Toro Ultra Sonic Boom 41218 User manual

FormNo.3374-162RevB
UltraSonicBoom™LevelingKit
2010andAfterMulti-Pro®TurfSprayersandWorkman®200Spray
System
ModelNo.41218—SerialNo.312000001andUp
InstallationInstructions
Thisattachmentmaintainsconsistentdistancesfromtheboomnozzlestothegroundwhensprayingover
unevensurfacesandisintendedtobeusedbyprofessional,hiredoperatorsincommercialapplications.Itis
primarilydesignedforsprayinggolfcourseapplications,parks,sportselds,andoncommercialgrounds.It
isdesignedtoonlybeusedinconjunctionwithmachinesdesignatedbythemanufacturer.
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
94-8582
119-9431
©2013—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethehardstops.
Hinge2
Angledstrap(foranuncoveredboom)2
Angledstrap(foracoveredboom)2
Toporbottomstrap2
Compressionspring4
Bushing8
Hex-headbolt(5/16x3-1/4inch)4
Flatwasher12
3
Locknut(5/16inch)4
Assemblethesensormounting
hardware.
Sonicboomsensor2
Bracket2
Programmingplug2
Sensorcover2
Lowersensorhousing2
Captube2
Sensorguardbracket2
Sensorcable(4m)2
Largenut4
U-bolt6
Locknut(1/4inch)8
Bolt(5/16x3/4inch)8
Bolt(5/16x1-1/4inch)4
Locknut(5/16inch)12
4
Cabletie12
Installthesonicboomsensors.
Mountplate1
Relay4
Bolt(1/4x5/8inch)4
Lockwasher(1/4inch)4
Nut(1/4inch)4
Wireharness1
Screw(#10)4
Nut(#10)4
ElectronicControlUnit(ECU)1
Fuseretainer1
Bolt(1/4x1-1/4inch)4
Locknut(1/4inch)4
Bolt(5/16x3/4inch)2
Lockwasher(5/16inch)2
Flatwashers2
U-boltclamps2
5
Nut(5/16inch)4
Mounttheelectroniccontrols.
2

ProcedureDescriptionQty.Use
Decal,94-85821
6Lightassembly1Installtheindicatorlight.
Rockerswitch1
Cableties6
Indicatorlight(Workman200only)1
7Grommet(Workman200only)1
Installthecontrols.
8Nopartsrequired–Calibratethesonicbooms.
Note:Decal119-9431isusedwithahand-helddiagnostictoolandthereforeisnotinstalledonthemachine.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
1
PreparingtheMachine
NoPartsRequired
Procedure
Positionthemachineonalevelsurface,stoptheengine,
removetheignitionkey,andengagetheparkingbrake.
CAUTION
Ifyouleavethekeyintheignitionswitch,someone
couldaccidentlystarttheengineandseriously
injureyouorotherbystanders.
Removethekeyfromtheignitionswitchbefore
installthekit.
2
RemovingtheHardstops
NoPartsRequired
Procedure
Ifyourmachinehashardstopsinstalled,theymustbe
removedbeforeinstallingtheSonicBoomKit.The
hardstopsarelocatedinthecenterboomofthecaged
boomsandcanbeseenwhentheboomsareinthe
upright,transportposition.Ifyourmachinedoesnot
havehardstopsinstalled,skiptothenextprocedure.
1.Raisetheboomsintothetransportpositionand
removetheignitionkey.
2.Removethe4bolts(5/16x1inch)andnuts(5/16
inch)thatsecurethestopstothecenterboomframe
asshownin(Figure1).
Note:Removethehardstopassembliesonboth
sidesofthecenterboom.Retainallpartsforlater
use.
G009415
1
2
3
4
Figure1
Rightsideshown
1.Centerboomassembly3.Bolt(5/16x1inch)
2.Assembledbracketand
bumper
4.Nut(5/16inch)
3

3
AssemblingtheSensor
MountingHardware
Partsneededforthisprocedure:
2Hinge
2Angledstrap(foranuncoveredboom)
2Angledstrap(foracoveredboom)
2Toporbottomstrap
4Compressionspring
8Bushing
4Hex-headbolt(5/16x3-1/4inch)
12Flatwasher
4Locknut(5/16inch)
Procedure
Note:Howyouassemblethesensormounting
hardwaredependsuponwhethertheCoveredBoomKit
(model41602)isinstalled.
1.Layoutthehingesandstrapsasshownin
Figure2(foranuncoveredboom)orFigure3(fora
coveredboom).
Note:Thereare2setsof2angledstrapsinloose
parts.Onesetisforanuncoveredboomandthe
othersetisforacoveredboom.Youwillhaveone
setof2angledstraps(eitherforthecoveredboom
orfortheuncoveredboom)thatyouwillnotuse
onthemachine.
Note:Thetopstrapsfortheuncoveredboomsalso
serveasthebottomstrapsforthecoveredbooms.
1
3
2
G017128
3
4
Figure2
Foruncoveredboomsonly
1.Hinge(2)3.Bushings(8)
2.Angledstrap(2)4.Topstrap
1
3
2
G017129
3
4
Figure3
Forcoveredboomsonly
1.Hinge(2)3.Bushing(8)
2.Angledstrap(2)4.Bottomstrap
2.Insertthebushingsintotheweldedtubeopenings
inthehingesandstrapsasshowninFigure2or
Figure3.
3.Installaatwasheroneachofthe2hex-headbolts
(3-1/4inch).
4

4.Inserttheboltsthroughthehingedweldedtube
openings,hinges,andstraps(Figure4).
Figure4
Hardwareforacoveredboomshown
1.Hex-headbolt4.Springs
2.Flatwasher5.Locknuts(5/16inch)
3.Weldedtubeopening
5.Installaatwasherontheexposedendofeachof
thebolts.
6.Installaspringontheendofeachbolt(Figure4).
7.Installaatwasherandalocknutontheendofeach
bolt,andtightenthelocknutsuntilthereisnoslack
inthespring.
Note:Checktoensurethatthehingesarenotso
tightthatthemountedsensorsdonotfreelypivot
onthehinges.
4
InstallingtheSonicBoom
Sensors
Partsneededforthisprocedure:
2Sonicboomsensor
2Bracket
2Programmingplug
2Sensorcover
2Lowersensorhousing
2Captube
2Sensorguardbracket
2Sensorcable(4m)
4Largenut
6U-bolt
8Locknut(1/4inch)
8Bolt(5/16x3/4inch)
4Bolt(5/16x1-1/4inch)
12Locknut(5/16inch)
12Cabletie
Procedure
1.Installamountingbracketonthefrontsideofeach
boomneartheoutermostnozzlewith3U-boltsand
6locknuts(1/4inch)(Figure5andFigure6).
1
2G017147
Figure5
Frontview
1.Mountingbracket(2)2.U-bolt(6)
5

1
2
G017148
Figure6
Rearview
1.Mountingbracket(2)2.Locknuts(1/4inch)(12)
2.Installthesensorguardbracketontothemounting
bracketwith2bolts(5/16x3/4inch)and2ange
nuts(5/16inch)asshowninFigure7.
1
G017149
Figure7
1.Sensorguardbracket
3.Installthesensormountinghardwareontothesensor
guardbracketwith2bolts(5/16x3/4inch)and
2locknuts(5/16inch)asshowninFigure8(fora
coveredboom)orFigure9(foranuncoveredboom).
G017150
12
Figure8
Foracoveredboomonly
1.Sensorguardbracket2.Hinge(ofsensormounting
hardware)
G017157
1
2
Figure9
Foranuncoveredboomonly
1.Sensorguardbracket2.Hinge(ofsensormounting
hardware)
4.Installthelowersensorhousingontothesensor
mountinghardwarewith2bolts(5/16x1-1/4inch)
and2locknuts(5/16inch)(Figure10).
6

1
2
4
3
3
5
G017151
6
7
8
Figure10
Uncoveredboomcongurationshown
1.Cover5.Captube
2.Sensor6.Bolts(5/16x1-1/4inch)
3.Largenut7.Locknuts(5/16inch)
4.Lowersensorhousing8.Finishedsensorassembly
5.Installtheprogrammingplugonthesensor
(Figure11).
Important:Ensurethatyoualignthearrow
belowthesideways“T”withthenotchonthe
topedgeofthesensor(Figure11).
Figure11
1.Sideways“T”3.Notch
2.Arrowsaligned4.Sensor
6.Insertthesensorintothelowersensorhousing,and
secureitwith2largenutsprovidedwiththesensor
(Figure10).
Note:Discardthelockwashersthatcomewiththe
sensors.
7.Installthecaptubeandthecover(Figure10).
Note:Ensurethatthesensorwireisroutedthrough
thesmallopeninginthecoverbeforeinstallingthe
sensorcover.
8.Securethewirecomingfromthesensortotheboom
withcableties.
Important:Ensurethatyouallowenoughslack
inthewirearoundthesensorsothatthesensor
canfreelypivotonthehingewithoutpullingon
thewire.
9.Repeatthestepsabovefortheotherboom.
Note:Forcoveredboomsonly:Thesensorsshould
notdetecttheboomcoverasthismayinterferewith
thesignal.Ifyouexperienceanydifcultiesduringthe
calibrationprocess,checkthesensorstoensurethat
theirsignalsdonotdetecttheboomcover.
7

5
MountingtheElectronic
Control
Partsneededforthisprocedure:
1Mountplate
4Relay
4Bolt(1/4x5/8inch)
4Lockwasher(1/4inch)
4Nut(1/4inch)
1Wireharness
4Screw(#10)
4Nut(#10)
1ElectronicControlUnit(ECU)
1Fuseretainer
4Bolt(1/4x1-1/4inch)
4Locknut(1/4inch)
2Bolt(5/16x3/4inch)
2Lockwasher(5/16inch)
2Flatwashers
2U-boltclamps
4Nut(5/16inch)
Procedure
1.Secure4relaystothefrontofthemountplatewith
4bolts(1/4x5/8inch),4lockwashers(1/4inch),
and4nuts(1/4inch)asshowninFigure12.
1
23
4
5
6
9
8
7
G018924
Figure12
1.Relay6.Nut(#10)
2.Nut(1/4inch)7.Screw(#10)
3.Lockwasher(1/4inch)8.Fuseblock
4.Bolt(1/4x5/8inch)9.Fuseretainer
5.Mountplate
2.Securethefuseblockendsofthewiringharnessand
thefuseretainertothemountingplatewith4screws
(#10)and4nuts(#10)asshowninFigure12.
3.SecuretheECUtothemountingplatewith4bolts
(1/4x1-1/4inch)and4locknuts(1/4inch)as
showninFigure13.
G016081
12
34
Figure13
1.Bolt(1/4x1-1/4inch)3.Mountplate
2.ECU4.Locknut(1/4inch)
4.Connecttherelayleadsonthewiringharnesstothe
4relaysonthemountingplate.
8

5.Connectthecontrollerleadonthewiringharness
totheECU.
6.Installthemountplatetothevehicleframe,under
thedashboard.
A.FortheMulti-Pro1200and1250:Installthe
mountplateusing2bolts(5/16x3/4inch),2
lockwashers(5/16inch),and2atwashersas
showninFigure14.
G016082
1
2
345
Figure14
Frameunderthedashboard
1.Bolt(5/16x3/4inch)4.ECMandMountplate
2.Lockwasher(5/16inch)5.Vehicleframe
3.Flatwasher
B.FortheWorkman200SpraySystem:Install
themountplateusing2U-boltclampsand2nuts
(5/16inch)asshowninFigure15.
G016282
1
2
3
4
Figure15
1.Vehicleframe3.Mountplate
2.U-boltassembly4.Nut(5/16inch)
6
InstallingtheIndicatorLight
Partsneededforthisprocedure:
1Decal,94-8582
1Lightassembly
Procedure
1.Installdecal94-8582overthelightholeinthedash
(Figure16).
G016376
1
2
3
Figure16
1.Decal94-85823.Pushnut
2.Light
2.Installthelightinthedashandsecureitfrom
underneaththedashwiththepushnut(Figure16).
3.Connectthelighttothecorrespondingconnectoron
thebranchofthewiringharness.
7
InstallingtheControls
Partsneededforthisprocedure:
1Rockerswitch
6Cableties
1Indicatorlight(Workman200only)
1Grommet(Workman200only)
InstallingtheControlsonaMultiPro
1200or1250TurfSprayer
InstallingtheSwitches
9

1.Removethespraycontrolpaneltoexposethe
bottomside(Figure17forthe1200andFigure18for
the1250).
Figure17
MultiPro1200
1.Sonicboomswitch
location
2.Spraycontrolpanel
Figure18
MultiPro1250
1.Plug3.Notch(atback)
2.Switch4.Spraycontrolpanel
2.Removethepluginthesonicboomslotfromthe
spraycontrolpanelonthevehicle,andinstallthe
rockerswitchprovidedinitsplace(Figure17forthe
1200andFigure18forthe1250).
Note:Ensurethattheorientationoftheswitch
matcheswhatisshowninFigure18,withthenotch
pointingtowardtherearofthevehicle.
WiringtheSwitches
1.Routethebranchofthesonicboomwireharness
withthe3largeconnectorsintothecontrolpanel
area.
2.Ifboomliftswitchesareinstalled,removeany
existingconnectorspluggedintotheliftswitches.
3.Connecttheconnectorslabeled“leftboomlift
switch”and“rightboomliftswitch”tothe
correspondingpanelswitches.
4.Connecttheconnectorlabeled“sonicboomswitch”
tothesonicboomswitch.
5.Routethefreeendofthewiringharnessdown
throughtheoorandrearward,followingthespray
systemwireharnesstothecenterboomassemblyat
thebackofthevehicle.
Note:Usecabletiestosecurethewiringharness
totheotherwiringharnessesawayfromtheengine
andmovingparts.
6.Installthespraycontrolpanelandsecureitwiththe
fastenersthatyouremovedpreviously.
ConnectingtheWiringtotheFuseBlock
1.Routethebranchofthesonicboomwiringharness
withthesmallspadeconnectorandaringorfork
terminalintotheseatboxandtothefusearea.
2.Lifttheseattoaccessthefusearea,andlocatethe
auxiliarysolenoidandgroundterminalblock.
3.Connecttheringlabeledgroundontheblackwireto
thegroundterminalblock(Figure19).
Figure19
1.Blackwire3.Redwire
2.Groundterminalblock4.Auxiliarysolenoid
4.Connecttheredwiretotheloadsideoftheauxiliary
solenoid.
10