Installation Instructions

ManualsBrandsToro ManualsSprayersPro Control Spray System, Workman

Model No. 41080-90001 & UP

Model No. 41021-90001 & UP

Model No. 41031-90001 & UP

Model No. 41220-90001 & UP

Model No. 41223-90001 & UP

Model No. 41230-90001 & UP

SET-UP AND

PARTS LIST

FORM NO. 95-9299

©The TORO Company - 1999

PRO CONTROL SPRAY SYSTEM

for the WORKMAN® Vehicle

NOTE: “Right”, “Left”, “Front” and “Rear” are

referenced while seated in the operator’s

position.

1. Install the TORO APU Electric Clutch Kit as per

the instructions provided with that kit.

SPEED SENSOR INSTALLATION:

Remove four bolts and discard the Aluminum

Cover located on top of Transaxle. Apply a thin

bead of RTV sealer around the outer bottom edge

(side opposite tapped hole) of the the new Sensor

Cover. Position the Sensor Cover on the Transaxle

as shown in FIG. 1 and secure with bolts earlier

removed. Apply a few drops of oil to the Speed

Sensor and insert into Sensor Cover. Secure with

the M6-12 screw and M6 lockwasher provided.

PUMP INSTALLATION:

1. Slide Pulley Spacer onto the pump shaft and

install Square Key into pump shaft keyway. Place

the Pump Pulley on the pump shaft and secure

with a 5/16" x 3/4" hex hd. cap screw, 5/16" I.D. 10

GA. flat washer, and lockwasher. See FIG. 2.

2. Attach the Idler Pivot Bracket to the Pump by

removing the two pump housing bolts and replace

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

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

System.

FIG. 1

1. Sensor Cover Assy. 2. Speed Sensor

3. Install one flange bushing into each end of the

Idler Pivot assembly tube and attach to the Idler

Bracket using the 3/8" x 3" hex hd. cap screw and

locknut (FIG. 2).

FIG. 2

1. Pump Mounting Brkt. 5. Rubber Mount

2. Centrifugal Pump 6. Tab Mount

3. Idler Pivot Assy 7. Pulley Spacer

4. Idler Pivot Brkt.

4. Mount the small Inside Idler Pulley on the long

arm of the Idler Pivot Assy. using the 3/8" x 2-3/4"

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

as required between Idler Pivot Assy and Inside

Idler Pulley with the (3) 3/8” flat washers to

align with Pump Pulley. Attach the Tension Spring

to the short arm of the Idler Pivot Assy. See FIG.

NOTE: In the following instructions, sealer

refers to Teflon Tape when used for pipe fittings.

5. Apply sealer and install the 90° x 1-1/4" street

elbow into the suction port of the Pump. Apply

sealer and install 1"x 3" nipple, (2) 45° x 1" elbows,

and Quick Adapter into the discharge port of the

Pump (FIG. 2).

Summary of content (24 pages)

PAGE 1
FORM NO. 95-9299 Model Model Model Model Model Model No. No. No. No. No. No. 41080-90001 41021-90001 41031-90001 41220-90001 41223-90001 41230-90001 & & & & & & UP UP UP UP UP UP SET-UP AND PARTS LIST PRO CONTROL SPRAY SYSTEM for the WORKMAN® Vehicle Refer to the illustrated Parts List for details of parts used in assembling the Pro-Control TM System. NOTE: “Right”, “Left”, “Front” and “Rear” are referenced while seated in the operator’s position. 3.
PAGE 2
6. Install the Rubber Mount into the Tab Mount and loosely attach the Tab Mount to the Pump Mounting Bracket using the (2) 3/8" x 1" hex hd. cap screws, flatwashers, and locknuts (FIG. 2). NOTE: For the installation of the Pump Mounting Plate, it is necessary to first remove the rear mounting bolt in the Hydraulic Valve. If equipped with the Auxiliary Hydraulics package, it is necessary to remove the last two mounting bolts for that valve.
PAGE 3
CONTROL CONSOLE & HARNESS INST: 1. Unplug the wire harness connectors from both Headlights. 2. Remove (15) screws and washers securing Front Hood to vehicle frame and remove hood. 3. Temporarily mount the Console Mounting Bracket to the upper dash support using two of the earlier removed machine screws and washers (FIG. 6). FIG. 7 1. Frequency Divider 3. 2. Speed Sensor Cable 4. Control Console Console Control Cable 8. Plug the connector from the Speed Sensor Cable into the Frequency Divider (FIG. 7).
PAGE 4
TANK INSTALLATION: 1. Remove (2) 3/8" nuts and attaching bolts that hold the left rear fender to the vehicle frame. Place a 10 GA. flat washer on each bolt. Install bolts through fender and vehicle frame and mount the Tank Support Bracket with these bolts. Reinstall the nuts and tighten securely. See FIG. 8. 1074 1. FIG. 8 Tank Support Brkt. 2. Cut the shipping straps and remove the Spray Tank and Skid Assembly from the shipping pallet. 3.
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3. Position the Upper Cross Support angle and attach it to the Boom Mount Upright angles with (2) 1/2" x 1-1/4" hex hd. cap screws and locknuts. 4. Position the Spacer Tubes between the Boom Mount Upright angles and the lugs on the Boom Main Frame tube. Secure Boom Main Frame tube to the Boom Mount Uprights with (2) 1/2" x 4" hex hd. cap screws and locknuts (FIG. 13). 1. FIG. 11 Attachment Mounting Brkt. 14. Release the Strut Support Rod and lower the Tank Saddle assembly.
PAGE 6
3. Attach the Strut Assemblies to the Adjustable Clevis Assemblies found on each side of the Boom Main Frame tube with (2) 1/2" x 2" clevis pins and (2) 1/8" x 1" cotter pins (FIG. 13). 6. Secure the two plates of Boom Support Assembly to the Extension Boom Pipe, using (2) 1/4" U-bolts, (4) flat washers, and (4) locknuts (FIG. 15). IMPORTANT: Do not over tighten nuts in steps 4 & 6. The clamping action could crush the Boom Pipe. 7. Assemble the RH Boom Support Assembly to the other Extension Boom Pipe.
PAGE 7
2. Apply thread sealer and install a 3/4” 90° Hose Barb into the outlet port of the each Solenoid Valve. Install 3/4" x 1/4" Reducer Bushing and 1/4" x 3/8" Hose Barb in the end of Solenoid Assembly. See FIG. 16. 3. Loosely attach the Motorized Control Valve Bracket to the Lower Cross Support with (2) 5/16" x 3/4" hex flange hd. screws and flange lock nuts. 4. Install two (2) Grommets in 1” holes in Solenoid Mounting Bracket. 5. Slide head of M6 x 16mm hex hd.
PAGE 8
11. Connect the 3/4" x 28" Agitator Hose to the RH Ball Valve and connect the other end to the Hose Barb in the Rear tank Tee. Secure the hose with hose clamps. See FIG. 16. 12. Connect the 1" x 5" Connector Hose between the Ball Valve in the center tee and the 90° Hose Barb in the left side of the Rear Tank Tee. See FIG. 16. Secure with hose clamps. FLOW CONTROL CABLE: 1. Locate the Extension Cable and connect it to the Fowmeter Cable.
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NOTES: 9
PAGE 10
SAFETY INSTRUCTIONS The following safety and instruction decals are installed on the XXXX. If any become damaged or illegible, replace them. Decals and part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor. 75-5190 NO RIDERS SPRAYER 20 AMP WARNING 92-2663 Part No. 92-2663: Located at Fuse Block (1). Part No. 75-5190: Located on Radiator Cover top, front & rear (2).
PAGE 11
1064 Pro ControlTM Console (3000) Ref. Part No. Description 1 93-0907 Switch Cover 1 2 93-0908 1-Set Filler Spacers 1 3 93-0909 Face Plate Assy 1 4 93-0910 Display Board Spacer 1 5 93-0911 LCD Display Board 1 6 93-0912 Processor Board 1 7 93-0913 Connector Plate Assy 1 8 93-0914 Back Assy 1 1 Qty. 2 3 4 TANK LID ASSY (94-7088) Ref. 5 6 7 8 9 10 1066 Part No. Description Qty.
PAGE 12
SKID & TANK (200) * INDICATES FASTENERS INCLUDED WITH THE VEHICLE 12
PAGE 13
SKID & TANK (200) Ref. Part No. Description Qty. Ref. 1 42983 Hold-In Brace Assy 2 3217-6 3 2 Hex Nut, 5/16 12 3256-23 Flatwasher, 5/16 S.A.E. 14 4 92-0010 U-Bolt, 1/4 5 42198 Rubber Hold-Down Strap 6 42259 Boom Hold-In -L.H. (shown) 7 42316 Part No. Description 36 40480 Female Quick Coupler, 1" 37 21146 Hose Clamp 4 38 92-0012 Hose Barb, 1" NPT x 1" 2 4 39 40020 Ball Valve, 1" NPT 1 3 40 41307 90 St.
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BOOM FRAME 14
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BOOM FRAME Ref. Part No. Description Qty. Ref. Part No. Description 1 92-3671 2 Qty. Boom Mtg Angle - L.H. 1 23* 42196 Compression Spring 2 92-3672 Cross Angle - Upper 1 24* 42706 Breakaway Pivot Assy. 2 3 32153-5 Lock Nut, 1/2 10 25* 32121-78 Spring Pin, 1/4 x 2" 2 4 92-3670 Boom Mtg Angle - R.H. 1 26* 3256-23 Flatwasher, 5/16 S.A.E.
PAGE 16
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) 16 9
PAGE 17
SPRAYER PUMP ASSEMBLY (3000) Ref. 1 Part No. Description 41307 1" 90° Street Elbow Qty. Ref. 1 Part No. Description Qty. 42703 Strainer Gasket (f/w 42701) AR 42992 Reducing Nipple, 1-1/4" x 1" 1 2 40480 Quick Coupler x 1" 1 19 3 93-0887 90° St. Elbow, 1-1/4" 1 20 322-5 HHCS, 5/16 x 1" 3 4 93-6505 Centrifugal Pump 1 21 3253-4 Lock Washer 4 5 5706 45° St.
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PAGE 19
PRO CONTROL SPRAY SYSTEM (3000) Ref. Part No. Description Qty. 1 92-3688 Console Ctrl. Cable (18 ft.) 1 2 3256-23 Flatwasher, 5/16 3 32128-20 Hex Nut, 5/16 4 92-3675 5 3234-5 6 7 Ref. Part No. Description Qty. 26 41480 Motorized Control Valve 1 8 27 41309 Reducing Nipple, 1" x 3/4” 1 10 28 48-7620 HHCS, M6 x 16mm 3 Manifold Mtg. Plate 1 29 95-9236 Solenoid Valve Assy.
PAGE 20
1103-4 TURRET BODIES & BOOM HOSES 20 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 - Double 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 21
1497 CONTROL CONSOLE (3000) Ref. Part No. Description Part No. Description 41472 Control Console 1 12 41230 Cable Clamp 2 41344 Console Protective Cover 1 13 92-2661 Wiring Harness - Speed Sensor 1 2 42722 3 42723 POWER Switch 1 14 92-3679 Control Console Bracket 1 Rate 1/Rate 2 Manual Switch 1 15 32105-26 Pan Hd. Mach.
PAGE 22
CONTROL VALVE FLOW METER Ref. Part No. Description 1 2 3 4 5 6 7 8 9 10 42475 42476 93-1098* 42477 42478 42479 42480 42469 42481 41483 Sensor Housing S.S. Screw, #10 x 3/4" O-Ring (Viton) Dual O-Ring Transducer Assy Turbine Turbine Hub/Bearing Ass’y Turbine Stud Assembly O-Ring (Viton) Hub Housing w/Inserts Mounting Bracket (not shown) Qty. 1 12 2 1 1 1 1 1 1 1 Ref. 1 2 3 4 5 6 7 8 9 10 Part No.
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NOTES: 23
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