Installation Instructions

ManualsBrandsToro ManualsSprayersSprayer Pump 3000 for Manual Spray System, Workman 3000

Install the TORO APU Electric Clutch Kit as per

the instructions provided with that kit.

PUMP INSTALLATION:

1. Slide the Pulley Spacer on the Pump Shaft.

Install the square key into the centrifugal pump

shaft key slot. Place the pump pulley on the

pump shaft and secure to the shaft using 5/16" x

3/4" hex hd. cap screw, 5/16 I.D. 10 GA. flat washer,

and lockwasher (FIG. 1).

FIG. 1

1. Pump Mounting Brkt. 5. Rubber Mount

2. Centrifugal Pump 6. Tab Mount

3. Idler Pivot 7. Pulley Spacer

4. Idler Pivot Brkt.

2. Attach the idler pivot bracket to the pump

by removing the two pump housing bolts and

replacing with (2) 3/8" x 1" hex hd. cap screws.

(See FIG. 1)

3. Install one flange bushing into each end of

the idler pivot assembly mounting hole and attach

to the idler bracket using the 3/8" x 3" hex hd cap

screw and locknut.

Refer to the illustrated Parts List for details of parts used in assembling the Pro-Control

System.

NOTE: Right, Left, Front and Rear are

referenced while seated in the operators

position.

4. Mount the small inside idler pulley on the

long arm of the idler pivot using the 3/8" x 2 3/4"

hex hd cap screw, 7/8" spacer, and locknut. Shim

as required between Idler Pivot Ass'y and

Inside Idler Pulley with the (3) 3/8" flat washer

to align with Pump Pulley. Attach the tension

spring to the short arm of the idler pivot assembly

(FIG. 1).

NOTE: In the following instructions, sealer

refers to Teflon Tape when used for pipe

fittings.

5. Apply sealer and install the 90 degree x 1 1/4"

street elbow into the suction port of the pump.

Apply sealer and install the 1" x 3" nipple, (2) 45

degree x 1" elbows, and quick adapter into the

discharge port of the pump (FIG. 1).

6. Install the rubber mount into the tab mount

and loose fit the tab mount to the pump mounting

bracket using the (2) 3/8" x 1" hex hd cap screws,

flat washers, and locknuts (FIG. 1).

NOTE: For the installation of pump mount

bracket it is necessary to first remove the rear

mounting bolt on the hydraulic valve. If

equipped with the auxiliary hydraulic package,

it is necessary to remove the last two mounting

bolts of this valve. This will allow for usage of

the bolt holes to properly install pump mount

bracket. Reuse the fasteners earlier removed.

7. Attach the pump mount bracket assembly

to the left side of the vehicle frame using the (3)

5/16" x 1" hex hd cap screws, lockwashers, and

hex nuts (FIG. 3). Next, attach the tab mount to

the crossmember using the 3/8" x 1 1/2" hex hd

cap screw, 3/8" I.D. 10 GA. flat washer, and

locknut. See FIG. 1. Tighten all fasteners securely.

8. At the hydraulic control valve, loosen and

disconnect the fittings for the right hand dump

cylinder hoses. Reroute these hoses to the

underside of the pump suction hose. Reconnect

and tighten fittings, then secure with tie straps.

Secure all other hoses and cables with tie straps

to ensure they do not rub against pump pulleys

and belts (FIG. 2).

FORM NO. 99-0548 REV. A

SET-UP AND

PARTS LIST

MODEL NO. 41080-90001 & UP

MODEL NO. 41021-90001 & UP

MODEL NO. 41220-90001 & UP

MODEL NO. 41223-90001 & UP

MODEL NO. 41222-90001 & UP

MANUAL SPRAY SYSTEM

FOR THE WORKMAN 3000 VEHICLE

1067

Summary of content (20 pages)

PAGE 1
FORM NO. 99-0548 REV. A MODEL MODEL MODEL MODEL MODEL NO. NO. NO. NO. NO. 41080-90001 41021-90001 41220-90001 41223-90001 41222-90001 & & & & & UP UP UP UP UP SET-UP AND PARTS LIST MANUAL SPRAY SYSTEM FOR THE WORKMAN 3000 VEHICLE Refer to the illustrated Parts List for details of parts used in assembling the Pro-Control NOTE: Right, Left, Front and Rear are referenced while seated in the operators position.
PAGE 2
FIG. 2 1. Hydraulic Control Valve 3. Pump Suction Hose 2. R.H. Dump Cylinder Hoses 9. Mount the pump and the spring tab to the pump mount bracket using the (2) 3/8" x 1 1/2" hex hd cap screws, flat washers, and locknuts. Attach the spring to the spring tab located at the base of the pump (FIG 1). FIG. 4 1. Pump Pulley 3. Inside Idler Pulley 2.
PAGE 3
4. Using (2) 1/4" x 5/8" hex washer head screws, flat washers and nuts, secure the "U" shaped console bracket to the console bracket to the console mounting bracket. Mount the console to the "U" shaped bracket using the (2) mounting knobs (FIG. 5). 5. Route the control cable under the dash and through the hole in the floorboard. See Fig. 6. Loosen the bolts on the channel under the floorboard and feed the cable through the channel. 6.
PAGE 4
7. Attach right Boom Hold-In assembly to Hold-In Brace assembly using (2) 1/4" U-bolts and (4) 1/4" lock nuts. Attach Rubber Hold-Down to Hold-In Brace assembly. Repeat steps 6 and 7 for left side. 8. Mount Wash Tank Bracket (open end forward) to right-hand Hold-In Brace assembly using (2) 5/16" x 1" hex hd. cap screws, flat washers, and hex nuts. Place Clean Water Wash Tank into Wash Tank Bracket and secure with Rubber Hold-Down, as shown in FIG. 8. 11.
PAGE 5
NOTE: Steps 2-4 apply to the assembly of the standard boom only. If the optional "Boom Pivot Kit" will be installed, see the instructions furnished with that kit. The lower cross support to be used with that kit is different than the support to be used on the standard boom. 2. Position the lower cross support angle and attach it to the boom mount upright arms with (2) 1/2" x 1 1/4" hex hd cap screws and locknuts (FIG. 11). 3.
PAGE 6
9. Attach three double barb and one single barb turret assemblies on each extension boom pipe as shown in FIG. 14. Turret assemblies are to be level & spaced on 20" centers. Connect the turret assemblies with the 3/4" x 19" jumper hoses. Secure with hose clamps. NOTE: Two jumper hoses provided with this kit are 21" long. They should be cut to 19" long for this set-up. FIG. 15 1. Bottom Cross Support 4. Solenoid Mtg. Bracket 2. Top Cross Support 5. Control Valve 3. Supply Hose 1" x 42" 6.
PAGE 7
6. Install Control Valve Bracket to Bottom Cross Support. See FIG. 16. Secure with two (2) flange cap screws and Hex Flange Nuts. (Do not tighten). 7. Place Straight Hose Barb through circular opening in Control Valve Bracket and screw into the inlet port of the Control Valve. Tighten Control Valve Bracket fasteners securely. 8. Install Reducer Bushing/Gauge Tube Fitting to end port of Solenoid Valve Assembly. Connect Pressure Gauge Tube to Gauge Tube Fitting. 9.
PAGE 8
CAUTION Part No. 92-2663: Located at Fuse Block (1). TO AVOID ELECTRIC SHOCK AND PERSONAL INJURY TO BYSTANDERS INSPECT AREA OVERHEAD FOR WIRES BFORE RAISING BOOMS. ROTATING MEMBERS 80-8040 Part No. 80-8040: Located on Radiator Cover top, front & rear (2). NO STEP 87-0570 Part No. 75-5190: Located on Radiator Cover top, front & rear (2). WARNING 92-2663 KEEP BYSTANDERS AWAY WHILE RAISING AND LOWERING BOOMS. 36-3400 75-5190 NO RIDERS SPRAYER 20 AMP Part No.
PAGE 9
1 2 3 4 5 6 7 8 9 10 1066 TANK LID ASM (94-7088) Ref Part No. Description 1 2 3 4 5 94-7205 94-7213 94-7206 94-7207 94-7208 Swivel Arm Pivot Pin O-Ring, EPDM Spray Tank Lid Gasket EPDM Qty Ref Part No.
PAGE 10
SKID & TANK (200) * INDICATES FASTENERS INCLUDED WITH THE VEHICLE 10
PAGE 11
SKID & TANK (200) Ref Part No. Description 1 2 3 4 5 6 42983 3217-6 3256-23 92-0010 42198 42259 7 42316 Hold-In Brace ASM Hex Nut, 5/16 Flat Washer, 5/16 S.A.E.
PAGE 12
BOOM FRAME 12
PAGE 13
BOOM FRAME Ref Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 * 22 92-3671 92-3672 32153-5 92-3670 325-5 42225 42258 3217-6 42234 3256-3 323-6 3256-4 40493 40494 32153-2 42227 42257 42711 42710 322-7 42707 3256-62 Boom Mtg. Angle - LH Cross Angle - Upper Lock Nut, 1/2 Boom Mtg. Angle - RH HHCS, 1/2 x 1-1/4 Cross Supprot Angle Spacer Tube, 1-1/4" Lg.
PAGE 14
SPRAYER PUMP ASSEMBLY (3000) 14 11 15 12 11 13 5 7 10 6 2 8 16 4 3 1 1107 CENTRIFUGAL PUMP (93-6505) 14 9
PAGE 15
SPRAYER PUMP ASM (3000) Ref Part No. Description 1 2 3 4 5 6 7 41307 40480 93-0887 93-6505 5706 92-3731 41316 41318 323-8 67-1440 32153-2 3231-7 52-2890 92-3742 92-3727 68-0030 323-13 92-0050 42701 93-0687 94-7065 1" 90° Street Elbow Quick Coupler x 1" 90° St. Elbow, 1-1/4" Centrifugal Pump 45° St.
PAGE 16
PAGE 17
MANUAL SPRAY SYSTEM (3000) Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part No. Description Qty Ref Part No. Description 99-0529 99-0528 42872 99-0530 99-0536 92-8557 92-0045 99-0539 43-2830 48-8020 32128-20 3234-5 48-7620 41294 42944 99-0531 42940 42941 41310 42936 41313 Control Valve Bracket Solenoid Valve Bracket Throttling Valve Bypass Solenoid Valve ASM Single Solenoid Hose Barb, 90° 1/2" x 3/4" H.B.
PAGE 18
TURRET BODIES & BOOM HOSES 18 Ref Part No. Description * 95-9183 * 95-9181 * 95-9184 1 2 † 3 4 5 6 † 7 8 † 9 † 10 † 11 † 12 13 14 99-0811 99-0812 95-9191 95-9192 95-9197 95-9196 95-9198 95-9200 95-9199 99-0815 99-0813 41003 95-9193 95-9202 Turret Body - Doubvle Barb (Incl. Ref. #'s 1-14) Turret Body - Single Barb (Incl. Ref #'s 1-13 & 15) Turret Body - Barb x 1/2 NPT (Incl. Ref.
PAGE 19
1381 CONTROL CONSOLE (3000) Ref Part No. Description 1 2 3 4 42933 42934 42932 99-0530 99-0536 42936 42931 42930 42935 42929 41276 92-3716 42928 92-3733 92-3679 12-10 AWG Female Terminal 16-14 AWG Female Terminal Insulated Female Terminal Solenoid Valve ASM Single Solenoid Control Valve Male Fitting Tubing 72" Cable ASM (Valve Hook-up) Union Fitting Push-On Terminal, 5/16 Ring Terminal, 5/16 96" Cable ASM (Encl.
PAGE 20
SOLENOID VALVE (99-0536) 20 Ref Part No. Description 1 2 3 4 5 6 7 8 95-9317 † 95-9318 95-9319 93-1031 † 93-1034 Coil ASM-Nylon Encapsulated Spring - Stainless Steel Armature - Stainless Steel Retaining Ring - Steel, Plated Upper Diaphragm House (blk) Diaphragm - Viton Seal Washer - Retainer, SS Seal Washer - Viton † Indicates parts included in Viton Seal Kit. Order Part No. 99-0546 Qty Ref Part No.