Installation Instructions

ManualsBrandsToro ManualsAttachmentsFoam Marker Kit, Multi-Pro 1200, 1250, 5600 and 5700 Turf Sprayers and Workman 200 Spray Systems

W 2005 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Printed in the USA

Original Instructions (EN)

Foam Marker Kit

for Multi Pro

)

1200, 1250, 5600, 5700 Turf Sprayers and

Workman

)

200 Spray Systems

Model No. 41228—Serial No. 250000001 and Up

Form No. 3353-362 Rev A

Installation Instructions

Note: Determine the left, right, front, and rear sides of the machine while seated in the normal operating position.

Note: If you are installing this kit on a vehicle equipped with an enclosed boom system, use these instructions along with the

enclosed boom system instructions.

Note: RTV silicone sealant is used in the installation of this kit.

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Tank/compressor assembly

Workman adapter bracket

Multi-Pro 1200 series adapter bracket

Bolt, 3/8 x 1 inch

Flange locknut, serrated, 3/8 inch

Locknut 3/8 inch

Carriage bolt, 3/8 x 1-1/4 inch

Flange locknut, non-serrated, 3/8 inch

Mixer assembly

Flat washer, 3/8 inch

Rocker switch

Fuse, 15 amp (spare)

Boom hose

Punched-hole boom cap

Extension hose

Large hose clamp

Supply hose, 108 inches

Small hose clamp

Plastic ties

Install the foam marker (you may have leftover

parts, depending on which vehicle you are

installing this kit on)

Parts Catalog 1 Use for ordering replacement parts.

Installation instructions 1 Read before installing the kit.

Setup

Separate instructions for the installation of the Foam

Marker kit are provided for the Workman 200 Spray

System, the Multi-Pro 1200 series sprayers, and the

Multi-Pro 5000 series sprayers on the following pages:

• Workman 200 on page 2.

• Multi-Pro 1200 series on page 6.

• Multi-Pro 5000 series on page 11.

Turn the appropriate page for your machine to begin the

installation.

Summary of content (20 pages)

PAGE 1
Form No. 3353-362 Rev A Foam Marker Kit for Multi Pro) 1200, 1250, 5600, 5700 Turf Sprayers and Workman) 200 Spray Systems Model No. 41228—Serial No. 250000001 and Up Installation Instructions Note: Determine the left, right, front, and rear sides of the machine while seated in the normal operating position. Note: If you are installing this kit on a vehicle equipped with an enclosed boom system, use these instructions along with the enclosed boom system instructions.
PAGE 2
Installing the Kit on a Workman 200 Spray System 5. Secure the hose ends with small hose clamps. 6. Route both of the supply hoses rearward along the left side of the sprayer to the rear of the machine following the sprayer wiring harness. Installing the Tank, Compressor, and Mixer 7. Attach the cover to the tank/compressor assembly using 3 of the 4 hex-head bolts (1/4 x 1 inch) and flat washers that you removed previously. Leave the bottom right bolt out until later in the installation (Fig. 1). 1.
PAGE 3
11. Mount the foam marker assembly to the frame using two bolts (3/8 x 1 inch), two washers (3/8 inch), two flange nuts (3/8 inch) included in loose parts; and the left handle and fasteners removed previously (Fig. 4). 13. Slide the marked supply hose onto the barb on the check valve located at the tee assembly (Fig. 6). 4 6 5 7 4 3 3 1 5 1 2 2 m–6451 Figure 6 1. Check valve 2. Hose from the compressor 3. Hose from the needle valve m–7192 Figure 4 1. 2. 3. 4.
PAGE 4
3. Route the hoses along the wiring harness to the rear of the sprayer and to the mixer tee using the cable ties. Secure the hose end with a small hose clamp. Installing the Switches 1. Loosen the 4 screws securing the front panel to the control box (Fig. 9). 2 2. Remove the front panel expose the inside of the control box (Fig. 9). 3 3 4 1 m–6446 2 1 Figure 7 1. Wiring harness 2. Compressor 6 3. Solenoid 5 2. Locate the connectors in the rear wiring harness of the sprayer (Fig. 8). m–7194 A.
PAGE 5
. Remove the existing boom cap from the end of the boom pipe. 6. Insert the 15-amp fuse in the top slot in the fuse block. Make sure the corresponding wire in the fuse block is connected to the red/black wire in the harness (Fig. 10). 6. Insert the boom hose into the hole drilled in the right boom pipe and push it into the boom pipe until 2 to 3 inches of boom hose extends beyond the opposite end of the boom pipe (Fig. 12). 2 1 3 2 6 m–7193 5 Figure 10 1. 15-amp 2. Fuse block 3.
PAGE 6
Installing the Kit on a Multi Pro 1200 or 1250 Turf Sprayer 2 5 1 Installing the Tank, Compressor, and Mixer 3 4 1. Mount the Multi-Pro 1200 series adapter bracket to the right side of the vehicle above the battery (Fig. 13) using 4 bolts (3/4 x 1-1/4 inch) and 4 flange locknuts (3/4 inch). Note: It is easiest if you remove the battery before performing this step. Refer to your vehicle Operator’s Manual for instructions. m–7190 Figure 14 1. Cover 2. Tank/compressor assembly 2 4 1 3. Flat washer 4.
PAGE 7
6. Secure the hose ends with small hose clamps. 11. Locate the supply hoses routed to the rear of the machine previously. 7. Route both of the supply hoses rearward along the right side of the sprayer to the rear of the machine following the sprayer wiring harness. 12. Slide the marked supply hose onto the barb on the check valve located at the tee assembly (Fig. 18). 8. Attach the cover to the tank/compressor assembly using 4 hex-head bolts (1/4 x 1 inch) and 4 flat washers that you removed previously.
PAGE 8
2 1 4 3 2 3 m–6453 1 Figure 19 1. Plug 2. Switch m–6446 3. Notch (at back) 4. Spray control panel Figure 21 1. Wiring harness 2. Compressor 3. Solenoid 2. At the rear of the machine, plug the harness connectors into the boom solenoid assemblies. Plug the connector with the blue wire to the right solenoid; plug the connector with the yellow wire to the left solenoid (Fig. 22). 2 1 1 2 m–6458 Figure 20 1. Foam marker switches 2. Spray control panel 3 Wiring the Kit 2 1.
PAGE 9
Completing the Installation 2 Note: If you are installing this kit on a previously setup sprayer, you may need to disassemble the boom assembly for steps 1 through 10 below. 6 1. Locate, mark, and drill (through the top surface only) a hole (5/8 inch dia) 1-1/2 inch from the plugged end of the right boom pipe (Fig. 23). 5 2. Repeat step 1 for the left boom pipe. 3. Use a round file or deburring tool to deburr the holes you drilled in the boom pipes (Fig. 23). 1 4.
PAGE 10
5 4 3 1 m–6451 2 Figure 25 1. Check valve 2. Hose from the compressor 3. Hose from the needle valve 4. Right boom hose 5. Left boom hose 14. Connect the right boom hose to the right side solenoid valve assembly and the left supply hose to the left side solenoid assembly. 15. Secure both hoses with small hose clamps (Fig. 25). 16. Secure all loose wires and hoses to the vehicle frame using plastic ties. 17.
PAGE 11
Installing the Kit on a Multi Pro 5600/5700 Turf Sprayer Installing the Switches 1. Remove the throttle knob by unscrewing it from the throttle rod at the center console. Installing the Tank, Compressor, and Mixer 2. Release the latch and remove the switch panel assembly from the center console assembly (Fig. 28). 1. Remove 4 bolts (1/4 x 1 inch) and flat washers that hold the cover to the tank/compressor assembly. 3 2. Remove the cover. 1 3. Set the cover and fasteners aside. 4.
PAGE 12
11. Insert the 20-amp fuse in the second fuse slot in the block (from the front of the vehicle). To complete the installation, refer to Completing the Installation, page 12. Completing the Installation 2 Note: If you are installing this kit on a previously setup sprayer, you may need to disassemble the boom assembly for steps 1 through 10 below. 3 1 1. Locate, mark, and drill (through the top surface only) a hole (5/8 inch dia) 1-1/2 inch from the plugged end of the right boom pipe (Fig. 31).
PAGE 13
2 6 1 5 3 2 1 m–6450 2 3 4 Figure 33 m–7221 1. Compressor hose 2. Needle valve hose Figure 32 1. 2. 3. 4. Boom hose Punched hole boom cap Hose clamp Extension hose 5. 2 to 3 inches of boom hose past the boom cap 6. End of the boom pipe 3. To the mixer tee 15. Secure the hose ends with small hose clamps (Fig. 33). 16. Route both of the supply hoses rearward along the right side of the vehicle frame to the mixer tee following the foam marker wiring harness. 7.
PAGE 14
21. Connect the right boom hose to the right side solenoid valve assembly and the left supply hose to the left side solenoid assembly. 22. Secure both hoses with small hose clamps (Fig. 34). 23. Secure all loose wires and hoses to the vehicle frame using plastic ties. 24. Attach the cover to the tank/compressor assembly using the 4 hex-head bolts (1/4 x 1 inch) and flat washers that you removed previously. 25. Close the foam density adjustment valve completely.
PAGE 15
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 94-7275 94-7287 Operation Using the Controls Caution Right boom switch—activates the compressor, generating a flow of foam to the right boom section. The contents of the foam marker tank are under pressure. Loosening the fittings on the tank could result in personal injury.
PAGE 16
Important Do not add more than 2-1/2 gallons (9.5 l) of solution into the tank. 5 7 Note: Extreme pH levels (hardness/softness) of the water will affect the amount of foam concentrate needed. 5. Install the lid on the solution tank. 8 6. Ensure that the lid is positioned properly for a tight seal and push down on the clamp lid. 4 7. Close the pressure relief valve. 8. For the initial operation, open the foam density adjustment valve 1/8 to 1/4 turn (Fig. 36). 6 9.
PAGE 17
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure 100 Hours • Inspect the hose between the foam tank and the compressor for accumulated water. • Inspect and clean the check valve in the tee on top of the compressor. Replace the valve if necessary. • Remove and clean the strainer at the top of the solenoid valve, next to the compressor.
PAGE 18
6. Assemble strainer and nozzle body/hose barb as shown in Figure 38 and install into nozzle adapter/solenoid assembly. 7. Attach liquid hose to hose barb and un–clamp. 8. Flip pressure release valve to the down position. If the problem persists, please contact your local Authorized Toro Distributor. Storage 1. Remove the couplers on top of the tank. 2. Loosen and unhook the foam marker tank strap. 3. Remove the tank from the bracket, remove the tank lid, and empty the contents of the tank. 4.
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