Form No. 3406-964 Rev A Road Light and Homologation Kit Multi-Pro 5800 Turf Sprayer Model No. 41628 Installation Instructions WARNING Introduction This kit is designed to add the light components required for on-road travel. It is a dedicated attachment for a turf spray application vehicle and is intended to be used by professional, hired operators in commercial applications.
Installation Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 Description Qty. Use No parts required – Prepare to install the kit. No parts required – Remove the undercarriage shroud and heat shield.
Procedure 11 12 Description Use Qty. No parts required – Install the undercarriage shroud. No parts required – Finish the rinse tank kit installation. 1 Preparing to Install the Kit No Parts Required Procedure WARNING Incorrect battery cable routing could damage the sprayer and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
g028168 Figure 3 1. Forward heat shield 2. Hex-head bolts and washers 3. Front of the machine Removing the Undercarriage Shroud g208653 Figure 5 2017 machine shown; 2016 machines are similar G032041 g032041 1. Undercarriage shroud 3. Flange-head bolts (5/16 x 7/8 inch) 2. Washers (5/16 inch) 4. Front of the machine Figure 4 2.
3 Assembling the Worklight and Wire Harness Parts needed for this procedure: g032043 Figure 6 1 Wire Harness 1 Grommet 2 Worklight mount 1. Engine mounts 4. Flange locknuts (5/16 inch) 1 Support channel 2. Bolt—shown for clarity; do not remove 3. Undercarriage shroud 5. Front of the machine 4 Flange-head bolt (3/8 x 2-1/4 inches) 4 Spacer 4 Flange locknut (3/8 inch) 2 Worklight 3. Lift the support straps over the bolts that secure the undercarriage shroud to the engine-mount brackets.
Assembling the Wire Harness to the Worklight Support move the grommet toward the 112 cm (44 inches) wire harness branch (Figure 9). 1. Assemble the 2 worklight mounts onto the 112 cm (44 inches) wire harness branch and the 99 cm (39 inches) wire harness branch as shown in Figure 10. g207890 Figure 10 1. Worklight mount 3. 99 cm (39 inches) wire harness branch—LEFT FRONT TURN/RUNNING LIGHT 2. 112 cm (44 inches) wire harness branch—RIGHT FRONT TURN/RUNNING g207895 Figure 8 1.
g207904 g208157 Figure 12 g207896 Figure 11 1. Flange locknut (3/8 inch) 4. Support channel 2. Worklight mount 5. Flange-head bolt (3/8 x 2-1/4 inches) 7. Repeat steps 2 through 6 for the worklight mount at the other end of the support channel (Figure 11). 3. Spacer Installing Worklights to the Support 3. Assemble the support channel to the worklight mount (Figure 11) with the 4 flange-head bolts (3/8 x 2-1/4 inches), 4 spacers, and 2 flange locknuts (3/8 inch). 1.
Installing the Worklight Assembly to the Machine 1. Assemble the worklight mount and support channel to the frame of the floor plate with 2 flange locknuts as shown in Figure 14. g207892 Figure 14 1. Stud (worklight) 4. Locknut (10 mm) 2. Serrated shell 5. Flange (worklight mount) g207893 Figure 16 3. Spherical joint 3. Assemble the worklight into the hole in the flange of the worklight mount (Figure 14) with a serrated shell, spherical joint, and locknut (10 mm), and tighten the lamp by hand. 3.
4 Installing the Wire Harness for the Switches Parts needed for this procedure: 1 Flange-head bolt (1/4 x 3/4 inch) 1 Flasher module (CE) g208202 1 Flange locknut (1/4 inch) 2 Cable tie 1 Horn switch 1 Jam nut (5/8 inch) 1 Knurled nut (5/8 inch) 1 Button 1 Switch—rocker (on-off-on) 1 Switch—rocker (illuminated) 1 Turn-signal switch 1 Hose clamp Figure 18 1. Front wire harness (machine) 3. Grommet (floor plate) 2. 108 cm (42-1/2 inches) wire harness branch 4.
g208200 Figure 20 1. Hole—inboard wall (storage compartment) 2. Flange-head bolt (1/4 x 3/4 inch) g208201 Figure 22 4. Assemble the CE flasher module to the flange-head bolt with a flange locknut (1/4 inch), and tighten by hand (Figure 21). 1. Flasher module (CE) 3. 6-pin connector—front wire harness of the machine (light kit interface) 2. 6-socket connector—kit wire harness (CE flasher module) 4. 6-pin connector—kit wire harness (TO MAIN HARNESS) 6.
Installing the Horn Switch 1. Remove the round knockout from the dash panel as shown in Figure 24. g208263 Figure 25 1. Terminal (TO HEAD SWITCH PIN 1) g208262 Figure 24 LIGHT 4. 2-socket connector (horn switch) 2. 8-socket connector (hazard switch—switch connector) 5. Horn switch 3. 8-socket connector (turn signal—harness connector) 6. Jam nut (5/8 inch) 3. Thread the jam nut (5/8 inch) onto the threads of the horn switch (Figure 25). 2.
6. Assemble the horn switch to dash panel with the knurled nut (5/8 inch), and tighten the nut by hand (Figure 27). 2. Remove the 8-socket connector labeled HEADLIGHT SWITCH from the headlight switch (Figure 28). Note: Discard the headlight switch. 3. Align the socket terminal at the end of the 108 cm (42-1/2 inches) branch of the kit wire harness labeled TO HEAD LIGHT SWITCH PIN 1 to the back of the 8-socket connector for the headlight switch (Figure 29). g208260 Figure 27 1. Horn switch 2.
Installing the Flasher Switch 1. Remove the rectangular knockout from the dash panel as shown in Figure 32. g208277 Figure 31 1. 8-socket connector (HEADLIGHT SWITCH) 2. Switch—rocker (on-off-on) 6. Insert the rocker switch into the opening in the dash panel until the switch snaps securely into the dash (Figure 31). g208339 Figure 32 2. Align the 8-socket connector for the hazard switch through the opening in the dash panel (Figure 33) that you made in step 1.
2. Plug the 8-socket connector of the 108 cm (42-1/2 inches) branch of the kit wire harness for the turn signal into the 8-pin connector of the wire harness from the turn-signal switch (Figure 35). g208338 Figure 33 1. 8-socket connector (hazard switch—switch connector) 2. Switch—rocker (illuminated—on-none-on) g208384 3. Plug the illuminated-rocker switch into the 8-socket connector for the hazard switch (Figure 33). Figure 35 1.
6 Installing the Wire Harness to the Chassis g207491 Parts needed for this procedure: 5 Cable tie Routing the Wire Harness Under the Floor Plate g207490 Figure 36 1. Flange-head bolt (3/8 x 1 inch) 3. Hole 10 mm (3/8 inch)—floor-plate angle 2. Flange locknut (3/8 inch) 4. Horn assembly 2. Assemble the bracket of the horn assembly to the floor-plate angle (Figure 36) with a flange-head bolt (3/8 x 1 inch) and flange locknut (3/8 inch). g208166 Figure 37 1.
g208159 g208160 Figure 38 Figure 40 1. Rear wire harness (machine) 4. Wire harness trunk (kit) 1. Rear wire harness (machine) 3. Wire harness trunk (kit) 2. Spade-electrical connectors 3. R-clamp (in front of the front axle) 5. Front of the machine 2. R-clamp (behind the front axle) 4. Front of the machine Routing the Wire Harness Along the Frame 2. Plug the 2 terminals of the wire harness labeled HORN onto the 2 spade-electrical connectors of the horn (Figure 39). 1.
g208162 Figure 42 1. Front of the machine 4. Wire harness trunk (kit) 2. Cable ties 5. Hydraulic motor (right) 3. Hydraulic pump g208165 Figure 44 4. Secure the wire harness of the kit to the rear wire harness of the machine with 2 cable ties as shown in Figure 42. 1. Cable tie 3. Wire harness trunk (kit) 2. Rear wire harness (machine) 4. Hydraulic filter 2. Secure the wire harness of the kit to the rear wire harness of the machine with a cable tie as shown in Figure 44.
7 Installing the Speed Signs and License Plate Brackets Parts needed for this procedure: Figure 45 3. 71 cm (28 inches) wire harness branch (RIGHT TURN SIGNAL) 2. Wire harness trunk 4. Front of the machine Speed decal 1 Speed sign 2 Flange-head bolts (5/16 x 3/4 inch) 2 Flange locknuts (5/16 inch) Installing the Speed Decal on the Sprayer Tank g208164 1. 89 cm (35 inches) wire harness branch (LEFT TURN SIGNAL) 3 g207686 Figure 46 1.
Installing the Speed Sign on the Center-Boom Section 2. Measure 11 cm (4-1/4 inches) from the right edge of the Toro Multi Pro 5800 decal and mark the tank with a pencil Figure 47. 1. Remove the backing from a speed decal (Figure 49). 3. Remove the backing from a speed decal and align the decal to the mark that you made in step 1 and the top edge of the masking tape (Figure 47). 4. Apply to decal to the tank and remove the masking tape (Figure 47). 5.
g207639 g207640 Figure 51 Figure 50 1. Flange locknuts (5/16 inch) 3. Bracket (lift-cylinder manifold) 2. Lift-cylinder mount 4. Flange-head bolts (5/16 x 1 inch) 1. Flange locknuts (5/16 inch) 4. Bracket (speed sign) 2. Lift-cylinder mount 5. Flange-head bolt (5/16 x 1 inch) 3. Bracket (lift-cylinder manifold) 5. Align the holes in the speed-sign bracket, lift-cylinder manifold bracket, and lift-cylinder mount (Figure 51). 6.
Installing the License Plate Brackets 1. Assemble the license-plate bracket to the support bracket with the 2 flange-head bolts (5/16 x 3/4 inch) and 2 flange locknuts (5/16 inch) as shown in Figure 52. g207638 Figure 53 g207637 Figure 52 1. Flange locknuts (5/16 inch) 3. License-plate bracket 2. Support bracket 4. Flange-head bolts (5/16 x 3/4 inch) 1. Flange-head bolt (5/16 x 3/4 inch) 3. Truss (center-spray section) 2. Support bracket 4. Flange locknut (5/16 inch) 4.
9 Assembling the Taillights Parts needed for this procedure: g037014 Figure 54 1. License-plate light 3. Bullet connector (labeled LICENSE LIGHT) 2. Socket 1 Taillight bracket 4 Flange-head bolt (5/16 x 1 inch) 4 Flange locknut (5/16 inch) 2 Rear taillamp 3 Cable tie Installing the Taillight Brackets 1. Align the holes in the taillight bracket with the 2 holes 8 mm (5/16 inch) in the truss of the center spray section (Figure 56). 2.
Installing the Taillights • Connect the 4-socket connector of the kit wire harness labeled RIGHT TURN SIGNAL to the 4-pin connector of the right taillight lead. 1. Remove the 2 nuts (5 mm) from each of the rear taillights (Figure 57). • Connect the 4-socket connector of the kit Note: Do not remove the jam nuts. wire harness labeled LEFT TURN SIGNAL to the 4-pin connector of the left taillight harness. g024730 Figure 59 g207346 Figure 57 1. Rear taillamp 3. Screw (5 x 16 mm) 2. Jam nut (5 mm) 4.
10 Installing the Data Plate Parts needed for this procedure: 1 Data plate 4 Rivet Procedure g207760 Figure 62 1. Left corner of the floor plate channel to the left edge of the data plate 150 mm (5-15/16 inches) g207793 Figure 61 3. Floor-plate channel 2. Top of the floor plate to the 4. Data plate top edge of the data plate 10 mm (5/16 inch) 1. Align the left edge of the data plate 150 mm (5-15/16 inches) from the left corner of the floor-plate channel as shown in Figure 62. 2.
g032043 g207762 Figure 65 Figure 63 1. Floor plate channel 3. Data plate 2. Rivet 1. Engine mounts 4. Flange locknuts (5/16 inch) 2. Bolt—shown for clarity 5. Front of the machine 3. Undercarriage shroud 11 2. Slip the forward mounting flanges of the undercarriage shroud over the bolts and carriage bolts at the engine-mount brackets of the machine (Figure 65). Installing the Undercarriage Shroud and Forward Heat Shield 3.
Installing the Forward-Heat Shield 1. Align the rear flange of the forward heat shield over the forward flange of the rear heat shield (Figure 67). g028177 Figure 67 1. Front of the machine 3. Rear flange (forward heat shield) 2. Hex-head bolts and washers 4. Forward flange (rear heat shield) 2. Align the holes in the forward heat shield with the threaded holes in the chassis (Figure 67). g208653 3.
12 Connecting the Battery No Parts Required Procedure WARNING g207211 Figure 68 Electrical sparks can cause the battery gasses to explode, resulting in personal injury. 1. Battery cover 4. Negative battery post 2. Positive battery cable 5. Negative battery cable Incorrect battery cable routing could damage the sprayer and cables causing sparks. 3. Positive battery post • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 2.
Using the Worklights and Headlights Operation Using the Turn Signals g208460 Figure 70 g208463 Figure 69 1. Indicates a right turn 3. Turn-signal switch 2. Indicates a left turn • Lift up the lever of the turn-signal switch to indicate 1. HEADLIGHTS ON position (sloped end of the switch) 3. WORKLIGHTS ON position (rounded end of the switch) 2. SWITCH OFF position 4. Light switch • Move the light switch forward (toward the shoulder that you are making a right turn.
Maintenance Using the Horn Press in the horn button to sound the horn (Figure 71). Replacing Light Bulbs Replacing a Worklight Bulbs 1. Ensure that the light switch is in the OFF position. 2. Remove the 6 screws securing the worklight (Figure 73). g208459 Figure 71 1. Horn button Using the Hazard Flasher Move the hazard-flasher switch up to turn the hazard flasher to the ON position (Figure 72). g209233 Figure 73 1. Screws 2. Worklight-lamp cover 3. Remove the worklight cover (Figure 73). 4.
Replacing a License Plate Bulb Replacing a Taillight Bulb 1. Remove the 2 screws that secure the cover to the base of the license-plate light, and remove the cover (A of Figure 76). 1. Ensure that the light switch is in the OFF position. 2. Remove the 2 screws that secure the cover and lens to the taillight base. 3. Remove the taillight cover. 4. Pushing down on the pin on the light bulb, rotate the light bulb to the left, and pull the light bulb out (Figure 75). g024763 Figure 75 1. Pin 2.
Replacing Fuses Replacing Fuse Block Fuse Replacing the Taillight Fuse The electrical system is protected by fuses, and requires no maintenance. If a fuse blows, check the component or circuit for a malfunction or short. 1. Pull out the open fuse. 2. Replace the open fuse with a new fuse (Figure 79). Note: Ensure that the correct-size fuse is installed. g208461 Figure 77 Note: Your machine has separate fuses for the left and right taillights. 1. Remove the cover from the fuse socket (Figure 78).
Schematics g208395 Wiring Diagram 122-0803 (Rev.
Notes:
