Toro 41228 User manual

FormNo.3353-750RevC
FoamMarkerKit
forMulti-Pro1200,1250,5600and5700TurfSprayersand
Workman200SpraySystems
ModelNo.41228—SerialNo.260000001andUp
InstallationInstructions
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Note:Ifyouareinstallingthiskitonamachineequippedwithanenclosedboomsystem,usetheseinstructions
alongwiththeenclosedboomsysteminstructions.
Note:Ifyouareinstallingthiskitonamachineequippedwithacab,abracketfromCustomProducts(partnumber
2–15904)needstobeinstalledaswelltoeliminatetheinterferencewiththecab.
Note:RTVsiliconesealantisusedintheinstallationofthiskit.
Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
94-7275
94-7287
©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Tank/compressorassembly1
Supplyhose,108inches2
Multi-Pro1200seriesadapterbracket1
Workmanadapterbracket1
Mudap1
Mudapbracket1
Bolt(3/8x1inch)4
Flangelocknut,serrated(3/8inch)2
Locknut(3/8inch)1
Carriagebolt,(3/8x1-1/4inches)4
Flangelocknut,non-serrated(3/8inch)4
Flangebolt(5/16x3/4inch)3
Locknut(5/16inch)3
Flatwasher(3/8inch)4
1
Hoseclamp,small2
Installthetank,compressorandmixer.
Bolt(3/8x1inch)1
Locknut(3/8inch)1
Mixerassembly1
2Flatwasher(3/8inch)2
Installthemixertee.
Wiringharness1
Hoseclamp,small6
3Plasticties12
Wirethekit.
Rockerswitch2
4Fuse,15-amp1Installtheswitchesandfuse.
Boomhose2
Grommet2
Punched-holeboomcap2
Extensionhose2
Hoseclamp,large2
5
Partscatalog1
Completetheinstallation
SeparateinstructionsfortheinstallationoftheFoam
MarkerkitaredenotedineachstepoftheSetup
wherespecicproceduresdeviatefromonemachine
toanother.Pleaselookfortheheadingdescribing
instructionsspecictothemachineyouareworking
withbeforeproceedingwitheachstepoftheSetup.
2

1
InstallingtheTank,
Compressor,andMixer
Partsneededforthisprocedure:
1Tank/compressorassembly
2Supplyhose,108inches
1Multi-Pro1200seriesadapterbracket
1Workmanadapterbracket
1Mudap
1Mudapbracket
4Bolt(3/8x1inch)
2Flangelocknut,serrated(3/8inch)
1Locknut(3/8inch)
4Carriagebolt,(3/8x1-1/4inches)
4Flangelocknut,non-serrated(3/8inch)
3Flangebolt(5/16x3/4inch)
3Locknut(5/16inch)
4Flatwasher(3/8inch)
2Hoseclamp,small
Procedure
MultiPro1200or1250TurfSprayer
1.MounttheMulti-Pro1200seriesadapterbracket
totherightsideofthevehicleabovethebattery
(Figure1)using4carriagebolts(3/8x1-1/4inches)
and4angelocknuts(3/8inch).
Note:Itiseasiestifyouremovethebatterybefore
performingthisstep.RefertoyourvehicleOperator’s
Manualforinstructions.
Figure1
1.Battery3.Carriagebolt(3/8x1-1/4
inches)
2.Multi-Pro1200series
adapterbracket
4.Flangelocknut,
non-serrated(3/8inch)
2.Removethe4bolts(1/4x1inch)andatwashers
thatholdthecovertothetank/compressorassembly
andremovethecover(Figure2).
Figure2
1.Cover4.Bolt(1/4x1inch)
2.Tank/compressor
assembly
5.Bottomrightbolt
3.Flatwasher
3.Setthecoverandfastenersaside.
4.Marka108inchsupplyhosewithablackmarkerat
eachend(Figure3).
3

Figure3
1.Compressorhose3.Tothemixertee
2.Needlevalvehose
5.Connectthemarkedsupplyhosetothehosebarb
atthecompressorandtheothersupplyhosetothe
hosebarbontheneedlevalve(Figure3).
6.Securethehoseendswithsmallhoseclamps.
7.Routebothofthesupplyhosesrearwardalongthe
rightsideofthesprayertotherearofthemachine
followingthesprayerwiringharness.
8.Attachthecovertothetank/compressorassembly
using4hex-headbolts(1/4x1inch)and4at
washersthatyouremovedpreviously.
9.Installthetank/compressorassemblytothe
Multi-Pro1200seriesadapterbracketusing2bolts
(3/8x1inch),2atwashers(3/8inch)asshown
Figure4.
Figure4
1.Tank/compressor
assembly
3.Bolt(3/8x1inch)
2.Multi-Pro1200series
adapterbracket
4.Flatwasher(3/8inch)
MultiPro5600/5700TurfSprayer
1.Remove4bolts(1/4x1inch)andatwashersthat
holdthecovertothetank/compressorassembly
(Figure5).
Figure5
1.Cover4.Bolt(1/4x1inch)
2.Tank/compressor
assembly
5.Bottomrightbolt
3.Flatwasher
2.Removethecover.
3.Setthecoverandfastenersaside.
4.Marka108inchsupplyhosewithablackmarkerat
eachend(Figure6).
Figure6
1.Compressorhose3.Tothemixertee
2.Needlevalvehose
5.Connectthemarkedsupplyhosetothehosebarb
atthecompressorandtheothersupplyhosetothe
hosebarbontheneedlevalve(Figure9).
6.Securethehoseendswithsmallhoseclamps.
7.Routebothofthesupplyhosesrearwardalongthe
leftsideofthesprayertotherearofthemachine
followingthesprayerwiringharness.
4

8.Mountthetank/compressorassemblytotheright
stepframeusing2bolts(3/8x1inch)and2at
washers(Figure7).
Figure7
1.Rightstepframe2.Tankassemblyframe
Note:Youmustinstallthefastenersfromthe
backsideofthestepframe.
9.Attachthecovertothetank/compressorassembly
using4hex-headbolts(1/4x1inch)and4at
washersthatyouremovedpreviously.
Workman200SpraySystem
1.Removethe4bolts(1/4x1inch)and4atwashers
thatholdthecovertothetank/compressorassembly
andremovethecover(Figure8).
Figure8
1.Cover4.Bolt(1/4x1inch)
2.Tank/compressor
assembly
5.Bottomrightbolt
3.Flatwasher
2.Setthecoverandfastenersaside.
3.Marka108inchsupplyhosewithablackmarkerat
eachend(Figure9).
Figure9
1.Compressorhose3.Tothemixertee
2.Needlevalvehose
4.Connectthemarkedsupplyhosetothehosebarb
atthecompressorandtheothersupplyhosetothe
hosebarbontheneedlevalve(Figure9).
5.Securethehoseendswithsmallhoseclamps.
6.Routebothofthesupplyhosesrearwardalongthe
leftsideofthesprayertotherearofthemachine
followingthesprayerwiringharness.
7.Removetherubberstripingonthebacksideofthe
tankcover(Figure10).
Figure10
1.Rubberstrip4.Mudap
2.Tankcover5.Bolt(5/16x3/4inch)
3.Mudapbracket6.Locknut(5/16inch)
8.Locatethemudapandmudapbracketinloose
parts.Installthemudaptothetankcover.Secure
theapusingthebracket,threebolts(5/16x3/4
5

inch)andthreelocknuts(5/16inch)asshownin
Figure10.
9.Attachthecovertothetank/compressorassembly
using3ofthe4hex-headbolts(1/4x1inch)and
atwashersthatyouremovedpreviously.Leavethe
bottomrightboltoutuntillaterintheinstallation
(Figure8).
10.MounttheWorkmanadapterbracketsuppliedinthe
kittothetank/compressorassemblyusing2bolts
(3/8x1inch),2atwashers(3/8inch)asshown
Figure11.
Note:Ifnecessary,cutbacktherubbertrimonthe
coversothatitdoesnotinterferewhenmounting
thebrackettothetank/compressorassembly.
Figure11
1.Workmanadapterbracket4.Flatwasher
2.Tank/compressor
assembly
5.Bolt(1/4x1inch)
3.Bolt(3/8x1inch)6.Flatwasher(1/4inch)
11.Installtheremainingbolt(1/4x1inch)andat
washer(1/4inch)throughtheWorkmanadapter
bracketandcoverintothetank/compressor
assembly(Figure11).
12.Removethelefthandleandfastenersfromtheleft
sideofthetankskid.Savefastenersforlateruse.
13.Mountthefoammarkerassemblytotheframeusing
twobolts(3/8x1inch),twowashers(3/8inch),two
angenuts(3/8inch)includedinlooseparts;and
thelefthandleandfastenersremovedpreviously
(Figure12).
Note:Rotatethetanksothatthehandleisclosest
totheframe.
Figure12
1.Foammarkerassembly5.Flangenut,serrated(3/8
inch)
2.Frame6.Leftsprayerhandle
3.Bolt(3/8x1inch)7.Fasteners
4.Washer(3/8inch)
2
InstallingtheMixerTee
Partsneededforthisprocedure:
1Bolt(3/8x1inch)
1Locknut(3/8inch)
1Mixerassembly
2Flatwasher(3/8inch)
Procedure
Forallsprayers,serialnumber259999999andlower
1.Attherearofthemachine,mountthemixer
assemblyfacingrearwardtothebracketonthe
centerboomassemblywithabolt(3/8x1inch),at
washer,andlocknut(Figure13).
6

Figure13
1.Mixerteeassembly2.Centerboom
Note:IfnecessaryonWorkman200SpraySystems,
rotatethemixerassemblydownsothatitdoesnot
interferewiththepump.
2.Locatethesupplyhosesroutedtotherearofthe
machinepreviously.
3.Slidethemarkedsupplyhoseontothebarbonthe
checkvalvelocatedattheteeassembly(Figure14).
Figure14
1.Checkvalve4.Rightboomhose
2.Hosefromthecompressor5.Leftboomhose
3.Hosefromtheneedle
valve
4.Connecttheothersupplyhosetothebarbed“Y”at
theteeassembly(Figure14).
5.Securethehoseswithsmallhoseclamps.
6.Connecttherightboomhosetotherightside
solenoidvalveassemblyandtheleftsupplyhoseto
theleftsidesolenoidassembly.
7.Securebothhoseswithsmallhoseclamps
(Figure14).
Forallsprayers,serialnumber260000001andhigher
1.Attherearofthemachine,mountthemixer
assemblyontheforwardfacingsideofthecenter
boomassemblywithabolt(3/8x1inch),atwasher,
andlocknut(3/8inch)asshowninFigure15.
Figure15
1.Centerboom4.Bolt
2.Rightboommountbracket5.Locknut
3.Mixerteeassembly6.Flatwasher
2.Locatethesupplyhosesroutedtotherearofthe
machinepreviously.
3.Slidethemarkedsupplyhoseontothebarbonthe
checkvalvelocatedattheteeassembly(Figure16).
Figure16
1.Checkvalve4.Rightboomhose
2.Hosefromthecompressor5.Leftboomhose
3.Hosefromtheneedle
valve
4.Connecttheothersupplyhosetothebarbed“Y”at
theteeassembly(Figure16).
5.Securethehoseswithsmallhoseclamps.
7

6.Connecttherightboomhosetotherightside
solenoidvalveassemblyandtheleftsupplyhoseto
theleftsidesolenoidassembly.
7.Securebothhoseswithsmallhoseclamps
(Figure16).
3
WiringtheKit
Partsneededforthisprocedure:
1Wiringharness
6Hoseclamp,small
12Plasticties
Procedure
MultiPro1200or1250TurfSprayer
1.Locatethelabeledconnectorswiringharnessforthe
foammarkersolenoidandcompressorandmake
theconnectionstothecompressorandthesolenoid
locatedatthefoamtank/compressorassembly
(Figure17).
Note:Bothoftheplugconnectionsareidentical
(Figure17).
Figure17
1.Wiringharness3.Solenoid
2.Compressor
2.Attherearofthemachine,plugtheharness
connectorsintotheboomsolenoidassemblies.
Plugtheconnectorwiththebluewiretotheright
solenoid;plugtheconnectorwiththeorangewireto
theleftsolenoid(Figure18).
Figure18
1.Mixerteeassembly3.Wiringharness
2.Boomsolenoids
MultiPro5600/5700TurfSprayer
1.Locatethewiringharnessconnectorsfurnished
withthevehicleforthefoammarkerandmakethe
connectionstothecompressorandthesolenoid
locatedatthefoamtank/compressorassembly
(Figure19).
Note:Theconnectorsarelocatedalongtheright
sideframerailstrappedtothevehicleharness,where
thetank/compressorisinstalled.Bothoftheplug
connectionsareidentical(Figure19).
Figure19
1.Wiringharness3.Solenoid
2.Compressor
2.Locatethewiringharnessconnectorfurnishedwith
thevehicleforthefoammarkerboomsolenoidat
thecentersectionoftheboom(Figure20).
8

Figure20
1.Mixerteeassembly3.Wiringharness
2.Boomsolenoids
3.Plugtheharnessconnectorsintotheboomsolenoids
atthemixerteeassembly.Plugtheconnectorwith
thebluewiretotherightsolenoidandplugthe
connectorwiththeorangewiretotheleftsolenoid
(Figure20).
Workman200SpraySystem
1.Locatethewiringharnessandmaketheconnections
tothecompressorandthesolenoidlocatedatthe
foamtank/compressorassembly(Figure21).
Note:Bothoftheplugconnectionsareidentical
(Figure21).
Figure21
1.Wiringharness3.Solenoid
2.Compressor
2.Locatetheconnectorsintherearwiringharnessof
thesprayer(Figure22).
A.Plugtheconnectorwiththeyellow/bluewire
intotheleftboomsolenoid.
B.Plugtheconnectorwiththeblue/greenwireinto
therightboomsolenoid.
Figure22
1.Mixerteeassembly3.Boomsolenoid,left
2.Boomsolenoid,right4.Wiringharness
3.Routethehosesalongthewiringharnesstotherear
ofthesprayerandtothemixerteeusingthecable
ties.Securethehoseendwithasmallhoseclamp.
4
InstallingtheSwitchesand
Fuse
Partsneededforthisprocedure:
2Rockerswitch
1Fuse,15-amp
Procedure
MultiPro1200or1250TurfSprayer
1.Removethespraycontrolpaneltoexposethe
bottomside.
2.Liftandremovethe2plugsfromthespraycontrol
panelonthevehicleandinstallthe2rockerswitches
providedintheirplace(Figure23forthe1250and
Figure24forthe1200).
9

Figure23
1250
1.Plug3.Notch(atback)
2.Switch4.Spraycontrolpanel
Figure24
1200
1.Foammarkerswitches2.Spraycontrolpanel
3.Plugtheconnectorwiththeorangewirefortheright
foamsolenoidtotherightswitchandtheconnector
withthebluewirefortheleftfoamsolenoidtothe
leftswitch.
Note:Ensurethattheorientationoftheswitches
matcheswhatisshowninFigure23,withthenotch
pointingtowardtherearofthevehicle.
4.Insertthe15-ampfuseinthecorrespondingslotin
thefuseblock(atthefrontofthevehicle).
MultiPro5600/5700TurfSprayer
1.Removethethrottleknobbyunscrewingitfromthe
throttlerodatthecenterconsole.
2.Releasethelatchandremovetheswitchpanel
assemblyfromthecenterconsoleassembly
(Figure25).
Figure25
1.Controlpanel3.Foammarkerswitches
2.Latch
3.Removethefoammarkerswitchholeplugs.
4.Installthe2rockerswitchesintotheswitchpanel.
Note:Ensurethatthenotch/holeonthebottomof
eachswitchisorientedtowardtherearofthevehicle.
5.Plugtheharnessconnectorsfoundinthecenter
consoleintothefoammarkerswitches.
Note:Theplugsintheharnessaremarked:Boom
foamRS/LSswitch.Theleftconnectorhasaorange
wirewithabluestripeandtherightconnectorhasa
bluewirewithagraystripe.
6.Installtheswitchpanelandsecurethelatch.
7.Screwthethrottleknobontothethrottleroduntil
itishandtight.
8.Insertthe15-ampfuseinthecorrespondingslotin
thefuseblock(atthefrontofthevehicle).
Workman200SpraySystem
1.Loosenthe4screwssecuringthefrontpaneltothe
controlbox(Figure26).
2.Removethefrontpanelexposetheinsideofthe
controlbox(Figure26).
10