Toro 41339 User manual

FormNo.3357-963RevB
BBAComplianceKit
forMulti-Pro1250TurfSprayer
ModelNo.41339
InstallationInstructions
Note:Teontapeisusedduringtheinstallationofthiskit.Thetapeisusedtowrapthreadsofttingsbefore
assembly.Threadsshouldbewrappedfromlefttoright,startingatthebaseandtravelingtothetipoftting(if
lookingdowntheaxisofatting,tapeshouldbewrappedclockwisefrombacktofront).
Note:Anon-petroleumbasedlubricant,suchasvegetableoil,willberequiredfortheinstallationofthiskit.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
•TheComplianceKitcomprisesthreeseparate
kits:theSprayGunKit,theRinseKitandtheCE
compliancekit.Thefollowingsetupinstructions
installeachkitinordertokeeppartsfromseparately
packagedkitstogetherduringinstallationforclarity.
Itisacknowledgedtheresultinginstructionsthat
followhavestepsthatreworkinstallationsperformed
inprecedingsteps.
•Disregardanyinstallationinstructionsfoundin
thoseindividualkits.
•Loosepartsnotpackagedwithinindividualkitsare
denotedasBBAkitpartsinthiskit.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparingthemachine.
Hosehook,singlebend1
Spraygunbracket1
Carriagebolt(5/16x3/4inch)2
2Locknut(5/16inch)2
Installthehosehooks(SprayGunKit).
Controlvalve1
Controlvalvebracket1
Phillipsscrew2
Supportbracket(forMulti-ProSprayers)1
Flange-headbolt(1/4x3/4inch)4
Flangenut(1/4inch)4
Teeassembly1
Pressuregauge1
Barbedtting(1/2inch)1
3
Retainerfork,large1
Installthecontrolvalve(SprayGunKit).
Hose,long1
O-ring,smallclear1
Spraygun1
4Hoseclamp,small1
Installthespraygun(SprayGunKit).
Bulkhead1
5Plasticringnut1
Installtherinsetankbulkheadtting
(RinseKit).
©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved

ProcedureDescriptionQty.Use
Rinsenozzletube1
Plasticthreads2
Nozzlebulb1
Bulkhead1
O-ring,largeclear1
O-ring,smallblack1
Plasticringnut1
60degreetting1
1/2inchconnectortting1
Plasticretainerring1
Retainernut,large1
Retainernut,small1
Retainernut,medium1
Hosebarbtting1
O-ring,clearsmall2
6
Hoseclamp1
InstalltheRinseNozzle(RinseKit)
Decal,107-8784,rinsetankvalve1
Decal,107-8785,rinsenozzlevalve1
Rinsetankvalve1
Rinsenozzlevalve1
Reducer1
7
Retainerfork,large4
Installthevalves(RinseKit).
Suctionhose1
Rinsetanksuctionhose1
Rinsenozzlehose1
Retainerfork,small3
Retainerfork,large1
8
Plastictie3
Installthehoses(RinseKit).
Flangebolt(5/16x3/4inch)2
9Flangenut(5/16inch)2
Installthebatterycoverfasteners(CE
Kit).
Horn1
Bolt(5/16x3/4inch)1
10Locknut(5/16inch)1
Installthehorn(CEKit).
11Decal104-6957,horn1Applythehorndecal(CEKit).
Decal108-3308,Multi-Pro12001
121ApplytheSpray-Pro™decal(CEKit).
Taillight1
Taillightbracket1
Palnut(1/4inch)2
Bolt(5/16x3/4inch)2
13
Locknut(5/16inch)2
Installthetaillightandbracket(CEKit).
14Decal,104-8904boom2Applythedecalsonthebooms(CEKit).
Hornbuttonassembly1
Wireharness1
15Plasticties7
Installthewireharnessandhornbutton
(CEKit).
1
Bolt(3/16x5/8inch)2
Lockwasher2
16Nut(3/16inch)2
Installthebrakeswitch(CEKit).
2

ProcedureDescriptionQty.Use
17Pressuregauge1Installthepressuregauge(BBAKit).
Pressurelter1
Spring1
Ball1
Reducer,red1
18
Hose,lterush1
Assemblethepressurelter(BBAKit)
Pressureltermount1
Bolt(5/16x1inch)4
Washer(5/16inch)4
19Flangenut(5/16inch)4
Mountthepressurelter(BBAKit).
Tankdrainassembly1
Lockwasher4
Locknut4
Template1
20
90degreeelbowtting1
Installthetankdrain(BBAKit).
Mixingtee1
Retainerforks,small3
Bypasshose1
211
Installthebypassline(BBAKit).
Filtersupplyhose1
22Manifoldsupplyhose1
Installthepressurelterhoses(BBA
Kit).
Straighttting,brass1
Teetting,metal1
23Pipeplug1
Installthepressuretap(BBAKit).
24Decal112-79061Installthedecal(BBAKit).
Retainerfork2
Straighthosebarb2
Bulkheadtting1
25T estbeaker1
Finishtheinstallation(BBAKit).
G005853
1
2
3
4
5
Figure1
BBAKitHoseLegend
1.Filterushhose4.Filtersupplyhose
2.Bypasshose5.Manifoldsupplyhose
3.Tankreturnhose
3

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Movethesprayerontoalevelsurface,settheparking
brake,stopthepump,stoptheengine,andremove
theignitionkey.
2.Drainthecontentsofthetanktoremoveany
solutioninlines.RefertotheOperator’sManualfor
moreinformation.
Note:Takecautionwhiledisconnectinganyhoses
duringtheinstallationofthiskitandhaveacatch
bucketreadyforanysolutionsremaininginthehose.
Chemicalsarehazardousandcancause
personalinjury.
•Readthedirectionsonthechemicallabels
beforehandlingthechemicalsandfollow
allmanufacturerrecommendationsand
precautions.
•Keepchemicalsawayfromyourskin.
Shouldcontactoccur,washtheaffectedarea
thoroughlywithsoapandcleanwater.
•Weargogglesandanyotherprotective
equipmentrecommendedbythechemical
manufacturer.
2
InstallingtheHoseHooks
Partsneededforthisprocedure:
1Hosehook,singlebend
1Spraygunbracket
2Carriagebolt(5/16x3/4inch)
2Locknut(5/16inch)
Procedure
1.Removethefastenerssecuringtherightsideofthe
fronttankstrap(Figure2).
3
1
2
G005779
Figure2
1.Fronttankstrap3.Spraygunbracket
2.Hosehook
2.Installthehosehookandspraygunbracketasshown
inFigure2,using2carriagebolts(5/16x3/4inch)
andlocknuts(5/16inch).
3.Securethetankstrapusingthefastenersyou
removedpreviously.
4

3
InstallingtheControlValve
Partsneededforthisprocedure:
1Controlvalve
1Controlvalvebracket
2Phillipsscrew
1Supportbracket(forMulti-ProSprayers)
4Flange-headbolt(1/4x3/4inch)
4Flangenut(1/4inch)
1Teeassembly
1Pressuregauge
1Barbedtting(1/2inch)
1Retainerfork,large
Procedure
1.Removehoselargeretainerforktodisconnectthe
boomsupplyhosefromthesupplytee(Figure3).
G005780
2
1
3
4
5
Figure3
1.Supplytee4.Tubetting
2.Hoseretainer5.Boomsupplyhose
3.Pressuregaugetube
2.Removethefourscrewssecuringthesupplyteeto
themountingbracket(Figure4).Removethesupply
teeandhoses.
2
2
1
G005781
Figure4
1.Supplyteemounting
bracket
2.Screws
3.Installthenewcontrolvalveintotheopenport
onthesupplyteeandsecureitwithanewretainer
(Figure5).
G005782
2 4 1
3
Figure5
1.ControlValve3.Boomhose
2.Retainerfork,new4.Retainerfork,existing
4.Connecttheboomhoseyoudisconnectedinstep1
totheopenportonthecontrolvalveandsecureit
withtheretaineryouremovedin1(Figure5).
5.Removethe2boltssecuringthesupplyteemounting
brackettothevehicle.Retainthefasteners.
6.Installthecontrolvalvebracketbetweenthesupply
teebracketandthevehicle(Figure6).
5

4 2 3
1
G005783
Figure6
1.Supplyteemounting
bracket
3.Bolt
2.Controlvalvebracket4.Mountingframe
7.Securethesupplyteebracketandcontrolvalve
brackettothemountingframeusingtheboltsyou
removedin5(Figure6).
8.Securethesupplyteebracketandcontrolvalve
bracketusingthescrewsyouremovedinstep2.
9.Securethecontrolvalvetothebracketwithtwo
Phillipsscrews.
10.InstallthesupportbracketasshowninFigure7,
using4ange-headbolts(1/4x3/4inch)and4
angenuts(1/4inch).
G005784
4
1
4
2
3
Figure7
1.Controlvalvebracket3.Flange-headbolt(1/4x
3/4inch)
2.Supportbracket4.Flangenut(1/4inch)
11.Connectthelargeadapterendoftheteeassemblyto
thecontrolvalve(Figure8).
1
3
2
3
4
7
6
5
G005785
Figure8
Teeassemblyshownexploded
1.Adapter5.Reducerassembly
2.Largeplasticnut6.Plasticnut
3.LargeO-ring7.Reducernipple
4.Tee
12.Turnthelargeplasticnuttosecuretheteeassembly
tothecontrolvalve(Figure8).
13.WrapTeontapearoundthethreadsofthepressure
gauge(Figure9).
1
2
3
G005786 4
Figure9
1.Pressuregauge3.Longhose
2.Wrappedthreads4.O-ring,smallclear
14.Installthepressuregaugeintotheopenporttothe
rightofthecontrolvalve(Figure9).
6

4
InstallingtheSprayGun
Partsneededforthisprocedure:
1Hose,long
1O-ring,smallclear
1Spraygun
1Hoseclamp,small
Procedure
1.Locatethesmall,clearO-ringinloosepartsand
lubricateitusinganon-petroleumbasedlubricant
suchasvegetableoil.InstalltheO-ringbetweenthe
longhoseandcontrolvalveassembly(Figure9).
2.Connectthethreadedttingontheendofthelong
hosetothecontrolvalveassembly(Figure9).
3.Removeanyplugsinthefreeendofthehose.Then
connectthelonghosetothettingonthegun
(Figure10).
G005787
1
2
3
Figure10
1.Spraygun3.Hose
2.Hosetting
4.Securetheendofthehosewithasmallhoseclamp.
5.Wrapthehosearoundthehooksonthetankand
placethesprayguninthegunbracket.
5
InstallingtheRinseTank
BulkheadFitting
Partsneededforthisprocedure:
1Bulkhead
1Plasticringnut
Procedure
1.Removethefastenersecuringtherightsideofthe
fronttankstraptothemaintankassembly.
Note:Retainallpartsandfasteners.
2.Liftthefronttankstrapandremovetherinsetank
(Figure11).Removethecapfromtherinsetank
andretain.
2
1
4
5
6
7 3
G005788
Figure11
1.Rinsetank5.Washer
2.Maintank6.Locknut
3.Frontstrap7.Cap,rinsetank
4.Bolt
3.Turntherinsetankupsidedownandlocatethedrill
pointintanksumparea.
4.Drillaholeinthesumpoftherinsetankusinga5.4
cm(2-1/8inch)holesaw.
Important:Donotelongatetheopening.An
elongatedopeningwillnotbesealedcorrectly
bythebulkheadttingyettobeinstalledand
therinsesystemwillleak.
5.Useabladetocleantheplasticburrsandexcess
materialfromthedrilledhole.
7

6.Turnthetankrightsideupandusecompressedair
toblowoutanydebrisdepositedinthetank.
Important:Debrisleftinsideatankcanclog
anddamagethespraysystemduringoperation.
7.Insertthebulkheadttingthroughtopopeningand
maneuveritintoplacesothatthesealsideofthe
bulkheadttingisincontactwiththeinteriorofthe
drilledtankopening(Figure12).
2
3
7
5
1
2
3
7
4
6
4
6G005789
Figure12
1.Rinsetank5.Retainerforkholes,
correctorientation
2.Bulkhead6.Retainerfork
3.O-ring,clear7.Sump,rinsetank
4.Plasticnut
8.Securethenewbulkheadttingtotherinsetank
usingtheplasticnutinloosepartsasshownin
Figure12.
Note:Thesealmustbeseatedbetweenthetting
andtankaroundtheentirecircumferenceofthehole
edge(Figure12).
Note:Orientatethebulkheadsothattheretainer
forkwillcomefromthefronttothebackofthe
machine(Figure12).
9.Installtherinsetankcap.
10.Installtherinsetankassemblywiththenewtting
tothemachine.
11.Securethetankusingthefronttankstrapand
fastenersremovedpreviously.
6
InstallingtheRinseNozzle
Partsneededforthisprocedure:
1Rinsenozzletube
2Plasticthreads
1Nozzlebulb
1Bulkhead
1O-ring,largeclear
1O-ring,smallblack
1Plasticringnut
160degreetting
11/2inchconnectortting
1Plasticretainerring
1Retainernut,large
1Retainernut,small
1Retainernut,medium
1Hosebarbtting
2O-ring,clearsmall
1Hoseclamp
DrillingtheMainTank
1.Openthetanklidandremovethestrainerbasket.
2.Locatethetankridgeareatothebackandrightof
themaintanklid.
3.Measure6.4cm(2-1/2inches)fromtheridgeedges
asshowninFigure13.Markthetankatthatspot.
Note:Thetankmayalreadyhaveadrillpointat
thespotbeingmeasured.Usethisindentation,if
present,todrillthehole.
8

G005790
1
2
3
4
4
Figure13
1.Maintanklid3.Drillpoint
2.Tankridge,backandright
oflid
4.6.4cm(2-1/2inches)
Note:Placeareceptacleinsidethetankandbelow
theareatobedrilledtocatchanydebriscreated
duringthedrillingprocess.
Important:Debrisleftinsideatankcouldclog
anddamagethespraysystemduringoperation.
4.Drilla3.5cm(1-3/8inch)diameterholeinthetank
atthespotmarkedpreviously(Figure13).
5.Useabladetocleantheplasticburrsandexcess
materialfromtheholedrilled.
6.Cleananydebrisfromthedrillingprocessleftinside
thetank.
AssemblingtheRinseNozzle
1.Snapathreadedttingoveroneendoftherinse
tubeasshowninFigure14.
Important: Do not installthreadedttingson
bothendsoftherinsetubeatthistime.
1
2
3
G005791
Figure14
1.Rinsetube3.Rinsenozzlebulb
2.Threadedtting
2.Installtherinsenozzlebulboverthethreadedside
oftherinsetube(Figure14).
InstallingtheRinseNozzle
1.Locatetherinsenozzlebulkheadinlooseparts.If
thebulkheadisshippedassembled,disassembleas
showninFigure15.
A.Removetheplasticringnutfromthebulkhead.
B.Pushthelarge,clearO-ringonthebulkheadup
ushtotheangettingtokeepitseated.
C.RemovethelargeretainernutandO-ring
D.Retainallparts.
G005792
4
5
1
3
2
4
5
1
3
2
Figure15
1.Bulkheadtting4.Retainernut,large
2.Plasticringnut5.O-ring,smallblack
3.O-ring,largeclear
2.Installthebulkheadttingwiththesealfacingdown
intotheholedrilledinthemaintank(Figure16).
Important:Ensurethatthesealisseated
correctlybetweenthebulkheadangeandthe
tanksurface(Figure16).
1
2
3
4
5
6
G005793
Figure16
1.Bulkhead4.Maintank
2.Flange,bulkhead5.Threadedend,bulkhead
3.O-ring,clear6.Plasticringnut
3.Securethettingandseatthesealbyinstallingthe
plasticringnuttothethreadsofthettinginthe
tankinteriorandhandtightening(Figure16).
4.Installassembledrinsenozzleandtubeupthrough
thebulkheadttinginstalledinthemaintank
(Figure17).
9

Important: Do not installtheremaining
threadedttingontheendoftherinsetubeat
thistime.
G005794
5
4
1
3
2
Figure17
1.Bulkheadassembly4.O–ring,small,black
2.Rinsenozzleandtube
assembly
5.Retainernut,large
3.Maintanksurface
5.Installthesmall,blackO-ringandlargeretainernut,
whichyoupreviouslyremoved,overthetopofthe
un-threadedendoftherinsetubeprotrudingfrom
thebulkheadtting(Figure17).
Note:Donottightenthenutatthistime.
6.Adjusttherinsenozzleassemblypositionsothe
topoftheun-threadedendofthetubestands
approximately10cm(4inches)fromthetanksurface
(Figure18).
G005795
2
4
3
1
5
Figure18
1.Rinsenozzleassembly4.Retainernut,large
2.Un–threadedendoftube5.10cm(4inches)
3.Tanksurface
7.Setthetubeheightbytighteningthelargerretainer
nutinstalledabove(Figure18).
8.Snapthethreadedttingovertheremainingendof
therinsetube.
9.Installthe1/2inchmiddlettingintoplaceand
secureitwiththemediumretainernutfromloose
parts(Figure19).
G005796
1
2
3
4
5
6
Figure19
1.Threadedtting4.Retainernut,medium
2.Rinsetube5.O-ring,smallclear
3.1/2inchmiddletting6.60degreeelbow
10.Installasmall,clearO-ringintothe60degreeelbow
ttingandtheninstallthettingonto1/2inch
middletting.
11.Positiontheelbowttingsothatitfacestotheright
andtotherearofthemachine.
12.Usethefollowingproceduretoassembletherinse
nozzlehoseasshownin(Figure20).Locateasmall,
clearO-ring,thehosebarb,smallretainernut,metal
clamp,andrinsenozzlehoseinlooseparts.
G005797
1
2
3
45
Figure20
1.O-ring,smallclear4.Hoseclamp
2.Hosebarb5.Hose
3.Retainernut,small
A.Slidethehoseclamp,loose,overtherinsenozzle
hose.
B.InstalltheO-ringoverthebarbedendofthe
ttingandpushitushtothettingange.
C.Installtheplasticnutoverthebarbedendofthe
ttingandO-ring.
10

D.Installthebarbedttingassemblyintotheopen
endoftherinsenozzlehose.
E.Tightenthehoseclamp.
13.Settherinsenozzlehoseassemblyasideforlater
installation.
7
InstallingtheValves
Partsneededforthisprocedure:
1Decal,107-8784,rinsetankvalve
1Decal,107-8785,rinsenozzlevalve
1Rinsetankvalve
1Rinsenozzlevalve
1Reducer
4Retainerfork,large
InstallingtheRinseTankValve
1.Locatethebluerinsetankvalveinloosepartsand
thedecal.
2.Installthedecalnumber107-8784ontothevalve
faceinthecorrectorientation(Figure21).Makesure
thedecalalignswiththeowofthevalve.
3 1 2
G005798
Figure21
1.Rinsetankvalvedecal,
partnumber107-8784
3.Flowofvalve
2.Rinsetankvalve,blue
3.Disconnectthesuctionhoserunningfromthetop
ofthemaintanktotheuppermixertee.Discardthis
hoseandretaintheforksforlateruse.
4.Brushanon-petroleumbasedlubricatesuchas
vegetableoilonthebulkheadttingreducerand
O-ring(Figure22)
1
2
G005799
Figure22
1.Brush2.Reducer
5.Installthebulkreducerttingtotherinsetank
sideofthevalve(Figure23).Secureitwithalarge
retainerforkfromlooseparts.
G005800
1
23
4
5
6
78
Figure23
1.Rinsetankvalve,blue5.Uppermixertee
2.Reducerbulkheadtting6.Retainerfork,large
3.O-ring7.Applynon-petroleum
basedlubricanthere.
4.Decal,107–87848.Retainerfork,existing
6.Installthetankrinsevalveontothetopmixertee
asshowninFigure23withthebulkheadfacing
rearward.Securethevalvewithanexisting,large
retainerfork.
InstalltheRinseNozzleValve
1.Locategreenrinsenozzlevalveinlooseparts.
2.Installdecal107-8785ontothevalvefaceinthe
correctorientation(Figure24).Makesurethedecal
alignswiththeowofthevalve.
11

G005801
1
2
3
Figure24
1.Rinsenozzlevalvedecal,
partnumber107-8785
3.Flowofvalve
2.Rinsenozzlevalve,green
3.Brushanon-petroleumbasedlubricatesuch
asvegetableoilonthebulkheadttingreducer
(Figure22).
4.Installthebulkreducerttingtotherinsetankside
ofthevalve.Secureitwithalargeretainerforkfrom
looseparts.
5.Installtherinsenozzlevalveintheorientation
showninFigure25formachineswithaspraygun
attachmentsinstalled.
G005802
5
23
4
1
6
7
Figure25
1.Rinsetankvalve,blue5.Boomsupplyhose,
existing
2.Rinsenozzlevalve,green6.Retainerfork,large
3.Controlvalve,spraygun7.Retainerfork,large,
existing
4.Rinsenozzlehose
6.Removetheretainerforkandtheboomsupplyhose
fromthesprayguncontrolvalve.
7.Installtherinsenozzlevalveintothecontrolvalve
atthenowopenport.Orientatetheowofthe
valveverticallysotherinsenozzlehosesideofthe
decalisonthetopandtheboomsupplysideison
thebottom.
8.Useaexisting,largeretainerforktosecuretherinse
nozzlevalveinthecorrectorientation.
9.Securetheboomsupplyhosetotheboomsupply
sideoftherinsenozzlevalvewiththeexisting,large
retainerfork.
12

8
InstallingtheHoses
Partsneededforthisprocedure:
1Suctionhose
1Rinsetanksuctionhose
1Rinsenozzlehose
3Retainerfork,small
1Retainerfork,large
3Plastictie
Procedure
G005803
4
8
11
3
7
9
10
13
7
3 1 2
4
4
5
6
11
12
11
Figure26
1.Maintank5.Checkvalve9.Rinsenozzlevalve13.Plastictie
2.Rinsetank6.Correctowdirection10.Boomsupplyhose,existing
3.Suctionhose7.Rinsenozzlehose11.Retainerfork,small
4.Rinsetanksuctionhose8.Rinsetankvalve12.Retainerfork,large
InstallingtheSuctionHose
1.Locatesuctionhoseinlooseparts.
2.Installthehosefromthemaintankupperportto
themaintanksideoftherinsetankrinsevalve
(Figure26).
3.Secureoneendofthehosewiththeexisting,extra
largeretainerforktotheupperportonthemain
tank.
4.Securetheotherendofthehosetotherinsetank
valvewithalargeretainerforkfromlooseparts.
InstalltheRinseTankSuctionHose
1.Locaterinsetanksuctionhosefromthelooseparts.
13

2.Plumbthehosefromthebottomoftherinsetankto
therinsetankvalvesothatthehosewrapsaround
thepumpandisroutedalongthemainpumphose.
3.Routetherinsetanksuctionhosebehindthevalve
assemblytotherinsetanksideoftherinsetankvalve.
Important:Installtherinsetanksuctionhose
sothatthecheckvalvearrowshowsthedirection
ofowfromtherinsetanktotherinsetankvalve.
4.Securethehosetotherinsetankusingthesmall
retainerforkinlooseparts.
5.Installthehosetotheinputsideoftherinsetank
valveandsecureitwiththeretainerforkincluded
inlooseparts.
6.Usetheplastictieslocatedinloosepartstosecure
therinsetanksuctionhosetothemainpumphose
asshowninFigure26.
InstallingtheRinseNozzleHose
1.Locaterinsenozzlehoseassemblysetasideearlier.
2.Installthehosetotheinputsideoftherinsenozzle
valve.
3.Plumbthehoseunderandbehindthemainpump
andmaintanksuctionhose,tothebarbedelbow
ttingintherinsetube(Figure26).
4.Securetherinsenozzlehosetothe60degreeelbow
ttingbythreadingthesmallretainernutoverthe
elbowtting.Makesurethesmall,clearO-ringis
seatedinthesmallretainernutattheendoftherinse
nozzlehose.Handtighten.
9
InstallingtheBatteryCover
Fasteners
Partsneededforthisprocedure:
2Flangebolt(5/16x3/4inch)
2Flangenut(5/16inch)
Procedure
Replacethebatterycoverhandknobswithfasteners
fromtheCEkit.
1.Loosenandremovethetwohandknobssecuring
batterycovertobatterybase(Figure27).
Figure27
1.Handknob3.Batterycover
2.Battery
2.Installthetwoangebolts(5/16x3/4inch)and
twoangenuts(5/16inch)inplaceoftheremoved
handknobtosecurethebatterycover.
10
InstallingtheHorn
Partsneededforthisprocedure:
1Horn
1Bolt(5/16x3/4inch)
1Locknut(5/16inch)
Procedure
Preparethemachinefortheinstallationofthehorn.
1.Drillahole,8.5mm(11/32inch)indiameter,in
thevehicleframeundertheoorboard.Thehole
shouldbe4cm(1-1/2inches)downfromtheframe
topand5cm(2inches)fromthefrontoftheframe
(Figure28).
2.Securethehorntotheframeusingabolt(5/16x
3/4inch)andalocknut(5/16inch)asshownin
Figure28.
14

Figure28
1.Vehicleframe4.Horn
2.Bolt(5/16x3/4inch)5.Locknut(5/16inch)
3.Tire,leftfront
3.Drillahole,16mm(5/8inch)indiameter,inthe
dashpanel.Theholeshouldbe23cm(9inches)
totheleftofthesteeringcolumnbaseand5cm(2
inches)fromthetopofthedash(Figure29).
3
G002961
1
23
Figure29
1.Drillholehere3.Steeringcolumn
2.Dash
Note:Donotinstallthehornbuttonatthistime.
11
ApplyingtheHornDecal
Partsneededforthisprocedure:
1Decal104-6957,horn
Procedure
Installthehorndecalabovethedashhole.
1.Cleanthedecalareaabovethehornbuttonholeand
makesureitisfreeofdirt,grease,orotherforeign
material.
2.Removethebackingofthenewdecalandplace
about6.5mm(1/4inch)abovethehornbuttonon
thedash(Figure30).
Figure30
1.Horn
15

12
ApplyingtheSpray-Pro™
Decal
Partsneededforthisprocedure:
1Decal108-3308,Multi-Pro1200
1
Procedure
Installthefollowingdecalsforappropriatemodelof
Multi-ProSprayer:
•Multi-Pro1200decalnumber108-3308
•Multi-Pro1250decalnumber108-3309
1.CleanthedecalareaaroundtheSpray-Promonitor
andmakesureitisfreeofdirt,grease,orother
foreignmaterial.
2.Removethetoppartofthedecalfromthebacking
andplaceitjustabovethedialonthemonitorface.
Besuretocovertheexistingcompletely.Repeatthe
processforthebottompartofthedecaljustbelow
thedial.
Important:Donotattempttoremovethe
dialtofacilitatetheinstallationofthedecals.
Removingthedialwilldamagetothemonitor
andyourabilitytomanipulatethecontrols.
Figure31
Multi-Pro1200decal,108-3308
1.Toppart2.Bottompart
Figure32
Multi-Pro1250decal,108-3309
1.Toppart2.Bottompart
13
InstallingtheTailLightand
Bracket
Partsneededforthisprocedure:
1Taillight
1Taillightbracket
2Palnut(1/4inch)
2Bolt(5/16x3/4inch)
2Locknut(5/16inch)
Procedure
1.LocatethetaillightbracketshowninFigure33in
looseparts.Thiswillbetheonlytaillightbracket
usedforthiskit.
G005972
Figure33
16

2.Installthetaillightbrackettothecenterboom
supportwith2bolts(5/16x3/4inch)and2locknuts
(5/16inch)(Figure34).
3.Installthetaillighttothetaillightbracketwith2
palnuts(1/4inch)(Figure34).
Figure34
1.Taillight4.Bolt(5/16x3/4inch)
2.Taillightbracket5.Locknut(5/16inch)
3.Leftsideboomsupport6.Palnut(1/4inch)
14
ApplyingtheDecalsonthe
Booms
Partsneededforthisprocedure:
2Decal,104-8904boom
Procedure
1.Measurefromtheendoftheboomsasshownin
Figure35.
Figure35
1.Decal3.Measure90cm(35-1/2
inches)
2.Boom
2.Cleanthedecalareaandmakesuretheareaisfreeof
dirt,grease,orotherforeignmaterial.
3.Removethebackingofthenewdecalandplaceonto
theboom(Figure35).
Figure36
Boomdecal,104-8904
1.Grabboomhere
4.Repeattheprocedureontheopposingboom.
15
InstallingtheWireHarness
andHornButton
Partsneededforthisprocedure:
1Hornbuttonassembly
1Wireharness
7Plasticties
InstallingtheHornButton
1.Openthehornbuttonpackingthatincludesthehorn
switchandbuttoncap,2screws,andaretainingring.
17

2.Removethehornbuttoncapandthreadtheretaining
ringontotheexposedthreadsoftheswitch.
3.Connectthewhiteandyellowwiresattheendofthe
wireharnesstothebackofthehornswitchusingthe
twoscrewsincluded(Figure37).
Figure37
1.Whiteandredwires4.Hornswitch
2.Wireharness5.Retainingring
3.Screws6.Hornbutton
4.Movetheswitchassemblyunderthedashandpush
itthroughtheholedrilledinthedashpreviously.
5.Screwthehornbuttoncapontotheswitchthreads
tosecuretheassemblytothedash.
Note:Adjusttheretainingringandhornbutton
capasnecessary.
InstallingtheWireHarnessforHorn
andBrake
1.Runthewireharnessfromthehornbutton,under
thedashpanel,throughthewireaccessholeinthe
oorboard,andthroughtheframehooksalongside
oftheheadlightwireharnesstotheelectricalpanel
locatedundertheoperator’sseat.
2.Undertheoorboard,connectthewireharnessto
thenewbrakeswitch.Securetheharnesstothe
switchusingaplasticwiretie.
3.Undertheoorboard,connectthetwoquick
connectterminalsontheblackandwhitewiresto
thehorn.
4.Undertheoperator’sseat,connectthesingleblack
wire(ground)inthemiddleofthewireharnessto
thegroundblock(Figure38)locatedundertheseat
neartothesolenoid.
Note:Rightandleftsidesaredeterminedfromthe
normaloperatingposition.
Figure38
1.Redpowerwirefromthe
wireharness.
3.Blackwiretogroundblock
2.Solenoid,hotorinputside
5.Connecttheredpowerwiretotherightsideofthe
solenoid(Figure38),locatedundertheseat.
Note:Connectingthewireharnesstothehotor
inputsidesolenoidpostwillallowthehorntobe
activewhentheignitionkeyisintheOffposition.
Note:Thehotorinputsidehasconstant12V
power.
6.Runthewireharnessendwiththetaillightconnector
alongtheleftsideoftheframetowardtherearof
themachine.
7.Connectthetaillightconnectoronthewireharness
tothetaillight(Figure39).
Figure39
1.Taillight2.Pigtailconnector
8.Tiethewireharnessdowntotheframealongwith
theexistingwiring.
Note:Makesuretheharnessdoesnottouchany
partoftheengineexhaustsystem.
18

16
InstallingBrakeSwitch
Partsneededforthisprocedure:
1
2Bolt(3/16x5/8inch)
2Lockwasher
2Nut(3/16inch)
Procedure
Installthebrakeswitchtooperatethetaillight.
1.Installthebrakeswitchtothebrakeleverusingthe2
bolts(3/16x5/8inch),lockwasher,andnut(3/16
inch)asshowninFigure40.
Figure40
1.Brakeswitch4.Lockwasher
2.Bolt(3/16x5/8inch)5.Mount
3.Nut(3/16inch)
2.Adjustthenewswitchsothebrakebuttonis
depressed6mm(1/4inch)whenthebrakeis
released(Figure41).
Figure41
1.Newbrakeswitch3.Brakereleased
2.Brakeengaged
Note:Ifthebrakelightstaysonwhenthepedal
released,loosentheboltssecuringthebrakeswitch
andadjustpositionoftheswitchsothelight
extinguisheswhenthepedalisreleased.
17
InstallingthePressureGauge
Partsneededforthisprocedure:
1Pressuregauge
Procedure
Note:Discardthepressuregaugethatcomeswiththe
CEkit.Usethepressuregaugelocatedinthelooseparts
oftheBBAkitthatdisplaysonlyBar.
1.Usingawrench,holdthereducerattheteebracket
andloosentheexistingpressuregauge.Removethe
gauge(Figure42).
Note:Theholeintheteebracketshouldbeslotted.
Ifnot,useadrilltoslightlyelongateholetoallow
forthelargerpressuregaugetot.
19

Figure42
1.Pressuregauge3.Teebracket
2.Reducer4.Reducernutandcoupler
2.Applysealertapetothreadsofthenewpressure
gaugeandinstallitintothereducer.Useawrench
toholdreducerwhiletighteningthenewpressure
gauge.
3.Positionthegaugesoitcanbeviewedbythe
operator.
Note:Thereducernutmayneedtobeloosenedandthe
wholeassemblyturnedtoallowthegaugetobeviewed.
18
AssemblingthePressureFilter
Partsneededforthisprocedure:
1Pressurelter
1Spring
1Ball
1Reducer,red
1Hose,lterush
Procedure
1.Locatethepressurelterinlooseparts.Locatethe
smallspring,ballandredreducerinlooseparts.
Locatethelterushhoseinlooseparts;referto
Figure1.
2.Installthespring,ball,andredplugthenelbowon
hoseassemblyintotheverticalpressureinletonthe
bottomofthelter(Figure43).
Figure43
1.Pressurelter4.Reducer,red
2.Spring5.Filterushhose
3.Ball
3.Securethepartsinternalbyconnectingthethreaded
nutsideoflterushhosetopressureinletonthe
bottomofthelter(Figure43).
19
MountingthePressureFilter
Partsneededforthisprocedure:
1Pressureltermount
4Bolt(5/16x1inch)
4Washer(5/16inch)
4Flangenut(5/16inch)
Procedure
1.Locatethepressureltermountbracketinloose
parts.
2.Mountthepressurelterassemblyasshownin
Figure44tothelterbracketusingtwobolts(5/16
x1inch),twowashers(5/16inch)andtwolocknuts
(5/16inch).
20