshowninFigure9.
g253033
Figure8
3

g253032
Figure9
1.Nut(5/16inch)3.Hexheadbolts(5/16-18x
3/4inch)
2.Carriagebolts(5/16-18x
3/4inch)
2.Markthesidelocationsontothecabframetobe
drilledasshowninBoxCofFigure9.
3.Removethehardwaresecuringthewipermount
ontothecabframe(Figure10).
g253031
Figure10
4.Drillaholeintotheframeusinga19/64inchdrill
bit(Figure10).
5.Cutanotchintobothsidesofthemotormount
tabsasshowninFigure11.
g253024
Figure11
1.3/16inchwide2.1/2inchdeep
4

6.Addsealanttotheinstallationlocationofthe
wipermountassembly(BoxAofFigure12).
7.Installthefoamsealontothewipermountframe
(BoxBofFigure12).
g253030
Figure12
1.Hexheadbolts(5/16-18x
3/4inch)
4.Bolt(1/4-20x1/2inch)
2.Nut(5/16inch)5.Nut(1/4inch)
3.Carriagebolt(5/16-18x
3/4inch)
8.Installthewipermountassemblyontothecab
frame(BoxCofFigure12).
9.Securethewipermountassemblyusing3hex
headbolts(5/16-18x3/4inch),2carriagebolts
(5/16-18x3/4inch),2nuts(5/16inch),2bolts
(1/4-20x1/2inch),and2nuts(1/4inch)as
showninBoxesDandEinFigure12.
4
RoutingtheWiperMotor
WireHarness
NoPartsRequired
Procedure
Routethepreviouslyremoved(step5of2Removing
andPreparingtheCab(page1))asshowninFigure
13andFigure14.
g253026
Figure13
g253011
Figure14
5

5
InstallingtheWiperMotor
Assemblies
Partsneededforthisprocedure:
1Counselmount
8Largeclipnut
8Washer
6Bolt(1/4–2x1inch)
1Roofsupport
4Smallclipnut
1Roofcounsel
4Bolt(#10)
Procedure
1.Installthewipermotor(Figure15).
g253021
Figure15
2.Install6largeclipnutsontothecounselmount
asshowninFigure16.
3.Installthecounselmountontothewipermount
using2bolts(1/4–2x1inch)and2washers
(Figure16).
g253014
Figure16
1.Bolts(1/4–2x1inch)3.Largeclipnuts
2.Washers
4.Installtheroofmountusing2bolts(1/4–2x1
inch)(Figure17).
5.Install2largeclipnutsontheroofmountas
showninFigure17.
g253018
Figure17
1.Bolt(1/4–2x1inch)3.Roofmount
2.Clipnuts,large
6.Installthefuseandgroundblocks(Figure18).
g253016
Figure18
1.Groundblock2.Fuseblock
7.Installtherooftrimsealintothetopofthecab
frame(Figure19).
Note:Installthetalledgeofthetrimsealtothe
outsideedge.
8.Usesealanttollinanygaps(Figure19).
6

g253020
Figure19
9.Install4ofthesmallclipnutsontothecounsel
frameasshowninBoxAofFigure20).
10.Securethecounselcoverontotheframeusing
2bolts(1/4–2x1inch),and4bolts(#10)as
showninBoxBofFigure20.
g253013
Figure20
1.Smallclipnuts3.Bolt(1/4–2x1inch)
2.Bolt(#10)4.Counselcover
11.Installtheremainderofthecounselassembly
previouslyremovedinstep5of2Removingand
PreparingtheCab(page1).
6
InstallingtheRoof
Partsneededforthisprocedure:
2Bolt(1/4-2-x1inch)
2Washer
Procedure
1.Installtheroofontotheframe(Figure21).
g253019
Figure21
2.Fromtheinsideofthecab,marktheouterholes
ontheroofbracket(Figure22).
g253022
Figure22
3.Removetherooffromthecabframe(Figure23).
7

g253025
Figure23
4.Drilltheholesintotheroofusinga5/16inchdrill
bit(Figure24).
g253012
Figure24
5.Installtheroofusing2bolts(1/4-2-x1inch)and
2washers(Figure25).
g253017
Figure25
7
RemovingtheCenter
ConsolePanelandSeats
NoPartsRequired
RemovingtheCenterConsole
Panel
ForWorkmanHDXMachines
1.Unscrewandremovealltheknobsfromthe
consoleleversandfromthegear-shiftlever
(Figure26).
g023161
Figure26
1.Shifterrod4.Controlrod
2.Jamnut5.Controlknob
3.Shifterhandle
2.Removethejamnutfromthegear-shiftlever
(Figure26).
3.Removethe6screwssecuringtheoutsideedge
ofthecoverplateofthecenterconsoletothe
chassisandremovethecoverplate(Figure27).
8

g023165
Figure27
1.Screw2.Coverplate
RemovingtheCenterConsole
Panel
ForWorkmanHDX-AutoMachines
1.Removealltheknobsfromtheconsolelevers
andfromthetransmissionleverbyrotatingthe
knobscounterclockwise(Figure28).
g024571
Figure28
1.Brakelever5.Transmissionlever(L
position)knob
2.Hydraulic-liftleverknob6.Hydraulic-liftlock(locked
position—left)
3.Speed-rangeleverknob7.Speed-rangelever(A
position)
4.Transmissionleverknob
2.Removethe4hex-headscrewssecuringthe
shift-indicatorcovertotheseatshroud(Figure
29).
g024588
Figure29
1.Indicatorconnector4.Controlcover
2.Shift-indicatorcover5.Machineharness
connector
3.Hex-headscrews
3.Lifttheshiftindicatorup,disconnectthe
indicatorconnectorfromthemachineharness
connector,andremovetheindicatorcoverfrom
themachine(Figure29).
4.Removethe6hex-headscrewssecuringthe
controlcovertotheseatshroud,andremovethe
controlcover(Figure29).
RemovingtheSeats
Removethe8socket-headboltssecuringtheseat
railsoftheseattothechassis,andremovetheseats
(Figure30).
g023164
Figure30
1.Socket-headbolts3.Seat
2.Seatrail
9

8
RemovingtheCVTCooling
Duct(HDX-AutoMachines
only),CoolantTank,and
SeatShroud
NoPartsRequired
RemovingtheCVTCoolingDuct
ForHDX-AutoMachinesOnly
RemovethehoseclampsecuringtheCVT-cooling
ducttotheangeoftheCVTintakeatthebackofthe
ROPSpanelonthepassengerside(Figure31).
g024791
Figure31
1.CVT-intakehose3.Intake-tubeconnector
2.Hoseclamp
RemovingtheCoolantTank
1.Liftthecoolanttankupandoutofthesupport
pocketonthebackoftheseatshroud(Figure
32).
g023166
Figure32
1.Coolanttank3.Seatshroud
2.Coolant-tankbracket
2.Setthecoolanttankuprightontothe
engine/chassis.
RemovingtheSeatShroud
ForWorkmanHDXmachines:
1.Ensurethattheparkingbrakeisengaged
(Figure33).
g023171
Figure33
1.Gear-selectorboot4.Differential-lockrod
2.Gear-selectorrod5.Hydraulic-bedliftrod
3.Parkingbrake6.High-lowrangeshifterrod
2.Movethedifferential-lockrodforwardandtothe
righttolockitintheengagedposition(Figure
33).
ForWorkmanHDX-Automachines:
10

1.Unplugtheshift-indicatorconnectorfromthe
machineharness(Figure34).
g025506
Figure34
1.Shift-indicatorconnector2.Machineharness
2.Liftandrotatethecentercontrolassemblyout
ofthewaytogainaccesstothesuspension
springs.
Bothmachines:
Lifttheseatshroudupandremoveitfromthemachine
(Figure35).
g026471
Figure35
ForWorkmanHDX-Automachines:
Removetheboltssecuringtheliftvalvetothecontrols
bracket,andthenutsandboltssecuringthecontrol
brackettothemachine(Figure36).
g027095
Figure36
1.Boltssecuringthecontrol
brackettothemachine
3.Boltssecuringthecontrol
brackettothemachine
2.Boltssecuringtheliftvalve
tothecontrolsbracket
4.Nuts
9
InstallingtheInnerFender
Partsneededforthisprocedure:
1Innerfender
2Fenderstrap
6Hex-headangebolt(1/4x3/4inch)
8Flangenut(1/4inch)
2Rubberbumper
2Washer
2Cabletie
Procedure
1.Alignthefenderstrapsatthebottomedgeofthe
seatbaseframe,andusethefenderstrapsasa
templatetomarkanddrill3holes(5/16inch)on
eachsideoftheseatbaseframe(Figure37).
11

g245709
Figure37
1.Fenderstrap2.Edgeoftheseatbase
frame
2.Installtheinnerfenderandfendersstrapsusing
6hex-headangebolts(1/4x3/4inch)and6
angenuts(1/4inch)asshowninFigure38.
g245710
Figure38
1.Innerfender3.Fenderstrap
2.Flangenut(1/4inch)4.Hex-headangebolt(1/4
x3/4inch)
3.Folddowntheapandtucktheapbehindthe
oorange(Figure39).
4.Securetheapwith2cabletiesaroundthe
centerframetube(Figure39).
g245761
Figure39
1.Cabletie2.Flaptuckedbehindthe
oorange
5.Installarubberbumperusingawasherand
angenut(1/4inch)oneachside(Figure40).
g245762
Figure40
1.Rubberbumper3.Flangenut(1/4inch)
2.Washer
12

10
InstallingtheCabMount
Brackets
Partsneededforthisprocedure:
1Leftmountassembly
1Rightmountassembly
2Adjusterbolt(3/8x2inches)
2Hexnut(3/8inch)
4Hex-angeheadbolt(3/8x1inch)
4Flangenut(3/8inch)
2Frontcabmountbracket
2Hex-headbolt(7/16inch)
2Thrustwasher
2Locknut(1/2inch)
2Rubberisolator
2Spacer
2Washer
2Locknut
2Flange-headbolt(1/2x2-1/4inches)
Procedure
1.Installtherearbracketsonthemachine(Figure
41)usingthepreviouslyremovedhardware.
g026243
Figure41
2.Torquetheboltsto94to108N∙m(70to80ft-lb).
3.Installtheleftmountassemblyandrightmount
assemblytothefrontcabmountbracketsusing
2hex-angeheadbolts(3/8x1inch)and2
angenuts(3/8inch)oneachside(Figure42).
Usethecenterholesinthemountassembly
wheninstalling.
4.Installtheadjusterbolt(3/8x2inches)and
hexnut(3/8inch)intotheleftmountassembly
andrightmountassemblyoneachsideofthe
machine(Figure42).
g245967
Figure42
1.Flangenuts(3/8inch)5.Hex-angeheadbolts(3/8
x1inch)
2.Frontcabmountbracket6.Adjusterbolt(3/8x2
inches)
3.Centerholes7.Hexnut(3/8inch)
4.Leftmountassembly
5.Installthefrontcabmountbracketsusinga
hex-headbolt(7/16inch),thrustwasher,and
locknut(1/2inch)oneachside(Figure43).
g245966
Figure43
1.Hex-headbolt(7/16inch)3.Locknut(1/2inch)
2.Thrustwasher4.Frontcabmountbracket
6.Installthe2rubberisolatorsusingaange-head
bolt(1/2x2-1/4inches),spacer,washer,and
locknutoneachside(Figure44).
13

Note:Usesoapywatertoassistwithinstalling
thebracket-supportmounts.
g254261
Figure44
1.Flange-headbolt(1/2x
2-1/4inches)
4.Washer
2.Rubberisolator5.Locknut
3.Spacer
11
InstallingtheSeatShroud
NoPartsRequired
Procedure
Bothmachines:
1.Aligntheopeningintheseatshroudforthe
parkingbrakewiththeparking-brakehandle.
2.Aligntheholeinthegear-selectorbootwiththe
rodforthegearselector.
3.Aligntheopeningintheseatshroudfortherods
fortheliftbedcontrol,high-lowrangeshifter,
andthedifferentiallock.
4.Lowertheseatshrouddown.
5.Aligntheholesintheshroudfortheseat
mountingwiththeseat-supportbracketsofthe
chassis.
Donottightenthebolts.
6.Plugintheshiftindicatorandsecurethecontrols
bracketwiththescrews(Figure34andFigure
36)removedinRemovingtheSeatShroud
(page10).
Important:ThisstepappliestoWorkman
HDX-Automachinesonly.
12
InstallingtheSide-Plate
PanelsandCabFrame
Partsneededforthisprocedure:
2Side-platepanel
1Cabframe
4Bolt(1/2inch)
4Washer(1/2inch)
4Nut(1/2inch)
1Lowerdashseal
Procedure
1.Loosentheboltsonthefendersapproximately
1turntoallowroomfortheside-platepanelsto
slideintoplace.
2.Slidetheside-platepanelsbetweentheseat
shroudandsidefenders(Figure45).
Note:Ensurethatthepanelsareseatedfully
beforetighteningthebolts.
g026246
Figure45
3.Tightentheboltsonthefenders.
Note:Donotovertightenthebolts.
4.Installthelowerdashsealtothecab(Figure46).
14

Ensurethatyouinstallthesealwithlongerlip
tothefront(Figure46).
g246051
Figure46
1.Lowerdashseal2.Longerliptothefront
5.Holdthecabframeusingtheliftingpointsand
placeitonthemachine(Figure47).
Note:Beforeloweringthecabontothe
machine,applysoapywatertothedashtokeep
thelowerdashseallubricated.
Note:Ensurethatthefrontandrearlipsonthe
lowerdashsealdorollunderduringinstallation.
g026247
Figure47
1.Liftingpoints
6.Securetheframetothemachineusingthe4
bolts(1/2inch),4washers(1/2inch),and4nuts
(1/2inch)asshowninFigure48.
Note:Donottightenthe4bolts(1/2inch).
g026272
Figure48
7.Adjustthecabfromsidetosidetoensurethat
thecabiscentered.
Usetheadjusterbolt(Figure42)tocenterthe
cab.
8.Torquethe4bolts(1/2inch)to91to113N∙m
(67to83ft-lb).
13
RoutingtheWireHarness
Partsneededforthisprocedure:
1Wireharness
4Cableties
1Fuse(30A)
Procedure
1.RoutethewireharnessasshowninFigure49
andsecureitwiththe4cableties.
15

g026273
Figure49
2.Connecttheringterminalontheharnessto
thegroundingblockandinsertthefuse-block
connectorintoanavailablefuse-block
connection(Figure50).
Note:Ifthereisnotanavailablefuse-block
connection,youmustaddafuseblocktothe
fuse-blockgrouping.ContactyourAuthorized
ServiceDealerformoreinformation.
g027950
Figure50
1.Fuseblock2.Groundblock
14
InstallingtheDashSupport
Partsneededforthisprocedure:
1Backplate
1Adjusterplate
1Tapbolt(1/2x4inches)
1Flangenut(1/2inch)
1Stopplate
4Carriagebolt(1/4x1-3/4inches)
4Flangenut(1/4inch)
Procedure
1.Measure20.7cm(8-1/8inches)totheleftfrom
thebottomedgeofthehoodbracketandmark
thelocation(Figure51).
g246001
Figure51
1.20.7cm(8-1/8inches)
16

2.Installtheadjusterplateandbackplatetothe
dash-supporttubeusingthe4carriagebolts
(1/4x1-3/4inches)andangenuts(1/4inch)
asshowninFigure52.
g245999
Figure52
1.Carriagebolt(1/4x1-3/4
inches)
3.Flangenut(1/4inch)
2.Adjusterplate4.Backplate
3.Installthetapbolt(1/2x4inches),angenut
(1/2inch),andstopplatetotheadjusterplate
(Figure53).
g246000
Figure53
1.Stopplate3.Adjusterplate
2.Flangenut(1/2inch)4.Tapbolt(1/2x4inches)
4.Closethegapbetweenthedashandcabby
adjustingthetapbolt(1/2x4inches)untilthe
stopplatepushesupwardonthedash(Figure
54).
g246149
Figure54
1.Gapbetweenthedashandcab
17

15
InstallingtheWaterGutter
Partsneededforthisprocedure:
1Watergutter
1Passenger’ssidecleartube—122cm(48inches)
1Driver’ssidecleartube—43cm(17inches)
1Floorcleartube—33cm(13inches)
1Teetting
3Magnetictie-wrapmount
3Cabletie
Procedure
1.Removethe5hex-washerheadboltsfromthe
dash(Figure55).
Retainthe5hex-washerheadbolts.
g245854
Figure55
1.Dash2.Hex-washerheadbolt
2.Slidethewatergutterbetweenthemachine
dashandsub-frameandsecurethewatergutter
usingthepreviouslyremoved5hex-washer
headbolts(Figure56).
g245853
Figure56
1.Watergutter2.Hex-washerheadbolt
3.Usingatinsnipper,removetheshippingtang
fromeachsideofthewatergutter(Figure57).
g246161
Figure57
1.Shippingtang
18

4.Connectthe122cm(48inches)cleartubeto
the33cm(13inches)cleartubeand43cm(17
inches)cleartubeusingtheteetting(Figure
58).
g245855
Figure58
1.Passenger’ssideclear
tube—122cm(48inches)
4.Driver’ssideclear
tube—43cm(17inches)
2.Teetting5.Watergutter
3.Floorcleartube—33cm
(13inches)
5.Startingfromthepassenger’sside,routethe
connectedcleartubedownthroughtheoor
board(withtheclutchpedal)tothedriver’sside
ofthemachine(Figure59).
6.Securetheconnectedcleartubewiththe3
magnetictie-wrapmountsand3cableties
(Figure59).
g245856
Figure59
1.Routedconnectedtubes2.Cabletiesandmagnetic
tie-wrapmounts
7.Pincheachendofthecleartubeandcutitata
45°angle(Figure60).
8.Alignthecleartubewiththebottomofthewater
guttersothatthetopoftheangleistothe
outsideofthemachineandinstallit(Figure60).
19

g246160
Figure60
1.Tubecutata45°angleandinstalledatthebottomedgeof
thewatergutter
16
InstallingtheFloorand
Side-PlatePanels
Partsneededforthisprocedure:
2Floor-platepanel
2Side-platepanel
1Side-platepanelseal
12Bolt(1/4inch)
Procedure
1.Installtheoor-platepanelsoneachsideof
themachineusing3bolts(1/4inch)asshown
inFigure61.
g026248
Figure61
1.Bolt(1/4inch)2.Floor-platepanel
2.Torquetheboltsto1017to1243N∙cm(90to
110in-lb).
3.Installtheside-plate-panelsealontothe
side-platepanels(Figure62).
20