Toro 41323 User manual

FormNo.3393-447RevA
BoomKit
2004through2009MultiPro®1200,1250,and5700-D
ModelNo.41323—SerialNo.315000001andUp
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
WARNING
Thiskitrequirespartstobeweldedtotheframe.Weldingcanexposeyoutoanumberofhazards,
includingtoxicfumes,smoke,dust,burns,res,explosions,electricshock,radiation,noise,andheat
stress,whichcancauseseriousinjuryanddeath.
•Ensurethatthepersonperformingtheweldingisadequatelytrainedtodoso.
•Ensurethattheareaisadequatelyventilatedandthatsuitablere-extinguishingequipmentisreadily
available.
•Weldinare-safeworkplace.Weldbehindre-safebarriersorcurtainsandonconcreteorother
re-safeooring.Removeorprotectallcombustiblesfromignitionsources.
•Wearproperprotectiveclothingwhenwelding,suchasre-retardantcoveralls.Protectyourhandswith
leathergauntletgloves.Wearhigh-topleathershoes,preferablysafetyshoes.
•Protectyoureyeswhenwelding.Aweldinghelmetorhandshieldwithlterplateandcoverplateis
mandatorytoprotecttheeyeswhilewelding.Weartransparentgogglesorsafetyglassesatalltimes.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationofIncorporation(DOI)at
thebackofthispublication.
Note:Thefollowingprocedure,attimes,willrequire2peopletoperform.Anoverheadhoistcanbeusedaswell.
Note:Formoreinformationonhowtoinstallthiskit,refertothePartsCatalogandtheServiceManual.
Note:Theinstallationofexistingsprayerkits(FoamMarkerKit,HoseReelKit,etc.)tothenewlymodiedboomsystemmay
requireadditionalpartsorupdatedkits.ContactyourAuthorizedToroDealerforadditionalinformation.
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3393-447*A

Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.
114-9576
1.Pinchpoint,hand—keephandawayfromhinge.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethetankassembly.
3Nopartsrequired–Removetheinstalledboomsystem.
Weldplate2
Bolt(1/2x1inch)2
4Jamnut(1/2inch)2
Installtheweldplates.
Wiringharness1
5Cabletie5Installtheelectricalharness.
Boomupright,rightside1
Boomupright,leftside1
Framewedge2
Boomframebolt2
6
Rollpin2
Installthenewboomuprights.
Mountingbar1
Bolt(5/16x3/4inch)3
Locknut(5/16inch)3
Valvebracketsupport1
Valvebracket,top1
7
Foamstrip1
Transferthevalveassembly(1250and
5700turfsprayersonly).
2

ProcedureDescriptionQty.Use
Centerboomassembly1
Boomtransportcradle2
Bolt(3/8x1-1/4inches)14
Spacer8
Locknut(3/8inch)14
Flangebolt(1/2x1-1/4inches)4
Flangenut(1/2inch)4
Leftboomextension1
Rightboomextension1
Extensionboomsupplyhose2
8
Centerboomsupplyhose1
Installtheboomassembly.
9Hoseclamp6Connecttheboomhoses.
10Nopartsrequired–Checktheboomhingesprings.
11Nopartsrequired–Adjusttheboomstolevel.
12PartsCatalog1Completethesetup.
1
PreparingtheMachine
NoPartsRequired
Procedure
UsetheServiceManualandPartsCatalogtohelppreparethe
machinefortheinstallationofthiskitasfollows:
Drainandrinsethemaintankassemblytoprepareit
forremoval.Flushthesystemthoroughly(3timesis
recommended)toeliminatedirectcontactwithchemicals
whileworkingonthemachine.
CAUTION
Chemicalsarehazardousandcancausepersonal
injury.
•Readthedirectionsonthechemicallabels
beforehandlingthechemicalsandfollow
allmanufacturerrecommendationsand
precautions.
•Keepchemicalsawayfromyourskin.Should
contactoccur,washtheaffectedareathoroughly
withsoapandcleanwater.
•Weargogglesandanyotherprotective
equipmentrecommendedbythechemical
manufacturer.
2
RemovingtheTankAssembly
NoPartsRequired
Procedure
1.Disconnectthehosesconnectingthespraytanktothe
machine.
2.Inventoryandmarkallhosesandconnectionsforlater
installation.
3.Removethelongboltsandfastenerssecuringthetank
strapstothetanksaddles.
4.Usinganoverheadlift,securethemaintankassembly.
Note:Raiseitofftheframeafewinchesand
ensurethatthetankassemblyisfullydisconnected.
Disconnectanyhosestillattachingthetanktothe
machine.
5.Raisethetankassemblyofftheframeandplaceitaside.
6.Removethefastenerssecuringthefrontandreartank
saddlestotheframe,andremovethesaddles.
7.Retainallpartsandfastenersforlaterinstallation.
3

3
RemovingtheInstalledBoom
System
NoPartsRequired
Procedure
Preparetheboomassemblyforremovalbysecuringitwith
anoverheadhoist.Usethefollowinginstructionstoallowthe
assemblytoberemovedinwhole.
1.Disconnectthenegativebatterycable.
2.Disconnectalltheelectricalconnectionstothebooms,
theextensions,andthevalveassembly.
3.Removethehoseclampssecuringtheboomsupply
hosestothevalveassembly.
4.Removethehoses,andretainanyttingsforconnecting
thehosetothevalveassembly.
CAUTION
Chemicalsarehazardousandcancause
personalinjury.
•Readthedirectionsonthechemicallabels
beforehandlingthechemicalsandfollow
allmanufacturerrecommendationsand
precautions.
•Keepchemicalsawayfromyourskin.
Shouldcontactoccur,washtheaffected
areathoroughlywithsoapandcleanwater.
•Weargogglesandanyotherprotective
equipmentrecommendedbythechemical
manufacturer.
Note:Removetheboomsupplyhoseswithcaution.
Thehosescanretainuidwhichmayhavechemicals
present.
5.Loosentheboomframeboltsbynomorethan3
revolutions(Figure1).
Figure1
1.Boom-framebolt
6.Usingaplasticorrubbermallet,taptheuprighttoback
theframeout(Figure2).
Important:Donotloosentheframeboltmore
than3turnsatatime.Thewedgeinsidetheboom
framesleevecanseparatefromtheuprightand
preventtheproperinstallationofthenewupright.
7.Repeatsteps5and6untiltheboom-frameuprights
breakfree.
Figure2
1.Boom-frameupright3.Mallet
2.Boom-framesleeve
8.Removetheboomassembly,andsetitasidetoallow
roomtoinstallthenewboomassembly.
Note:Retainallparts.Somefastenersandpartsoftheold
boomassemblywillbeusedforinstallingthenewbooms.
4

4
InstallingtheWeldPlates
Partsneededforthisprocedure:
2Weldplate
2Bolt(1/2x1inch)
2Jamnut(1/2inch)
Procedure
Note:Thisprocedureappliestoearliermachines.Newer
machineshavefactory-installedweldnuts.
1.Lineupaweldplatewiththeendoftheframe(Figure
3),anduseatransferpunchtomarkthecenterhole
oftheplate.
Figure3
1.Frame4.Jamnut(1/2inch)
2.Drilledhole5.Bolt(1/2x1inch)
3.Weldplate
2.Removetheplatefromtheframe,anddrillapilothole
inthetopoftheboxedframetubeatthespotmarked
bythepunch(Figure3).Enlargethediameterofthe
holetobetween1/2and5/8inch.
3.Placetheplateoverthedrilledholeintheframe,and
secureitintoplaceusingthebolt(1/2x1inch)and
jamnut(1/2inch);refertoFigure4.
Note:Doingthiswillholdtheplateinplaceduring
weldingandensureproperalignmentwiththeholethat
youdrilledpreviously.
Figure4
1.Bolt(1/2x1inch)3.Jamnut(1/2inch)
2.Weldplate
4.Weldthenewplatetotheframewitha1/4inchllet
ontheleftandrightsidesoftheplate(Figure5).After
theboltandjamnuthavecooled,removethem.
Figure5
1.Weldplate3.Jamnut(1/2inch)
2.Weld4.Bolt(1/2x1inch)
Note:Donotallowtheweldtopartiallyblockthe
openingoftheboxedframetube.Thiscouldprevent
theboomuprightsfromttingintotheframetube.
5.Repeattheprocedurefortheothersideoftheframe.
5

5
InstallingtheElectrical
Harness
Partsneededforthisprocedure:
1Wiringharness
5Cabletie
Procedure
InstallingtheElectricalHarness(1200SeriesTurf
Sprayers)
1.Removetheseatassemblyandtheconsoleassembly.
RefertotheServiceManualforadditionalinformation.
Note:Whenremovingtheconsoleassembly,keep
thecontrolpanelsandtheelectricalwiring-harness
connectionsintact.
A.Removetheseatandpins.
B.Lifttheseatbasefromthemachine.
C.Removetheshift-selectorknob,jamnut,and
screwssecuringtheshiftbootassemblytothe
fenders.
D.Removetheshiftbootassembly.
E.Removethefastenerssecuringthecontrolpanel
totheconsoleassembly.
Note:Donotdisconnectthewiringconnections
fromthecontrol-panelcomponents.
F.Dropthepanelthroughtheopeningsinthe
consoleassemblywhenremovingit.
G.Removeandretainthefastenersfortheconsole,
andlifttheconsoleaway.
2.Disconnecttheexistingconnectorsfortheboomlift
switches.
3.Connecttheboxconnectorslabeledleftandright
boomliftswitchtothecorrespondingswitchesinthe
controlpanel.
4.Routethewiringharnessdownthroughtheengine
compartmentandrearward.
5.Installtheringterminaloftheblackwiretothe
negativegroundboltorthegroundblock.
6.Installtheringterminalsofthe2redwirestothe
auxiliarysideofthesolenoid.
7.Routetheremainingharnessrearward,alongtheframe,
withtheexistingwiring.
8.Usecabletiestosecurethewiringharnesstothe
existingwiringintheseatcompartmentandalongthe
frame.
9.Installtheseatandconsolecomponentsasfollows:
A.Installtheconsolewhileliftingthecontrolpanels
upthroughtheopeningsintheconsoleassembly.
B.Securetheconsoletotheframeusingthefasteners
removedpreviously.
C.Securethecontrolpanelstotheconsoleusingthe
fastenersremovedpreviously.
D.Replacetheshiftbootassembly,jamnutandknob.
E.Installtheseattotheframe,andsecureitwiththe
pinandcotterthatyouremovedpreviously.
10.Attherearofthemachine,routethenewconnectors
totherightandtheleftaslabeled.
Note:Ifneeded,locatetheoldactuatorconnectors
andtiethemback,outoftheway.
InstallingtheElectricalHarness(5700TurfSprayers)
1.Lifttheoperator'sseatup,andremovethefastener
securingthecontrolpanel.
Note:Donotdisconnectthewiringconnectionsfrom
thecontrol-panelcomponents.
2.Installthewireharnessupintothecontrol-panel
housing.
3.Disconnecttheexistingconnectorsfortheboomlift
switches.
4.Connecttheboxconnectorslabeledleftandright
boomliftswitchtothecorrespondingswitchesinthe
controlpanel.
5.Routethewiringharnessdownintotheengine
compartmentandrearward.
6.Installthecontrolpanelandsecureitintoplace.
7.Installtheringterminaloftheblackwiretothe
negativegroundboltorthegroundblock.
8.Installtheringterminalsofthe2redwirestothe
auxiliarysideofthesolenoid.
9.Routetheremainingharnessrearward,alongtheframe,
withtheexistingwiring.
10.Usecabletiestosecurethewiringharnesstothe
existingwiringintheseatcompartmentandalongthe
frame.
11.Attherearofthemachine,routethenewconnectors
totherightandtheleftaslabeled.
Note:Ifneeded,locatetheoldactuatorconnectors
andtiethemback,outoftheway.
6

6
InstallingtheNewBoom
Uprights
Partsneededforthisprocedure:
1Boomupright,rightside
1Boomupright,leftside
2Framewedge
2Boomframebolt
2Rollpin
Procedure
1.Assembletheframeboltthroughtheuprightandinto
theframewedge(Figure6).
Note:Repeatthisstepfortheoppositeboomupright.
Figure6
LeftBoomUpright
1.Frameupright3.Boomframebolt
2.Wedge4.Rollpin(5700Turf
Sprayersonly)
2.For5700turfsprayers,installarollpinintotheoutside
hole,closesttotheanglesupport(Figure6).
Note:Repeatthisstepfortheoppositeboomupright.
3.Installthenewboomuprightsintotheframe.
A.For1200seriesturfsprayers,inserttheupright
intotheframeuntiltheendoftheframeis19-1/4
inchesfromthebaseoftheaxlehousingonthe
frame(Figure7).
B.For5700turfsprayers,inserttheboomuntilthe
rollpinthatyoupreviouslyinstalledstopsagainst
theframe.
Forallmachines,retaineachboomuprightwithabolt
(1/2x1inch)intheweldnutortheweldplatethat
youpreviouslyinstalled,andsecuretheboltwithajam
nut(1/2inch).
Figure7
1.19-1/4inches3.Retainingbolt
2.Boomupright4.Jamnut
4.Tightentheboom-framebolts(Figure8).Torquethe
boltsto91to113N-m(67to83ft-lb).
Figure8
1.Boom-framebolts
7

7
TransferringtheValve
Assembly(1250and5700
TurfSprayersOnly)
Partsneededforthisprocedure:
1Mountingbar
3Bolt(5/16x3/4inch)
3Locknut(5/16inch)
1Valvebracketsupport
1Valvebracket,top
1Foamstrip
Procedure
CAUTION
Chemicalsarehazardousandcancausepersonal
injury.
•Readthedirectionsonthechemicallabels
beforehandlingthechemicalsandfollow
allmanufacturerrecommendationsand
precautions.
•Keepchemicalsawayfromyourskin.Should
contactoccur,washtheaffectedareathoroughly
withsoapandcleanwater.
•Weargogglesandanyotherprotective
equipmentrecommendedbythechemical
manufacturer.
RemovingtheValveAssemblyfrom1250TurfSprayers
1.Removethehoseclampssecuringtheboomsupply
hosesfromthevalveassembly.
2.Removetheboomsupplyhosesfromthevalve
assembly
Note:Removetheboomsupplyhoseswithcaution.
Thehosecanretainuid,whichmaycontainchemicals.
3.Cutawayanyplastictiessecuringthevalveassembly
andwiringharnesstothecrossbar.
4.Removeandretainanyfastenerssecuringthevalve
assemblytothecrossbarbetweentheuprights.
5.Removevalveassemblyfromthecrossbarbetween
theuprights.
RemovingtheValveAssemblyfrom5700TurfSprayers
1.Removethehoseclampssecuringtheboomsupply
hosesfromthevalveassembly.
2.Removetheboomsupplyhosesfromthevalve
assembly.
Note:Removetheboomsupplyhoseswithcaution.
Thehosecanretainuid,whichmaycontainchemicals.
3.Removethefastenerssecuringthebracketandvalve
assemblytotheupperandlowercrossbars.
4.Removethebracketandvalveassembly.
5.Retainallfasteners.
6.Removethefastenerssecuringtheupperandlower
crossbarstotheolduprights.Removethecrossbars
andretainallthefasteners.Bothcrossbarswillbe
usedagain.
7.Disassemblethebracket.
8.Removethevalveassemblyandtheteevalvefromthe
lowerhalfofthebracket.
9.Retainthefastenersandthevalveassembly,anddiscard
thebracket.
InstallingtheValveAssemblyon1250TurfSprayers
1.Installthenewcrossbartothevalveuprightsbyusing
thefastenersthatyoupreviouslyremoved(Figure9).
Figure9
1.Crossbar5.Locknut,existing
2.Valveassembly6.R-clamp
3.Bolt,existing7.Locknut(5/16inch)
4.Bolt(5/16x3/4inch)
2.Securethevalveassemblytothebarusing3bolts(5/16
x3/4inch);refertoFigure9.
3.Installthehoseclamptotherightboomupright
(Figure9).
4.Connectthehosesfromthemachinetothevalve
assembly.
8

5.Connecttheelectricalconnectionsfromthemain
wiringharnessthatyoupreviouslydisconnectedfrom
thevalveassembly.
InstallingtheValveAssemblyon5700TurfSprayers
1.Installthelowercrossbarthatyouremovedfromthe
oldboomuprightsusingtheexistingfasteners(Figure
10).
Figure10
1.Uppercrossbar6.Carriagebolt,existing
2.Valvebracketsupport7.Locknut,existing
3.Lowercrossbar8.Bolt(5/16x3/4inch),
existing
4.Bolt,existing9.Locknut(5/16inch),
existing
5.Locknut,existing
2.Installthenewvalvebracketsupporttothelowercross
barusingexistingcarriageboltsandfasteners.
3.Installtheuppercrossbartotheuprightsandthe
bracketsupport.
Note:Secureittotheuprightswith2bolts(5/16x3/4
inch)and2locknuts(5/16inch).Securethebracketto
theuppercrossbarwiththeexistingfasteners.
4.Installthepreviouslyremovedteevalvetothebackside
ofthevalvesupportbracketusingtheexistingfasteners.
5.Securethevalveassemblytothevalvebracketsupport
usingthefastenersthatyoupreviouslyremoved(Figure
11).
Figure11
1.Valveassembly5.Locknut
2.Uppervalvebracket6.R-clamp
3.Foamstrip7.Locknut
4.Bolt8.Bolt
6.Installthefoamstriptotheuppervalvebracket(Figure
11).
7.Installtheuppervalvebrackettothevalvesupport
bracket,closingaroundthevalveassembly.Secure
thebracketsusingtheexistingfastenersandthenew
R-clamp.
8.Connectthetaggedhosesremovedpreviouslytothe
valveassembly.
9.Connecttheelectricalconnectionsfromthemain
wiringharnessthatyoupreviouslydisconnectedfrom
thevalveassembly.
9

8
InstallingtheBoomAssembly
Partsneededforthisprocedure:
1Centerboomassembly
2Boomtransportcradle
14Bolt(3/8x1-1/4inches)
8Spacer
14Locknut(3/8inch)
4Flangebolt(1/2x1-1/4inches)
4Flangenut(1/2inch)
1Leftboomextension
1Rightboomextension
2Extensionboomsupplyhose
1Centerboomsupplyhose
Procedure
1.Installtheboomtransportcradlestothecenterboom
assemblyusing6bolts(3/8x1-1/4inches)and6
locknuts(3/8inch)asshowninFigure12.
1
2
3
4
G023319
Figure12
1.Boomtransportcradle3.Bolt(3/8x1-1/4inches)
2.Centerboomassembly4.Locknut(3/8inch)
2.RefertoFigure13tolocatetheappropriatemounting
holesforinstallingthecenterboomonyourmachine.
G009746
Figure13
Rightsideboomframeuprightshown
1.Mountingholesfor1200
seriesturfsprayers
2.Mountingholesfor5700
turfsprayers
Note:Theuppersetofholesareforboomsdesigned
fornozzles20inchesofftheground.Youcanusethe
lowersetofholestomounttheboomssothatthe
nozzlesare18inchesofftheground.
3.Installthecenterboomassemblytotheuprightsusing
4angebolts(1/2x1-1/4inches)and4angenuts
(1/2inch)(Figure14).
Figure14
1200seriesturfsprayersinstallationshown
1.Boomupright3.Flangebolt(1/2x1-1/4
inches)
2.Centerboom4.Flangenut(1/2inch)
4.Maketheelectricalconnectionsfortheboomactuators
tothenewlyroutedconnectors.
5.Power-onthesystemandusetheboomliftswitches
toextendtheboomactuatorrods.Thisallowsyouto
installtheleftandrightboomextensions.
6.Removethe4bolts,4washersand4nutsonthehinge
plate.
10