GeoLink® Precision Spray System Finishing Kit

1. Remove the 2-socket connector of the machine wire harness that connects to the seat-switch connector.

   

   Figure 3

   1. 2-socket connector (machine wire harness)
   2. Seat-switch connector

2. Remove the hairpin that secures the prop rod to the bracket at the bottom of the seat plate.

   

   Figure 4

   1. Washer
   2. Bracket (seat)
   3. Hairpin
   4. Prop rod

3. Remove the 2 hairpins that secure the pivot fitting of the seat plate to the chassis brackets.

   

   Figure 5

   1. Seat plate
   2. Seat
   3. Hairpin
   4. Pivot fitting (seat pan)
   5. Chassis bracket
   6. Pivot pin

4. Remove the 2 pivot pins that secure the seat and seat plate to the chassis.

5. Lift the seat and seat plate up and out of the machine.

   

   Figure 6

   1. Seat plate
   2. Seat

1. Rotate up the handles for the latches of the engine-access panel.

   

   Figure 7

   1. Latch
   2. Panel-support bracket
   3. Engine access panel

2. Lift the engine-access panel and remove it from the machine.

1. Remove and discard the 2 push-in fasteners that secure the left, front fender to the lower ROPS channel.

   

   Figure 8

   1. Push-in fastener
   2. Left, front fender

2. Remove the 3 bolts (5/16 x 1 inch) and 3 washers (5/16 inch) that secure the fender to the frame of the machine.

   

   Figure 9

   1. Washer (5/16 inch)
   2. Bolt (5/16 x 1 inch)
   3. Left, front fender

3. Remove the fender from the machine.

4. Remove the 6 push-in fasteners and 5 washers (9/16 x 1/2 inch) that secure the inner-fender shroud to the frame of the machine.

   

   Figure 10

   1. Inner-fender shroud
   2. Push-in fastener
   3. Washer (9/16 x 1/2 inch)

5. Remove the inner-fender shroud from the machine.

   

   Figure 11

6. Repeat steps 1 through 5 for the fender and inner-fender shroud at the other side of the machine.

Note: If you damage the push-in fasteners removing them, replace the fasteners with Toro Part No. 117-2382.

1. Remove the 2 capscrews (5/16 x 1 inch) and 2 washers (5/16 inch) that secure the bottom console cover and end console cover to the machine, and remove the covers.

   

   Figure 12

   1. Capscrew (5/16 x 1 inch)
   2. Washer (5/16 inch)
   3. Console cover (bottom)
   4. Console cover (end)

2. Remove the capscrew (5/16 x 1 inch) and washer (5/16 inch) that secures the right, front fender to the platform floor.

   

   Figure 13

   1. Capscrew (5/16 x 1 inch)
   2. Washer (5/16 inch)
   3. Platform floor
   4. Right, front fender

3. Carefully remove the 2 push-in fasteners that secure the right, front fender to the roll bar mounting channel.

   

   Figure 14

   1. Push-in fastener
   2. Right, front fender

4. Remove the capscrew (5/16 x 1 inch) and washer (5/16 inch) that secures the right, front fender to the cross-member support.

   

   Figure 15

   1. Clip nut (cross-member support)
   2. Washer (5/16 inch)
   3. Capscrew (5/16 x 1 inch)
   4. Right, front fender

5. Remove the right, front fender from the machine.

6. Remove the 6 push-in fasteners and 5 washers (9/16 x 1/2 inch) that secure the inner-fender shroud to the right, upper and right, lower-frame tubes.

   

   Figure 16

   1. Washer (9/16 x 1/2 inch)
   2. Push-in fastener
   3. Inner-fender shroud

7. Remove the inner-fender shroud from the machine.

   Note: Retain the right, front fender, inner-fender shroud, capscrews, washers, and undamaged push-in fasteners.Replace damaged push-in fasteners with Toro Part No. 117-2382.

1. Disconnect the 2 electrical connectors (2-socket) of the machine wire harness from the 2-pin connectors of the left and right headlights.

   

   Figure 17

   1. Headlights
   2. 2-socket connector (machine wire harness)
   3. 2-pin connector (headlight)

2. Remove and retain the 9 push-in fasteners that secure the hood to the dash and frame of the machine.

   

   Figure 18

   1. Hood
   2. Push-in fastener

3. Remove and discard the hood from the machine.

1. At the outer boom section, remove the hose clamp that secures the hose to the barbed T-fitting.

   

   Figure 22

   1. Hose (outer-boom section)
   2. Outer-boom section
   3. Barbed T-fitting
   4. Hose clamp
   5. R-clamp

2. Remove the hose from the T-fitting.

3. Remove the free end of the hose from the R-clamp.

4. Repeat steps 1 through 3 for the supply hose at the other outer-spray section.

5. Under the center-boom section, remove the hose clamp that secures the supply hose for the center-spray section to the barbed T-fitting.

   

   Figure 23

   1. Front of the machine
   2. Center-spray section
   3. Supply hose (center-spray section)
   4. Hose clamp
   5. Barbed T-fitting

6. Remove and retain the retainers that secure the quick couplers of the left, center, and right supply hoses from the quick couplers if the section valves (Figure 24).

   

   Figure 24

   1. Quick coupler (section valve)
   2. Retainer
   3. Quick coupler (socket—supply hose)

7. Remove and discard the left, center, and right section-supply hoses from the quick couplers of the section valves, and remove the hoses from the machine.

1. Remove the hoses from the extend ports of the left and right lift cylinders.

   

   Figure 25

   1. Hose (extend position)
   2. Port C3 (lift-cylinder manifold)
   3. Port C4 (lift-cylinder manifold)
   4. Retract port (lift cylinder)
   5. Hose (retract position)
   6. Extend port (lift cylinder)

2. Remove and discard the hoses from the:

   • Ports C1, C2, C3, and C4 of the lift-cylinder manifold

   • Retract and extend ports of the left and right lift cylinder.

Note: Except where noted, retain all hardware that you remove.

1. Use lifting equipment of the specified capacity to support the outer-spray section.

2. Remove the hairpin and clevis pin that secure the rod end of the lift cylinder to the pivot bracket.

   

   Figure 26

   1. Hairpin
   2. Rod fitting (lift cylinder)
   3. Clevis pin
   4. Pivot bracket

3. Remove the flange locknut (5/16 inch) and flange-head bolt (5/16 x 3/4 inch) that secures the pivot pin to the cylinder mount.

   

   Figure 27

   1. Flange locknut (5/16 inch)
   2. Pivot pin
   3. Flange-head bolt (5/16 x 3/4 inch)
   4. Lift cylinder
   5. Cylinder mount

4. Remove the pivot pin and the lift cylinder from the machine.

Lift equipment capacity: 46 kg (100 lb)

Note: Except where noted, retain all hardware that you remove; you will use the hardware to install the center-boom extension.

1. Remove the flange bolt (5/16 x 1 inch) and flange locknut (5/16 inch) securing the pivot pin to the pivot bracket.

   

   Figure 28

   1. Pivot fitting (outer-boom section)
   2. Nylon-flange bushing
   3. Flange bolt (5/16 x 1 inch)
   4. Pivot pin
   5. Pivot bracket (center-boom section)
   6. Flange locknut (5/16 inch)

2. Remove the pivot pin from the pivot bracket for the center-boom section and the pivot fitting for the outer-boom section.

3. Separate the outer-boom section from the center-spray section and remove outer section from the machine.

4. Remove and discard the 2 nylon-flange bushings from the pivot fitting of the outer-spray section.

5. Repeat steps 1 through 3 in Removing the Lift Cylinders for the outer-boom section at the other side of the machine.

6. Repeat steps 1 through 4 of this section for the outer-boom section at the other side of the machine.

1. Remove the 2 flange locknuts (5/16 inch) and 2 flange-head bolts (5/16 x 1 inch) that secure the support bracket for the section-lift manifold to the cylinder mount, and separate the manifold and bracket from the cylinder mount.

   

   Figure 29

   1. Support bracket (section-lift manifold)
   2. Flange locknut (5/16 inch)
   3. Cylinder mount
   4. Flange-head bolt (5/16 x 1 inch)

2. Support the section-lift manifold by tying it to the valve mount bracket with a piece of rope.

Lifting-equipment capacity: 41 kg (90 lb)

1. Support the center-boom section with lifting equipment with the specified capacity.

   

   Figure 30

2. Remove and retain the 4 flange-head bolts (3/8 x 1-1/4 inches) and 4 flange locknuts (3/8 inch) that secure the center boom section to the support brackets.

   

   Figure 31

   1. Support brackets
   2. Center boom section
   3. Flange-head bolt (3/8 x 1-1/4 inches)
   4. Flange locknut (3/8 inch)

3. Lift the center boom section and remove it from the machine.

1. At the center-boom section, remove and retain the flanged locknut that secures the turret to the mount.

   

   Figure 32

   1. Flange locknut (5/16 inch)
   2. Single barbed-hose shank (3/4 inch)
   3. Sprayer nozzle on turret
   4. Hose (3/4 inch inside diameter)
   5. Double barbed-hose shank (3/4 inch)
   6. Hose clamp
   

   Figure 33

   1. Flange locknut (5/16 inch)
   2. Mount
   3. Hex-head bolt (5/16 x 3/4 inch)

2. Remove the stainless steel screw (#12 x 1-1/4 inches) that secures the upper clamp half and double or single barbed-hose shank (3/4 inch) to the turret body, and separate the barbed-hose shank and hose from the nozzle.

   Note: The hex-head bolt (5/16 x 3/4 inch—stainless steel) will separate from the upper clamp half when you open the clamp, retain the bolt for installation.

   

   Figure 34

   1. Upper clamp half
   2. Transfer tube
   3. Hex-head bolt (5/16 x 3/4 inch—stainless steel)
   4. Double barbed-hose shank (3/4 inch)
   5. Saddle on the turret
   6. Stainless steel screw (#12 x 1-1/4 inches)
   7. Single barbed-hose shank (3/4 inch)

3. Remove the turret from the center-boom section.

4. Repeat steps 1 and 2 for the other 2 turrets.

5. Remove the hoses (3/4 inch inside diameter), barbed-hose shanks, clamps and barbed T-fitting from the center-boom section.

   Note: You no longer need the hose, hose shanks, clamps, and T-fitting; retain all other parts.

1. Remove the 2 flange head bolts (3/8 x 1 inch) and 2 locknuts (3/8 inch) that secure the vertical flanges of the left and right truss frames.

   

   Figure 35

   1. Left truss frame
   2. Flange-head bolt (3/8 x 1 inch)
   3. Right truss frame
   4. Locknuts (3/8 inch)

2. Remove the 2 carriage bolts (1/2 x 1-1/4 inches) and 2 locknuts (1/2 inch) that secure the narrow cylinder mount, left and right truss frames, and narrow tie plate.

   

   Figure 36

   1. Carriage bolt (1/2 x 1-1/4 inches)
   2. Cylinder mount (narrow)
   3. Left truss frame
   4. Locknuts (1/2 inch)
   5. Tie plate (narrow)
   6. Right truss frame

   Note: Retain the flange-head bolts, carriage bolts, and locknuts. You no longer need the narrow cylinder mount and narrow tie plate.

3. Separate the left and right truss frames.

1. Loosely assemble the center-boom extension to the truss frame with the previously removed 2 flange-head bolts (3/8 x 1 inch) and 2 flange locknuts (3/8 inch).

   

   Figure 37

   1. Flange locknut (3/8 inch)
   2. Vertical flange (truss frame)
   3. Vertical flange (center-boom extension)
   4. Flange-head bolt (3/8 x 1 inch)

2. Loosely assemble the center-boom extension to the other truss frame with the 2 flange-head bolts (3/8 x 1 inch) and 2 flange locknuts (3/8 inch).

3. Insert the tie plate into the truss frame and center-boom extension and align the hole in the tie plate with the holes at the centerline of the trusses and boom extension.

   

   Figure 38

   1. Left truss frame
   2. Center-boom extension
   3. Cylinder mount (wide)
   4. Right truss frame
   5. Carriage bolt (1/2 x 1-1/4 inches)
   6. Tie plate (wide)
   7. Flange locknut (1/2 inch)

4. Assemble the cylinder mount, trusses, center-boom extension, and tie plate using 6 carriage bolts (1/2 x 1-1/4 inches) and 6 flange locknuts (1/2 inch).

   Note: 2 of the carriage bolts and locknuts are from previously removed parts.

5. Torque the 3/8 inch flange head bolts and flange locknuts to 37 to 45 N∙m (27 to 33 ft-lb).

6. Torque the 1/2 inch flange locknuts to 91 to 113 N∙m (67 to 83 ft-lb).

1. Using lifting equipment, raise the new center-boom section to a comfortable working height.

2. Remove the stainless steel screw that secures the upper clamp half to the saddle.

   

   Figure 39

   1. Hex-head bolt (5/16 x 3/4 inch—stainless steel)
   2. Transfer tube
   3. Upper clamp half
   4. Single barbed-hose shank (1/2 inch)
   5. Stainless steel screw (#12 x 1-1/4 inches)
   6. Turret
   7. Toward the spray section

3. Locate the hole in the side of single barbed-hose shank at the end of the hose 25 cm (10 inches) of the hose assembly (valve 5 or 6) for the center-boom section.

   

   Figure 40

   1. Hose 13 x 250 mm (1/2 x 10 inches—valve 5 or 6)
   2. Turret
   3. Single barbed-hose shank 13 mm (1/2 inch)
   4. Hose and barbed coupler 13 x 810 mm (1/2 x 32 inches—valve 5 or 6)

4. Align the transfer tube in the saddle of a turret with the hole in the side of the single barbed-hose shank (1/2 inch).

5. Close the upper clamp half around the barbed-hose shank and secure the clamp half and spray-nozzle body with the stainless steel screw (#12 x 1-1/4 inches); torque the stainless steel screw to 14 to 18 N∙m (20 to 25 in-lb).

   Important: Do not over tighten the stainless steel screw.

   Note: Ensure that the hex-head bolt (5/16 x 3/4 inch) is seated in the recess in the upper clamp half when closing the clamp.

6. Repeat steps 3 through 5 to the single barbed-hose shanks of the other hose assemblies (spray valve 5 or 6) for the center-boom section.

1. Route the hose 13 mm (10 inches) and turret assembly between the truss braces of the outer truss.

   

   Figure 41

   1. Hose 13 x 250 mm (1/2 x 10 inches)
   2. Truss braces (left truss)
   3. Hose and barbed coupler 13 x 810 mm (1/2 x 32 inches)
   4. Sprayer nozzle

2. Route the hose and turret above the truss brace and outward to the outboard nozzle mount.

3. Loosely secure the turret to the mount with the hex-head bolt (5/16 x 3/4 inch) and a flange locknut (5/16 inch).

   

   Figure 42

   1. Flange locknut (5/16 inch)
   2. Mount (outboard)
   3. Hex-head bolt (5/16 x 3/4 inch—stainless steel)

4. Route the other hose 13 mm (10 inches) and turret assembly between the truss braces of the outer truss.

5. Route the hose and turret above the truss brace and inward to the inboard turret mount.

6. Loosely secure the turret to the mount with a the hex-head bolt (5/16 x 3/4 inch) and flange locknut (5/16 inch).

7. Torque the flange locknut to 1978 to 2542 N∙cm (175 to 225 in-lb).

8. Route the hose and barbed coupler 13 x 810 mm (1/2 x 32 inches) to the side of the center-spray section with the left and right support brackets.

9. Repeat steps 1 through 8 for the other hose and turret at the other outer truss.

1. Remove the small retainer that secures the quick-disconnect fitting of the bypass hose to the quick-disconnect fitting of the right section-bypass valve.

   

   Figure 43

   1. Quick-disconnect fitting (right section-bypass valve)
   2. Quick-disconnect fitting (90° socket—bypass hose)
   3. Retainer (small)
   4. Bypass hose

2. Remove and retain the large retainer that secures the 90° barbed fitting at the lower end of the bypass hose to the bulkhead fitting of the spray tank.

   

   Figure 44

   1. 90° barbed fitting
   2. Retainer (large)
   3. Bulkhead fitting
   4. Bypass hose

3. Remove and discard the bypass hose from the machine.

1. Remove the 3 retainers that secure the 3 valve actuators to the left, center, and right section valves.

   

   Figure 45

   1. Section valve
   2. Retainer
   3. Valve actuator

2. Remove the valve actuators from the left, center, and right section valves.

3. Remove the retainer that secures the cap to the quick disconnect fitting of the bypass valve, and remove and discard the cap.

   

   Figure 46

   1. Quick disconnect fitting (bypass valve)
   2. Retainer
   3. Cap

4. Remove the 3 retainers that secure the 3 bypass valves to the left, center, and right section valves.

   

   Figure 47

   1. Quick disconnect fitting
   2. Quick connect fitting—socket (bypass valve)
   3. Quick connect fitting (section valve)
   4. Retainer

5. Lift the bypass valves from the section valves.

6. Rotate the bypass valves 180° and assemble them onto the quick disconnect fittings of the section valves.

7. Secure the 3 bypass valves to the section valves with the 3 retainers that you previously removed.

8. Assemble plug into the quick connect socket of the bypass valve.

   

   Figure 48

   1. Quick connect socket (bypass valve)
   2. Plug
   3. Retainer

9. Secure the plug to the quick connect socket with the previously removed retainer.

10. Assemble the 3 valve actuators onto the left, center, and right section valves with the previously removed retainers.

1. Remove and discard the 2 flange-head bolts (1/4 x 3/4 inch) and 2 locknuts (1/4 inch) that secure the left boom-section valve to the manifold mount.

   

   Figure 49

   1. Flange-head bolt (1/4 x 3/4 inch)
   2. Section valve
   3. Manifold mount
   4. Locknut (1/4 inch)

2. Remove the 2 flange-head bolts (1/4 x 3/4 inch) and 2 locknuts (1/4 inch) that secure the right boom-section valve to the manifold mount.

3. Remove the flange clamp 40 to 64 mm (1-9/16 to 2-1/2 inches) and gasket 25 x 35 mm (1 x 1-3/8 inches) that secures the flange of the left section valve to the adapter.

   Note: Retain the 2 flange-head bolts, 2 locknuts, flange clamp and gasket.

   

   Figure 50

   1. Adapter
   2. Flange (left section valve)
   3. Gasket 25 x 35 mm (1 x 1-3/8 inches)
   4. Flange clamp 40 to 64 mm (1-9/16 to 2-1/2 inches)

4. Remove the 3 section valves from the machine.

5. Remove the decals from the actuators of the 3 section valves.

   

   Figure 51

   1. Section-valve decal
   2. Actuator (section valve)

6. Remove and retain the flange clamp 51 mm (2 inches) and gasket 38 mm (1-1/2 inches) that secure the flange of the adapter to the flange of the flow meter.

   

   Figure 52

   1. Flange (flow meter)
   2. Gasket
   3. Flange clamp 51 mm (2 inches)
   4. Adapter

1. Disconnect the 3-socket connector of the machine wire harness labeled FLOW METER from the 3-pin connector of the flow meter.

   

   Figure 53

   1. 3-pin connector (flow meter)
   2. 3-socket connector (machine wire harness—FLOW METER)
   3. Push-in fasteners
   4. Section-valve bracket

2. Remove the 2 push-in fasteners of the machine wire harness from the bottom flange of the section-valve bracket.

3. Remove the 4 flange-head screws (5/16 x 3/4 inch) that secure the section-valve bracket from the valve mount, and remove the valve bracket from the machine.

   Note: Retain the 4 flange-head screws; you no longer need the section-valve bracket.

   

   Figure 54

   1. Flange-head screw (5/16 x 3/4 inch)
   2. Section-valve bracket
   3. Valve mount

1. Align the holes in the flow-meter bracket with the holes in the valve mount.

   

   Figure 55

   1. Flange-head screw (5/16 x 3/4 inch)
   2. Flow-meter bracket
   3. Valve mount

2. Assemble the flow-meter bracket to the valve mount with the previously removed 4 flange-head screws, and torque the screws to 1978 to 2542 N∙cm (175 to 225 in-lb).

3. Assemble the pair of clamp halves to the flow meter bracket with 2 bolts (1/4 x 4-1/2 inches) and 2 flange locknuts (1/4 inch).

   

   Figure 56

   1. Bolt (1/4 x 4-1/2 inches)
   2. Support-clamp half
   3. Flow-meter bracket
   4. Flange locknut (1/4 inch)

4. Torque the bolts and nuts to 1017 to 1243 N∙cm (90 to 110 in-lb).

Figure 57

1. 102 cm (40 inch) wire-harness branch—ASC10 and NOZZLE-VALVES 1 through 10
2. 89 cm (35 inch) wire-harness branch—RATE VALVE, MASTER VALVE, FLOW METER, LEFT SPRAY, CENTER SPRAY, and RIGHT SPRAY
3. Kit wire harness 457 cm (180 inch)
4. 84 cm (33 inch) wire-harness branch—PUMP CLUTCH

Figure 58

1. 61 cm (24 inch) wire-harness branch—PRESSURE TRANSDUCER GREEN WEDGE
2. 23 cm (9 inch) wire-harness branch—FLOW METER
3. 60 cm (23-1/2 inch) wire-harness branch—TO BATTERY POSITIVE, battery negative, and alternator
4. 66 cm (26 inch) wire-harness branch—ASC 10 ENABLE RELAY, 50 A FUSE, DIODE, SW’D PWR FOR GEN 2 TOPCON, and ASC 10 power and CAN from X25

1. Route the 84 cm (33 inch), 60 cm (23-1/2 inch), and 66 cm (26 inch) wire-harness branches of the rear harness to the left side of the machine along the machine wire harness.

   

   Figure 59

   1. Rear wire harness 457 cm (180 inch)
   2. 84 cm (33 inch) wire-harness branch, 60 cm (23-1/2 inch) wire-harness branch, and 66 cm (26 inch) wire-harness branch
   3. Machine wire harness
   4. Manifold mount
   5. 102 cm (40 inch) wire-harness branch
   6. 89 cm (35 inch) wire-harness branch
   

   Figure 60

   1. Machine wire harness
   2. Rear harness 457 cm (180 inch)
   3. 102 cm (40 inch) wire-harness branch—ASC10 and NOZZLE-VALVES 1 through 10
   4. 89 cm (35 inch) wire-harness branch—RATE VALVE, MASTER VALVE, FLOW METER, LEFT SPRAY, CENTER SPRAY, and RIGHT SPRAY

2. Route the 84 cm (33 inch), 60 cm (23-1/2 inch), and 66 cm (26 inch) wire-harness branches of the rear harness forward along the left frame channel.

   

   Figure 61

   

   Figure 62

   1. 84 cm (33 inches) wire-harness branch—pump clutch
   2. 60 cm (23-1/2 inch) wire-harness branch—TO BATTERY POSITIVE, battery negative, and alternator
   3. 66 cm (26 inch) wire-harness branch—ASC 10 ENABLE RELAY, 50 A FUSE, DIODE, SW’D PWR FOR GEN 2 TOPCON, and ASC 10 power and CAN from X25
   4. 102 cm (40 inch) wire-harness branch—ASC10 and NOZZLE-VALVES 1 through 10
   5. Rear harness 457 cm (180 inch)
   

   Figure 63

   Bottom of the machine

   1. Rear harness 457 cm (180 inch)
   2. Machine wire harness
   3. Front of the machine
   4. Left frame channel
   5. Cable tie

3. Route the 84 cm (33 inch), 60 cm (23-1/2 inch), and 66 cm (26 inch) wire-harness branches of the rear harness along the machine wire harness, outboard of the parking-brake assembly.

   

   Figure 64

   1. Rear harness 457 cm (180 inch)
   2. Cable ties
   3. 60 cm (23-1/2 inch) wire-harness branch—TO BATTERY POSITIVE, battery negative, and alternator
   4. Machine wire harness

4. Route the 84 cm (33 inch), 60 cm (23-1/2 inch), and 66 cm (26 inch) wire-harness branches of the rear harness across the shock-support tube.

   

   Figure 65

   1. Machine wire harness
   2. 66 cm (26 inch) wire-harness branch—ASC 10 ENABLE RELAY, 50 A FUSE, DIODE, SW’D PWR FOR GEN 2 TOPCON, and ASC 10 power and CAN from X25
   3. 60 cm (23-1/2 inch) wire-harness branch—TO BATTERY POSITIVE, battery negative, and alternator
   4. Rear harness 457 cm (180 inch)
   5. Cable ties

5. Secure the rear harness to the machine wire harness.

6. At the back of the machine, route the 89 cm (35 inch) wire-harness branch forward of the lift manifold, and to the right of the flow meter.

   

   Figure 66

   1. Machine wire harness
   2. 89 cm (35 inch) wire-harness branch—RATE VALVE, MASTER VALVE, FLOW METER, LEFT SPRAY, CENTER SPRAY, and RIGHT SPRAY
   3. 3-pin connector (CENTER SPRAY)
   4. 3-socket connector (NOZZLE VALVE 5)
   5. 102 cm (40 inch) wire-harness branch—ASC10 and NOZZLE-VALVES 1 through 10
   6. 40-socket connector (ASC 10)

7. Route the 102 cm (40 inch) wire-harness branch rearward of the lift manifold and to the right.

1. Connect the 3-pin connector of the 89 cm (35 inch) rear harness branch labeled LEFT SPRAY to the 3-socket connector of the machine wire harness labeled LEFT SPRAY VALVE.

   

   Figure 67

   1. Flow-meter bracket
   2. 3-socket connector—89 cm (35 inch) rear harness branch (RIGHT SPRAY)
   3. 3-pin connector (machine wire harness—RIGHT SPRAY VALVE)
   4. Push-in fastener

2. Connect the 3-pin connector rear harness labeled CENTER SPRAY to the 3-socket connector of the machine wire harness labeled CENTER SPRAY VALVE.

3. Connect the 3-pin connector of the rear harness labeled RIGHT SPRAY to the 3-socket connector of the machine wire harness labeled RIGHT SPRAY VALVE.

4. Insert the push-in fastener of the rear harness into the hole in the flange of the flow-meter bracket.

1. Connect the 3-socket electrical connector of the 89 cm (35 inch) rear harness branch labeled FLOW METER into the 3-pin connector of the flow meter.

   

   Figure 68

   1. 3-pin connector (flow meter)
   2. 3-socket electrical connector (89 cm (35 inch) rear harness branch—FLOW METER)

2. Connect the 3-pin connector of the 89 cm (35 inch) rear harness branch labeled MASTER VALVE into the 3-socket connector of the machine wire harness labeled MASTER SPRAY VALVE.

   

   Figure 69

   1. 3-pin connector(actuator—master-spray valve)
   2. 3-pin connector (89 cm (35 inch) rear sprayer-harness branch—MASTER VALVE)
   3. 3-pin connector (89 cm (35 inch) rear sprayer-harness branch—MASTER VALVE)
   4. 3-socket connector (machine wire harness—MASTER SPRAY VALVE)

3. Connect 3-pin connector of the actuator for the master-spray valve into the 3-socket connector of the 89 cm (35 inch) rear harness branch labeled MASTER VALVE.

4. Connect the 4-pin connector of the actuator for the rate valve into the 4-socket connector of the 89 cm (35 inch) rear harness branch labeled RATE VALVE.

   

   Figure 70

   1. 4-socket connector—89 cm (35 inch) rear harness branch—RATE VALVE)
   2. 4-pin connector (actuator—rate valve)

1. Assemble hose (1 x 5-3/4 inches) on to the straight hose barb (1 x 2 inches) with a hose clamp (3/4 to 1-1/2 inches), and tighten the clamp by hand.

   

   Figure 71

   1. Straight hose barb (1 x 2 inches)
   2. Hose clamp (3/4 to 1-1/2 inches)
   3. Hose (1 x 5-3/4 inches)
   4. Manifold
   5. Hose (1 x 16 inches)

2. Assemble the other end of the hose (1 x 5-3/4 inches) onto the barbed fitting of the manifold with a hose clamp and tighten the hose clamp by hand.

3. Assemble the hose (1 x 16 inches) onto the other barbed fitting of the manifold with a hose clamp, and tighten the clamp by hand.

1. Assemble the straight hose barb (1 x 2 inches) to the flange of the flow meter with the gasket 38 mm (1-1/2 inches) and flange clamp 51 mm (2 inches).

   

   Figure 72

   1. Flange (flow meter)
   2. Gasket 38 mm (1-1/2 inches)
   3. Flange clamp 51 mm (2 inches)
   4. Straight hose barb (1 x 2 inches)

2. Tighten the flange clamp by hand.

1. Align the bypass hose assembly to the tank.

   

   Figure 73

   1. 90° barbed fitting (bypass hose assembly)
   2. Bulkhead fitting (spray tank)
   3. Retainer

2. Secure the 90° barbed fitting to the bulkhead fitting of the tank with a retainer.

1. Secure the magnets to the controller using 4 bolts (#8), 4 washers, and 4 locknuts (#8).

   

   Figure 76

2. Place the controller assembly onto the valve mount.

   

   Figure 77

1. Assemble the 3 section valves onto the flange of valve 7 of the spray valve assembly with the flange clamp and gasket.

   Important: The left, center, and right section valves are identified in the GeoLink sprayer system as follows: left section valve—nozzle 8, center section valve—nozzle 9, and right section valve—nozzle 10.

   

   Figure 78

   1. Flange—section valve (left spray section—nozzle valve 8)
   2. Flange clamp
   3. Gasket
   4. Flange—section valve 7 (GeoLink spray valve assembly)

2. Secure the socket of the quick-disconnect coupling for bypass valve of section valve 8 to the quick-disconnect coupling for bypass valve of section valve 7 with the previously removed retainer.

   

   Figure 79

   1. Quick-disconnect coupling (socket—bypass valve)
   2. Retainer

3. Assemble nozzle valve 10 to the valve mount the with the previously removed 2 flange-head bolt (1/4 x 3/4 inch) and 2 locknuts (1/4 inch).

   

   Figure 80

   Machines without the Hand Spray Wand Kit or the Electric Hose Reel Kit

   1. Flange-head bolt (1/4 x 3/4 inch)
   2. Section valve 10
   3. Locknut (1/4 inch)
   4. Valve mount
   5. Quick-disconnect fitting (plug)
   

   Figure 81

   Machines with the Hand Spray Wand Kit or the Electric Hose Reel Kit

   1. Flange-head bolt (1/4 x 3/4 inch)
   2. Section valve 10
   3. Locknut (1/4 inch)
   4. Valve mount
   5. Quick-disconnect fitting (socket)

4. Torque the flange-head bolts and locknuts to 1017 to 1243 N∙m (90 to 120 in-lb).

Lifting-equipment capacity: 23 kg (50 lb)

1. Using lifting equipment with the specified capacity, lift the valve mount and section valve assembly and align it over the center-boom section.

   

   Figure 82

   1. Valve mount and sprayer-valve assembly

2. Align the holes on the mount bracket of the valve mount to the holes on the truss frame of the center boom section.

   

   Figure 83

   1. Bracket (valve mount)
   2. Truss frame (center boom section)
   3. Flange locknut (5/16 inch)
   4. Flange head bolt (5/16 x 3/4 inch)

3. Assemble the valve mount to the truss frame with 4 bolts (5/16 x 3/4 inch) and 4 flange locknuts (5/16 inch).

   

   Figure 84

   1. Flange head bolt (5/16 x 3/4 inch)
   2. Bracket (valve mount)
   3. Flange locknut (5/16 inch)
   4. Truss frame (center spray section)

4. Repeat steps 2 through 3 for the other mount bracket of the valve mount at the other truss frame.

5. Torque the flange-head bolts and flange locknuts to 1978 to 2542 N∙cm (175 to 225 in-lb).

1. Assemble the hose (1 x 16 inches) over the 90° flange fitting (1 inch).

   

   Figure 85

   1. 90° flange fitting (1 inch)
   2. Hose clamp
   3. Hose (1 x 16 inches)
   4. Push-in fastener (cable tie)
   5. Valve mount

2. Secure the hose to the flange fitting with a hose clamp.

3. Assemble the cable tie/push-in fastener into the hole at the top of the valve mount.

4. Secure the cable tie/push-in fastener around the hose (1 x 16 inches).

1. Remove the retainers from the sockets of the quick-connect fittings.

2. Assemble the quick-connect fitting of the bypass hose to the quick disconnect fitting at the bypass valve at section valve 10.

   

   Figure 86

   1. Quick disconnect fitting (bypass valve)
   2. Socket—quick-connect fitting
   3. Retainer

3. Secure the quick disconnect fittings for the bypass hose and the bypass valve with the retainer.

4. Repeat steps 1 through 3 for the quick disconnect fittings at section valve 1.

1. Assemble the push-in fasteners of the valve actuator electrical-connectors into the holes in the valve mount.

   

   Figure 87

   1. Push-in fastener (valve actuator electrical-connector)
   2. Valve mount
   3. 3-pin connector (valve actuator—position 10)
   4. 3-pin connector (valve actuator—position 8)
   5. 3-pin connector (valve actuator—position 9)

2. Connect 3-socket connector of the 89 cm (35 inch) rear harness branch labeled NOZZLE VALVE 1) into the 3-pin connector of the left most valve actuator (position 1).

   Note: The valve actuator positions 1 through 10 are arranged from left to right when standing behind the machine.

   

   Figure 88

   1. 3-pin connector (valve actuator—position 1)
   2. 3-socket connector—89 cm (35 inch) rear harness branch (NOZZLE VALVE 1)
   3. Valve actuator (position 1)

3. Connect 3-socket connector of the 89 cm (35 inch) rear harness branch NOZZLE VALVE 2) into the 3-pin connector of the valve actuator (position 2).

4. Connect the remaining 3-socket connectors of the 89 cm (35 inch) rear harness branch into the 3-pin connector of the valve actuators.

   Note: Ensure that the 3-socket connector are connected to the related valve actuator position.

Insert the 3-socket connector 61 cm (24 inch) branch of the rear harness labeled PRESSURE TRANSDUCER GREEN WEDGE into the 3-pin connector of the pressure transducer.

Figure 89

1. 3-socket connector—61 cm (24 inch) rear harness branch (PRESSURE TRANSDUCER GREEN WEDGE)
2. 3-pin connector (pressure transducer)

1. Insert the 40-socket connector of the 102 cm (40 inch) branch of the rear harness into the 40-pin connector if the ASC 10 spray controller.

   

   Figure 90

   1. 40-pin connector (ASC 10 spray controller)
   2. 40-socket connector (102 cm (40 inch) wire-harness branch)
   3. Thumbscrew

2. Thread the thumb screw of the 40-socket connector into the ASC 10 connector by hand.

3. Insert the 4-socket connector of the rear harness labeled TO ASC 10 into the 4-pin connector of the ASC 10 spray controller.

   

   Figure 91

   1. 4-socket connector (TO ASC 10)
   2. 4-pin connector (ASC 10 spray controller)

1. Align the fixed end of the lift cylinder to the 16 mm (5/8 inch) hole in the cylinder mount.

   Note: Ensure that the extend and retract ports of the cylinder align up.

   

   Figure 92

   1. Lift cylinder (fixed end)
   2. Pivot pin
   3. Flange locknut (5/16 inch)
   4. Flange-head bolt (5/16 x 3/4 inch)
   5. Cylinder mount

2. Assemble the cylinder to the cylinder mount with the pivot pin, flanged-head bolt, and flange nut.

3. Torque the bolt and nut to 1978 to 2542 N·cm (175 to 225 in-lb).

4. Repeat steps 1 through 3 for the other lift cylinder at the other side of the cylinder mount.

1. Loosely assemble a new hydraulic hose (1/4 x 24-3/4 inches) between the extend port of the left boom-lift cylinder and port C3 of the boom-lift manifold.

   

   Figure 93

   1. Extend port (left boom-lift cylinder)
   2. Hydraulic hose (1/4 x 24-3/4 inches)
   3. Port C3 (boom-lift manifold)
   4. Retract port (left boom-lift cylinder)
   5. Port C4 (boom-lift manifold)

2. Loosely assemble a new hydraulic hose (1/4 x 24-3/4 inches) between the retract port of the left boom-lift cylinder and port C4 of the boom-lift manifold.

3. Loosely assemble a new hydraulic hose (1/4 x 24-3/4 inches) between the extend port of the right boom-lift cylinder and port C1 of the boom-lift manifold.

   

   Figure 94

   1. Port C1 (boom-lift manifold)
   2. Hydraulic hose (1/4 x 24-3/4 inches)
   3. Extend port (right boom-lift cylinder)
   4. Port C2 (boom-lift manifold)
   5. Retract port (right boom-lift cylinder)

4. Loosely assemble a new hydraulic hose (1/4 x 24-3/4 inches) between the retract port of the right boom-lift cylinder and port C2 of the boom-lift manifold.

5. Torque the hose fittings at the extend and retract ports of the lift cylinders to 21 to 26 N∙m (15 to 19 ft-lb).

6. Torque the swivel nuts of the hoses at the boom-lift manifold to 24 to 30 N∙m (17 to 22 ft-lb).

1. Cut the hose between 2 turrets.

   

   Figure 95

   1. Flange locknut (5/16 inch)
   2. Turret mount
   3. Turret
   4. Hose (3/4 inch inside diameter)

2. Remove the flange locknut (5/16 inch) that secures the turret to the turret mount.

3. Repeat the steps for the other 3 turrets.

   Note: Retain the flange locknut and turrets.

   Note: Discard the hoses, clamps, and T-fitting.

4. Repeat the steps for the other outer-boom section.

5. Remove the stainless steel screws (#12 x 1-1/4 inches) that secures the upper clamp halves and the double or single barbed-hose shanks (3/4 inch) to the body of each of the sprayer nozzle, and remove the barbed-hose shanks.

   Note: The hex-head bolt (5/16 x 3/4 inch—stainless steel) will separate from the upper clamp half when you open the clamp, retain the bolt for installation.

   

   Figure 96

   1. Upper clamp half
   2. Transfer tube
   3. Hex-head bolt (5/16 x 3/4 inch—stainless steel)
   4. Double barbed-hose shank (3/4 inch hose)
   5. Turret
   6. Stainless steel screw (#12 x 1-1/4 inches)
   7. Single barbed-hose shank (3/4 inch hose)

Lift equipment capacity: 46 kg (100 lb)

1. Using lift equipment with the specified capacity, raise the outer boom.

2. Insert a nylon-flange bushing into the 31.8 mm (1-1/4 inches) hole at each side of the pivot fitting.

   

   Figure 97

   1. Nylon-flange bushing
   2. Pivot fitting (outer-spray section)

3. Align the bushings in the pivot fitting with the holes in the flanges of the pivot bracket at the end of the center-boom section.

   

   Figure 98

   1. Pivot fitting (outer-spray section)
   2. Flange bolt (5/16 x 1 inch)
   3. Pivot pin
   4. Pivot bracket (center-spray section)
   5. Flange locknut (5/16 inch)

4. Assemble the pivot fitting to the pivot bracket with the pivot pin, flange bolt (5/16 x 1 inch), and flange locknut (5/16 inch).

5. Torque the bolt and nut to 1978 to 2542 N∙cm (175 to 225 in-lb).

6. Align the rod end of the lift cylinder with the hole 25 mm (1 inch) in the horn of the pivot fitting.

   

   Figure 99

   1. Hairpin
   2. Rod end (lift cylinder)
   3. Clevis pin
   4. 25 mm (1 inch) hole—horn of the pivot-fitting

7. Secure the lift cylinder to the pivot fitting with the clevis pin and hairpin.

8. Repeat steps 1 through 7 at the outer-boom section at the other side of the machine.

Note: Ensure that the barbed fitting is fully seated onto the coupler.

Secure the barbed fittings to the couplers with a retainer.

Figure 100

1. Section valve 1
2. Section valve 2
3. Section valve 3
4. Section valve 4
5. Section valve 5
6. Section valve 6
7. Section valve 7
8. Section valve 8
9. Section valve 9
10. Section valve 10
11. Supply hose 279 cm (110 inches)
12. Supply hose 234 cm (92 inches)
13. Supply hose 188 cm (74 inches)
14. Supply hose 81 cm (32 inches)

Note: The supply hose assembly 81 cm (32 inches) has a T-fitting with 2 branch hoses and 2 single barbed-hose shanks.

Figure 101

Nozzle Locations

Use Figure 102 through Figure 106 to route the hoses. Only one side is shown. The routing is the same for both sides.

Figure 102

81 cm (32 inch) hose

Figure 103

188 cm (74 inch) hose

Figure 104

188 cm (74 inch) hose

Figure 105

234 cm (92 inch) hose

Figure 106

279 cm (110 inch) hose

1. Align the transfer tube in the saddle of a turret [with the hole in the side of the single barbed-hose shank (1/2 inch)].

   

   Figure 107

   1. Hex-head bolt (5/16 x 3/4 inch—stainless steel)
   2. Transfer tube
   3. Upper clamp half
   4. Single barbed-hose shank (1/2 inch)
   5. Stainless steel screw (#12 x 1-1/4 inches)
   6. Turret
   7. Toward the spray section

2. Close the upper clamp half around the barbed-hose shank and secure the clamp half and turret body with the stainless steel screw (#12 x 1-1/4 inches); torque the stainless steel screw to 14 to 18 N∙m (20 to 25 in-lb).

   Note: Ensure that the hex-head bolt (5/16 x 3/4 inch) is seated in the recess in the upper clamp half when closing the clamp.

3. Secure the turrets to the mounts using the previously removed flange locknuts (5/16 inch).

   

   Figure 108

   1. Flange locknut (5/16 inch)
   2. Turret mount
   3. Turret
   4. Back of the machine
   5. Hex-head bolt (stainless steel—5/16 x 3/4 inch)

4. Torque the flange locknut to 1978 to 2542 N∙cm (175 to 225 in-lb).

1. Align the end of the pressure-sense tube (plastic) for the pressure gauge in the dash with the locking collar for the tube coupler.

   

   Figure 109

   1. Pressure-sense tube (dash-pressure gauge)
   2. Locking collar (tube coupler)

2. Insert the sense tube into the locking collar until the tube is fully seated.

1. Secure the receiver plate to the receiver mount using 1 bolt (3/8 x 3-1/4 inches), 1 lock washer, 1 washer, 1 spacer (3/8 x 1 inch), and 1 locknut (3/8 inch).

   

   Figure 110

2. Assemble the flange-head bolt (5/16 x 3/4 inch) and flange locknut (5/16 inch) through the smaller hole in the receiver mount and the slot in the receiver plate.

   

   Figure 111

3. Tighten the bolts and nuts so that you can rotate the receiver plate with slight resistance.

1. Assemble the receiver mount and spacer (3/8 x 7/16 inch) to the roll bar with the flange-head bolt (3/8 x 1-1/2 inches).

   

   Figure 112

2. Tighten the bolts so that you can rotate the receiver plate with slight resistance.

3. Level the receiver plate left to right.

   

   Figure 113

4. Torque the flange-head bolt (5/16 x 3/4 inch) and flange locknut (5/16 inch) to 1978 to 2542 N∙cm (175 to 225 in-lb).

5. Level the receiver plate front to back.

6. Torque the bolt (3/8 x 3-1/4 inches) and flange locknut (3/8 inch) to 37 to 45 N∙m (27 to 33 ft-lb).

1. Install the receiver onto the mount using 4 bolts (5 x 16 mm) and 4 washers.

   Note: Ensure that both arrows are pointing toward the front of the machine.

   

   Figure 114

2. Torque the 3 bolts to 576 to 712 N∙cm (51 to 63 in-lb).

1. Install the modem antenna bracket to the roll bar.

   

   Figure 115

2. Clean any grease or oil from the antenna mount surface.

3. Remove the backing from the double sided adhesive liner and adhere the antenna to the mount.

   

   Figure 116

4. Secure the antenna and wire harness to the mount with 3 cable ties.

   

   Figure 117

5. Place the high gain antenna next to the other antenna on the roll bar.

   

   Figure 118

1. Route the modem-antenna harnesses to the right, along the roll bar.

   

   Figure 119

   

   Figure 120

2. Route the harness down and forward.

   

   Figure 121

   1. Connectors (modem-antenna harness)

1. Route the 302 cm (119 inches) branch of the navigation-data and electrical harness along the right ROPS tube with the 12-socket connector (gray) and 12-socket connector (black) up toward the navigation receiver.

2. Connect the 2 connectors at the long face of the 12-socket connector of the data harness labeled with the 2 connector slots into the adapter harness.

   

   Figure 123

3. Plug the adapter harness into the receiver.

1. Route the navigation-data and electrical harness along the right roll bar tube and the modem-antenna harness to the cross member for the seat support.

   

   Figure 124

2. Secure the harnesses to the roll bar with cable ties.

   Note: Ensure that the harness is slack between the 12-socket connectors and the cable tie.

3. Route the 227 cm (89-1/2 inches) branch of the navigation-data and electrical harness along the bottom of the control console of the machine.

   

   Figure 125

   1. 227 cm (89-1/2 inches) harness branch (navigation-data and electrical harness)
   2. 258 cm (101-1/2 inch) power-harness branch (navigation-data and electrical harness)
   3. Navigation-data and electrical harness
   4. Modem-antenna harness

4. Route the 258 cm (101-1/2 inch) branch of the navigation-data and electrical harness across the shock-support tube and toward the battery.

1. Adhere the magnetic mount of the rear harness to the right, upper tube frame of the machine.

   

   Figure 126

   1. Magnetic mount (rear harness)
   2. Right, upper tube frame
   3. 4-socket connector (labeled —rear harness)
   4. 4-pin connector (labeled —data harness)

2. Plug the 4-pin connector labeled of the data harness into the 4-socket connector labeled of the rear harness.

1. Mark the position of the steering wheel to the steering valve with a piece of tape.

   

   Figure 127

   1. Steering-wheel cover
   2. Nut (5/8 inch)
   3. Washer (5/8 inch)
   4. Steering wheel
   5. Shaft (steering valve)
   6. Tape

2. Remove the cover from the steering wheel.

3. Remove the nut (5/8 inch) and washer (5/8 inch) that secure the steering wheel to the steering valve, and remove the steering wheel.

1. Align the display mount to the machine as shown.

   

   Figure 128

   1. Monitor mount

2. Assemble the display mount to the housing of the steering valve with the 3 flange-head bolts (6 x 12 mm).

   

   Figure 129

   1. Monitor mount
   2. Flange-head bolt (6 x 12 mm)
   3. Housing (steering valve)

3. Assemble the plate of the display mount to the support tube of the machine chassis with the 2 U-bolts and 4 flange locknuts (5/16 inch).

   

   Figure 130

   1. Flange locknut (5/16 inch)
   2. Plate (display mount)
   3. Support tube (machine chassis)
   4. U-bolt (5/16 inch)

4. Torque the 3 flange-head bolts (6 x 12 mm) at the steering valve to 972 to 1198 N∙cm (86 to 106 in-lb); At the support tube, torque the flange locknuts to 1978 to 2542 N∙cm (175 to 225 in-lb).

1. Align the tape mark on the steering wheel to the tale mark on the housing of the steering valve.

   

   Figure 131

   1. Steering-wheel cover
   2. Nut (5/8 inch)
   3. Washer (5/8 inch)
   4. Steering wheel
   5. Shaft (steering valve)

2. Assemble the steering wheel onto the shaft of the steering valve with the previously removed washer (5/8 inch) and nut (5/8 inch).

3. Torque the nut to 206 to 254 N∙m (152 to 188 ft-lb).

4. Install the cover.

1. Assemble the ball mount to the bracket for the display mount with the 4 flange-head bolts (5/16 x 3/4 inch) and 4 flange locknuts (5/16 inch).

   

   Figure 132

   1. Bracket (display mount)
   2. Flange-head bolt (5/16 x 3/4 inch)
   3. Ball mount
   4. Flange locknut (5/16 inch)

2. Torque the bolts and nuts to 1978 to 2542 N∙cm (175 to 225 in-lb).

3. Assemble the ball fitting of the display and the ball mount on the machine to the long display arm.

   

   Figure 133

4. Adjust the display so that it is viewable from the machine operator’s position and tighten the display arm knob by hand.

1. Route the 227 cm (89-1/2 inch) branch of the navigation-data and electrical harness (the branch with the 26-socket connector) up and along the support tube for the display.

2. Plug the navigation data harness into the monitor.

   

   Figure 134

Remove the terminating resistor from the 6-socket connector labeled CAN 2 TERMINATOR of the data cable as shown.

Note: You no longer need the terminating resistor.

Figure 135

Screw the modem harness connector into the display.

Figure 136

1. Route the modem data harness along the data harness for the display.

2. Route the modem data harness under the shock-support tube of the machine

3. Route the modem data harness across the back if the relays and down.

   

   Figure 137

   1. Data harness (control console)
   2. Modem data harness

4. Align the 4-pin connector labeled of the modem data harness near the 4 connectors for the modem-antenna harness as shown.

   

   Figure 138

   1. Connectors (modem-antenna harness)
   2. 4-pin connector (labeled —modem data harness)

1. At the right, upper tube frame, bundle the navigation-data and electrical harness, and the CAN 2 ASC 10 BUS wire harness branch to the kit sprayer harness with 2 cable ties.

2. Bundle the modem-antenna harness and secure it to the kit sprayer harness bundle with 2 cable ties.

   

   Figure 139

   1. Kit sprayer harness
   2. Cable ties
   3. Navigation-data and electrical harness
   4. CAN 2 ASC 10 BUS wire harness branch
   5. Modem-antenna harness

3. Secure the modem-data harness and the navigation-data and electrical harness to the monitor tube with a cable tie.

   

   Figure 140

   1. Cable tie
   2. Modem-data harness
   3. Monitor tube
   4. Navigation-data and electrical harness

4. Secure the modem-data harness to the navigation-data and electrical harness with a cable tie.

1. Remove the push-in fastener that secures the wire harness of the machine to the prop-rod bracket.

   

   Figure 146

   1. Push-in fastener (machine wire harness)
   2. Prop-rod bracket

2. Secure the modem to the bracket using 2 bolts (#10-24 x 1-3/8 inches) and 2 nuts (#10-24).

   

   Figure 147

3. Secure the magnets to the modem bracket using the rivets.

   

   Figure 148

4. Place the modem bracket under the prop-rod bracket and behind the flange of the machine frame.

   

   Figure 149

5. Insert the upper push-in fastener of the wire harness into the holes in the prop-rod bracket.

   

   Figure 150

   1. Modem bracket
   2. Push-in fastener (machine wire harness)
   3. Prop-rod bracket

1. Plug the coaxial connector of the modem-antenna harness labeled into the coaxial port of the CL-55 modem marked WIFI/BT, and tighten the coaxial connector.

   

   Figure 151

   1. Coaxial connector (labeled —modem-antenna harness)
   2. Blue coaxial push-in connector (labeled ––modem-antenna harness)
   3. Violet coaxial push-in connector (labeled —modem-antenna harness)
   4. Red coaxial push-in connector (labeled —modem-antenna harness)

2. Plug the blue coaxial push-in connector of the modem-antenna harness labeled into the connector of the CL-55 modem marked , until the connectors latch securely.

3. Plug the violet coaxial push-in connector of the modem-antenna harness labeled into the connector of the CL-55 modem marked , until the connectors latch securely.

4. Plug the red coaxial push-in connector of the modem-antenna harness labeled into the connector of the CL-55 modem marked , until the connectors latch securely.

1. Plug the 4-pin connector of the modem data harness labeled into the 4-socket connector (unmarked) of the CL-55 modem, and tighten the knurled nut of the 4-pin connector.

   

   Figure 152

   1. 4-pin connector (labeled —modem data harness)
   2. 4-socket connector (unmarked—CL-55 modem)
   3. 18-socket connector (labeled —modem power harness)
   4. 18-pin connector (CL-55 modem)

2. Plug the 18-socket connector of the modem power harness labeled into the 18-pin connector of the CL-55 modem.

1. At the front of the control console of the machine, route the connector labeled of the ISO-CAN bus harness into the bottom of the display.

   

   Figure 154

   1. Connector (labeled —ISO-CAN bus harness)
   2. Connectors (labeled —ISO-CAN BUS HARNESS)

2. Remove the cap from the 4-socket connector labeled of the navigation-data and electrical harness.

   

   Figure 155

   1. 4-socket connector (labeled —navigation-data and electrical harness)
   2. Cap
   3. ISO-CAN bus harness

3. Plug the 4-pin connector labeled of the ISO-CAN bus harness into the 4-socket connector labeled of the navigation-data and electrical harness.

   

   Figure 156

   1. 4-socket connector (labeled —navigation-data and electrical harness)
   2. 4-pin connector (labeled —ISO-CAN bus harness)

4. Route the connectors labeled and of the ISO-CAN bus harness toward the fuse block.

   

   Figure 157

   1. Connectors (labeled and —ISO-CAN bus harness)

1. At the fuse block, remove the cap from the 3-socket connector labeled of the machine wire harness.

   

   Figure 158

   1. 3-socket connector (labeled —machine wire harness)
   2. Cap
   3. Connectors—kit sprayer harness (labeled and —do not connect)
   4. 3-pin connector (labeled —ISO-CAN bus harness)

2. Plug the 3-pin connector labeled of the ISO-CAN bus harness into the 3-socket connector labeled of the machine wire harness.

   Important: Do not connect the harness connectors labeled and of the rear harness.

1. Bundle the ISO-CAN bus harness and secure it to the navigation-data and electrical harness with a cable tie.

   

   Figure 159

   1. Cable tie
   2. ISO-CAN bus harness
   3. Right frame tube
   4. Navigation-data and electrical harness

2. Secure the ISO-CAN bus harness and navigation-data and electrical harness to the right frame tube with a cable tie as shown.

1. Remove the 2 flange locknuts and hold-down rod from the 2 J-bolts that secure the battery to the battery bracket of the machine.

   

   Figure 164

   1. Flange locknut (1/4 inch)
   2. Hold-down rod
   3. J-bolt
   4. Battery (300 A)

2. Remove and discard the 2 J-bolts and battery tray from the battery bracket.

   

   Figure 165

   1. J-bolt
   2. Battery tray

3. Remove the battery from the machine.

   Note: You no longer need the flange nuts, hold-down rod, and battery (300 A).

4. Remove and retain the 3 bolts (10-24 x 3/4 inch) and 3 nuts (10-24) that secure the fuse blocks to the battery bracket.

   

   Figure 166

   1. Bold-down rod
   2. Fuse block
   3. Flange-head bolt (3/8 x 3/4 inch)
   4. Bolt (10-24 x 3/4 inch)

5. Remove and retain the 2 flange-head bolts (3/8 x 3/4 inch) that secure battery bracket to the shock-support tube of the machine.

6. Remove and retain the 2 bolts (10-24 x 3/4 inch), 2 locknuts (10-24), and wire-support clip that secure the ground block and wire to the battery bracket.

   Note: Discard the wire support clip.

   

   Figure 167

   1. Wire-support clip
   2. Battery bracket
   3. Ground block
   4. Bolt (10-24 x 3/4 inch)

7. Remove and discard the battery bracket from the machine.

   

   Figure 168

   1. Battery bracket

1. Assemble the 2 bumpers to the battery bracket with 2 flange locknuts (1/4 inch).

   

   Figure 169

   1. Bumper
   2. Battery bracket
   3. Flange locknut (1/4 inch)

2. Assemble the strap through the 2 slots in the battery bracket.

   

   Figure 170

   1. Latch (strap buckle)
   2. Slot (battery bracket)

1. Align the new battery bracket to the shock-support tube of the machine and the fuse blocks.

   

   Figure 171

   1. Battery bracket

2. Assemble the battery bracket to the shock-support tube with the previously removed 2 flange-head bolt (3/8 x 3/4 inch).

   

   Figure 172

   1. Shock-support tube
   2. Battery bracket
   3. Flange-head bolt (3/8 x 3/4 inch)

3. Torque the flange head bolts to 37 to 45 N∙m (27 to 33 ft-lb).

4. Secure the ground block and to the battery bracket with the previously removed 2 bolts (10-24 x 3/4 inch), 2 locknuts (10-24) and secure the wire-support clip to the edge of the bracket.

   

   Figure 173

   1. Wire-support clip
   2. Battery bracket
   3. Ground block
   4. Bolt (10-24 x 3/4 inch)

5. Secure the fuse blocks to the battery bracket with the 3 previously removed bolts (10–24 x 3/4 inch) and 3 nuts (10-24).

   

   Figure 174

   1. Fuse block
   2. Bolt (10–24 x 3/4 inch)

6. Assemble the battery (650 A) into the battery bracket.

   

   Figure 175

   1. Battery-strap buckle
   2. Webbing (battery strap)

7. Feed the webbing of the battery strap through the buckle, and tighten the strap until the battery is secure.

1. At the pump head, loosen the 2 bolts to provide a 7 to 10 mm (1/4 to 3/8 inch) gap between the head of the bolts and the pump.

   Note: You do not need to remove the bolts from the spray pump.

   

   Figure 176

   1. Bolts (pump head)
   2. Pump head (11 o’clock position)
   3. Back of the machine

2. Align the alternator bracket between the bolts and the pump head.

   

   Figure 177

   1. Alternator bracket
   2. Bolts (pump head)

3. Torque the bolts to 61 to 75 N (45 to 55 ft-lb).

1. Loosen the nut for the idler-pulley shaft.

   Note: Ensure that there is no belt tension.

   

   Figure 178

   1. Belt-tension bolt (machine)
   2. Nut (idler-pulley shaft)

2. Rotate the belt-tension bolt to remove all tension from the sprayer-pump belt.

3. Remove the 4 bolts (1/4 x 1 inch) and 4 lock washers (1/4 inch) that secure the pulley to the sprayer pump.

   Important: Do not remove the pulley.

   Note: Retain the lock washer; you no longer need the bolts.

   

   Figure 179

   1. Bolt (1/4 x 1 inch)
   2. Lock washer (1/4 inch)
   3. Pulley (sprayer pump)

4. Align the holes in the pulley for the alternator (kit) with the holes in the pulley for the sprayer pump.

   

   Figure 180

   1. Drive pulley 279 mm (11 inch)
   2. Pulley (sprayer pump)
   3. Bolt (1/4 x 2-1/4 inches)
   4. Lock washer (1/4 inch)

5. Assemble the alternator pulley to the sprayer-pump pulley and sprayer pump with the 4 bolt (1/4 x 2-1/4 inches) and 4 lock washers (1/4 inch).

6. Torque the bolts to 1017 to 1243 N∙m (90 to 110 in-lb).

7. Rotate the belt-tension bolt to increase the tension of the belt until you measure belt 9.5 mm (3/8 inch) of belt deflection when you apply 4.5 kg (10 lb) halfway between the engine and spray pump sprockets.

   

   Figure 181

   1. Belt-tension bolt (machine)
   2. Nut (idler-pulley shaft)

8. Tighten the nut for the idler-pulley shaft to 37 to 44 N∙m (27 to 33 ft-lb).

1. Assemble the alternator (60 A) to the threaded boss of the alternator-bracket ith the flange-head bolt (3/8 x 1-1/2 inches).

   

   Figure 182

   1. Threaded flange (8 mm)—alternator (60 A)
   2. Slotted flange (alternator bracket)
   3. Flange-head bolt (8 x 25 mm)
   4. Flange-head bolt (3/8 x 1-1/2 inches)
   5. Flange (10 mm (3/8 inch) hole)—alternator (60 A)
   6. Threaded boss (3/8-16)—alternator-bracket

2. Assemble the threaded flange of the alternator to the slotted flange of the alternator bracket with the flange-head bolt (8 x 25 mm).

3. Assemble the V-belt over the drive pulley 279 mm (11 inch) and the pulley of the alternator.

   

   Figure 183

   1. Pulley (Alternator—60 A)
   2. V-belt
   3. Drive pulley 279 mm (11 inch)

4. Rotate the alternator up to increase tension on the belt until you measure belt 9.5 mm (3/8 inch) of belt deflection when you apply 4.5 kg (10 lb) halfway between the alternator pulley and drive pulley 279 mm (11 inch).

   

   Figure 184

   1. Flange-head bolt (8 x 25 mm)
   2. Flange-head bolt (3/8 x 1-1/2 inches)
   3. Belt deflection 9.5 mm (3/8 inch)

5. Torque the flange-head bolt (8 x 25 mm) to 23 to 29 N∙m (17 to 21 ft-lb).

6. Torque the flange-head bolt (3/8 x 1-1/2 inches) to 37 to 45 N∙m (27 to 33 ft-lb).

1. Connect the 2-socket at the end of the pink wire 57 cm (23-1/2 inches) of the harness onto the 2-pin connector of the alternator (50 A).

   

   Figure 185

   1. 2-pin connector—alternator (50 A)
   2. 2-socket connector—sense wire, pink 57 cm (23-1/2 inches)

2. Route the pink sense wire away from the alternator belts and secure the wire with a cable tie.

3. Remove the nut from the terminal post of the alternator (50 A).

   

   Figure 186

   1. Alternator cable (red—6 gauge)
   2. Nut
   3. Terminal post—alternator (50 A)

4. Assemble the end of the red, 6 gauge alternator cable with the insulator cover onto the terminal post of the alternator (50 A) with the nut.

5. Route the other end of the alternator cable toward the battery posts, away from the pulley and alternator belt.

6. Torque the nut to 47 to 57 N∙m (34 to 42 ft-lb).

7. Slip the insulator cover over the terminal post of the alternator.

1. Connect the 5-pin connector of the relay into the 5-socket connector of the harness labeled ASC 10 ENABLE RELAY.

   

   Figure 187

   1. Hole (shock-support tube)
   2. Relay
   3. Push-in fastener
   4. 5-socket connector (ASC 10 ENABLE RELAY)

2. Align the hole in the mounting tab of the relay with the hole in the shock-support tube, and secure the relay to the tube with a push-in fastener.

1. Prepare a multi-meter for preforming a continuity test.

2. At fuse block 3 of the machine, insert the multi-meter probe into contact 4 (the right column) of fuse-socket 2.

   

   Figure 188

   1. Fuse block 3 (machine)
   2. Multi-meter lead
   3. Fuse-socket 2—contact 4 (right column)
   4. Multi-meter probe

3. At the front side of the fuse blocks, use the other multi-meter probe to identify the blade connector at the end of the red 10-gauge wire that connects to fuse-socket 2—contact 4.

   

   Figure 189

   1. Multi-meter lead
   2. Tape
   3. Blade connector (red 10-gauge wire)
   4. Multi-meter probe

4. Use a piece of tape to mark the connector and wire that you identified in the previous step.

5. Connect the blade connector that you marked in the previous step into the socket connector at the end of the pink wire 51 mm (2 inches) of the harness.

   

   Figure 190

   1. Marked blade connector (red 10-gauge wire)
   2. Socket connector—pink wire 51 mm (2 inches)

6. Insert the fuse (15 A) into fuse-socket 2 of fuse block 3 until the fuse is fully seated.

   

   Figure 191

   1. Fuse-socket 2 (fuse block 3)
   2. Fuse (15 A)

1. Remove the hex nuts and washers from the handle quick-connect clamps.

2. Open the latch handle of the quick-connect clamp with the black handle.

   

   Figure 192

3. Assemble the quick-connect clamp onto the negative battery post, with the threaded post of the clamp aligned toward the center of the battery.

4. Close the latch handle of the quick-connect clamp.

   Note: If you need to adjust the clamping force of the quick-connect clamp, open the handle, rotate the knurled nut to increase or decrease the clamping force, and close the handle for the clamp.

5. Repeat the steps for the red handle clamp on the positive battery post.

1. Slit the insulator cover of the positive battery cable to the starter.

   

   Figure 193

   1. Slit (insulator cover—positive battery cable to the starter)

2. Assemble the following wire and cable terminals onto the threaded post of the positive battery terminal in the following order:

   Important: Ensure that the battery-cable terminal (positive) to the engine starter is positioned at the top of the stack of terminals on the threaded post.

   1. Ring terminal—165 cm (65 inch) modem power harness branch (labeled

   2. Battery-cable terminal (positive)—to the alternator (50 A)

   3. Ring terminal—258 cm (101-1/2 inch) navigation-data and electrical harness branch (labeled )

   4. Ring terminal—21.6 cm (8-1/2 inch) machine harness branch (labeled )

   5. Ring terminal—24 cm (9-1/2 inch) kit sprayer-harness branch (unlabeled)

   6. Battery-cable terminal (positive)—to the engine starter

   

   Figure 194

   1. Washer 1/4 inch (quick-connect clamp)
   2. Hex nut 1/4 inch (quick-connect clamp)
   3. Battery-cable terminal (positive)—to the engine starter
   4. Ring terminal—24 cm (9-1/2 inch) kit sprayer-harness branch (unlabeled)
   5. Ring terminal—21.6 cm (8-1/2 inch) machine harness branch (labeled )
   6. Ring terminal—258 cm (101-1/2 inch) navigation-data and electrical harness branch (not labeled—red wire insulation)
   7. Threaded post—quick-connect clamp (positive battery post)
   8. Battery-cable terminal (positive)—to the alternator (50 A)
   9. Ring terminal—165 cm (65 inch) modem power harness branch (labeled )

3. Assemble the hex nut (1/4 inch) and washer (1/4 inch) onto the threaded post, and torque the nut to 1017 to 1234 N∙cm (90 to 110 in-lb).

4. Align the insulator cover of the positive battery cable to the starter over the threaded post.

5. Assemble the following wire and cable terminals onto the threaded post of the negative battery terminal in the following order:

   Important: Ensure that the battery-cable terminal (negative) to the engine and chassis ground is positioned at the top of the stack of terminals on the threaded post.

   1. Ring terminal—258 cm (101-1/2 inch) navigation-data and electrical harness branch (not labeled—black wire insulation)

   2. Ring terminal—165 cm (65 inch) modem power harness branch (labeled )

   3. Battery-cable terminal (negative)—to the engine and chassis ground

   

   Figure 195

   1. Battery-cable terminal (negative)—to the engine and chassis ground
   2. Hex nut (1/4 inch—quick-connect clamp)
   3. Washer (1/4 inch—quick-connect clamp)
   4. Ring terminal—165 cm (65 inch) modem power harness branch (labeled )
   5. Threaded post—quick-connect clamp (negative battery post)
   6. Ring terminal—258 cm (101-1/2 inch) navigation-data and electrical harness branch (not labeled—black wire insulation)

1. Gather the excess length of the data harness against the right, upper-frame tube.

   

   Figure 196

   1. Cable tie
   2. Data-harness bundle
   3. Shock-support tube
   4. Right, upper-frame tube

2. Align the data harness to the shock-support tube, and secure the harness to the tube with a cable tie.

3. Align the data-harness bundle to the right, upper-frame tube, and secure the harness bundle to the frame tube with a cable tie.

4. Ensure that there is clearance between the pulleys and belts and the data harness, battery harness, kit wire harness, and battery cables.

   Secure the wire harness and cables with cable ties as needed to provide clearance away from the belts and pulleys.

1. Align the hood holes in the hood with the holes in the dash panel and frame of the machine.

   

   Figure 199

   1. Dash panel
   2. Hood
   3. Push-in fastener
   4. Dash support

2. Secure the hood to the dash and frame with 9 push-in fastener.

3. Connect the 2 electrical connectors (2-socket) of the machine wire harness from the 2-pin connectors of the left and right headlights.

   

   Figure 200

   1. Headlights
   2. 2-socket connector (machine wire harness)
   3. 2-pin connector (headlight)

1. Align the inner-fender shroud to the left, upper- and left, lower-frame tubes.

   

   Figure 201

   1. Left, upper-frame tube
   2. Inner-fender shroud
   3. Push-in fastener
   4. Left, lower-frame tube
   5. Washer (9/16 x 1/2 inch)

2. Secure the inner-fender shroud to the frame tubes with the 6 push-in fasteners.

3. Align the holes in the fender with the holes in the frame of the machine.

   

   Figure 202

   1. Washer (5/16 inch)
   2. Bolt (5/16 x 1 inch)
   3. Left, front fender

4. Loosely assemble the fender to the frame with the previously removed 3 bolts (5/16 x 1 inch) and 3 washers (5/16 inch).

5. Secure the fender to the frame channel with the 2 push-in fasteners.

   

   Figure 203

   1. Push-in fastener
   2. Left, front fender

6. Torque the bolt (5/16 x 1 inch) to 1978 to 2542 N∙cm (175 to 225 in-lb).

7. Repeat steps 1 through 6 for the inner-fender shroud and fender at the other side of the machine.

1. Align the inner-fender shroud to the right, upper and right, lower-frame tubes.

   

   Figure 204

   1. Washer (9/16 x 1/2 inch)
   2. Push-in fastener
   3. Inner-fender shroud

2. Secure the inner-fender shroud to the frame tubes with the 6 push-in fasteners and 5 washers (9/16 x 1/2 inch).

3. Align the right, front fender to the machine and align the holes in the fender with the holes in the frame.

   

   Figure 205

   1. Clip nut (cross-member support)
   2. Washer (5/16 inch)
   3. Capscrew (5/16 x 1 inch)
   4. Right, front fender

4. Secure right, front fender to the clip nut of the cross-member support with the capscrew (5/16 x 1 inch) and washer (5/16 inch).

5. Secure the right, front fender to the roll bar mounting channel with 2 push-in fasteners.

   

   Figure 206

   1. Push-in fastener
   2. Right, front fender

6. Align the hole in the right, front fender with the hole in the platform floor and secure the fender to the floor with a capscrew (5/16 x 1 inch) and washer (5/16 inch).

   

   Figure 207

   1. Capscrew (5/16 x 1 inch)
   2. Washer (5/16 inch)
   3. Platform floor
   4. Right, front fender

7. Align the hole in the bottom console cover to the hole in the shock-support tube and the hole in the end console cover to the hole in the cross-member tube.

   

   Figure 208

   1. Capscrew (5/16 x 1 inch)
   2. Washer (5/16 inch)
   3. Console cover (bottom)
   4. Console cover (end)

8. Secure the covers to the tubes with 2 capscrews (5/16 x 1 inch) and 2 washers (5/16 inch).

1. Align the latches of the engine access panel with the bushings in the panel-support brackets on the roll bar.

   

   Figure 209

   1. Latch
   2. Panel-support bracket
   3. Engine access panel

2. Assemble the panel onto the brackets.

3. Rotate the handles latches down to secure the panel to the brackets.

1. Align the seat and seat plate to the chassis of the machine.

   

   Figure 210

   1. Seat plate
   2. Seat

2. Align the holes in the pivot fittings of the seat pan with the holes in the chassis bracket.

   

   Figure 211

   1. Seat plate
   2. Seat
   3. Hairpin
   4. Pivot fitting (seat pan)
   5. Chassis bracket
   6. Pivot pin

3. Assemble the seat pan to the chassis brackets with the 2 pivot pins.

4. Secure the pivot pins to the machine with the 2 hairpins.

5. Assemble the prop rod to the bracket of the seat with the washer and hairpin.

   

   Figure 212

   1. Washer
   2. Bracket (seat)
   3. Hairpin
   4. Prop rod

6. Plug the 2-socket connector of the machine wire harness into the connector for the seat switch until the connectors latch securely.

   

   Figure 213

   1. 2-socket connector (machine wire harness)
   2. Seat-switch connector

7. Rotate the seat forward slightly, remove the prop rod from the detent, rotate the seat down until the seat latches securely.