Installation Instructions

ManualsBrandsToro ManualsSprayersBoom Mounting Kit, 2004 and After Multi-Pro 1200, 1250 and 5700-D

Form No. 3356-120 Rev C

Boom Mounting Kit

For Multi-Pro 1200, 1250 and 5700-D Turf Sprayers

Model Year 2004-5

Model No. 41323 —Serial No. 260000001 and Up

Installation Instructions

T his kit r equir es par ts to be w elded to the frame. W elding can expose y ou to a n umber of

hazards including to xic fumes, smok e, dust, bur ns, ﬁr es, explosions, electric shock, radiation,

noise, and heat str ess which can cause serious injur y and death.

• W elding por tions of the kit should be perf or med by a trained w elder .

• W elding must be perf or med in an adequatel y v entilated ar ea with suita ble ﬁr e extinguishing

equipment r eadil y a v aila ble.

• W eld in a ﬁr e-safe w or kplace. T his can be accomplished by w elding behind ﬁr e-safe

bar rier s or cur tains and on concr ete or other ﬁr e-safe ﬂooring . R emo v e or pr otect all

combustibles fr om ignition sources.

• W ear pr oper pr otecti v e clothing when w elding , such as ﬁr e r etardant co v eralls. Pr otect y our

hands with leather gauntlet g lo v es. F eet should be pr otected by high top leather shoes,

pr efera bl y safety shoes.

• Pr otect y our ey es when w elding . A w elding helmet or hand shield with ﬁlter plate and

co v er plate is mandator y to pr otect the ey es while w elding . T ranspar ent go g g les or safety

g lasses should be w or n at all times.

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Note: T he follo wing procedure , at times , will require tw o people to perfor m. An o v erhead hoist can

be used as w ell.

Note: T he installation of this kit can be aided b y referencing the P ar ts Catalo g and Ser vice Manual .

Note: T he installation of existing spra yer kits (F oam Mark er Kit, Hose R eel Kit, etc .) to the newly

modiﬁed boom system ma y require additional par ts or updated kits . Please contact y our A uthorized

T oro Dealer for additional infor mation.

8111 Lyndale Avenue South

Bloomington, MN 55420

Printed in the USA.

Summary of content (20 pages)

PAGE 1
Boom Mounting Kit Form No. 3356-120 Rev C For Multi-Pro 1200, 1250 and 5700-D Turf Sprayers Model Year 2004-5 Model No. 41323—Serial No. 260000001 and Up Installation Instructions This kit requires parts to be welded to the frame. Welding can expose you to a number of hazards including toxic fumes, smoke, dust, burns, ﬁres, explosions, electric shock, radiation, noise, and heat stress which can cause serious injury and death. • Welding portions of the kit should be performed by a trained welder.
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Installation Loose Parts Use the chart below to verify that all parts have been shipped. Step 1 2 3 4 5 6 7 8 9 10 11 12 Qty. Description Use No parts required – Preparing the machine. No parts required – Remove the tank assembly.
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Step 2. Inventory and mark all hoses and connections for later installation. 1 3. Remove the long bolts and fasteners securing the tank straps to the tank saddles. 4. Using an overhead lift, secure the main tank assembly. Preparing the Machine Note: Raise it off the frame a few inches and check that tank assembly if fully disconnected. Disconnect any hose still attaching the tank to the machine if necessary.
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Chemicals are hazardous and can cause personal injury. • Read the directions on the chemical labels before handling the chemicals and follow all manufacturer recommendations and precautions. • Keep chemicals away from your skin. Should contact occur, wash the affected area thoroughly with soap and clean water. Figure 2 1. Boom frame upright 2. Boom frame sleeve • Wear goggles and any other protective equipment recommended by the chemical manufacturer. 3. Mallet 6.
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Step 4 Modifying Frame Parts needed for this step: 2 2 2 Weld plate Jam nut (1/2 inch) Bolt (1/2 x 1 inch) Procedure Figure 4 1. Line up the weld plate with end of the frame (Figure 3). Use a transfer punch to mark the center hole of the plate and remove the plate. 1. 2. Bolt (1/2 x 1 inch) Plate 3. Jam nut (1/2 inch) 4. Weld the new plate to the frame with a quarter inch ﬁllet on the left and right sides of the plate (Figure 5).
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Step 5. Install the two red ring terminals to the auxiliary side of the solenoid. 5 6. Route remaining harness rearward, along the frame with existing wiring. 7. Use cable ties to secure the wiring harness to the existing wiring in the seat compartment and along the frame. Installing the Electrical Harness 8. Install the seat and console components. Parts needed for this step: 1 5 A. Install the console while lifting the control panels up through the openings in the console assembly.
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8. Route remaining harness rearward, along the frame with existing wiring. 9. Use cable ties to secure the wiring harness to the existing wiring in the seat compartment and along the frame. 10. At the rear of the machine, route the new connectors to right and left as labeled. If needed, locate the old actuator connectors and tie them back, out of the way. Step 6 Installing the New Boom Uprights Figure 6 Left Boom Upright 1. 2.
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Step 7 Installing the Tank Assembly No Parts Required Procedure 1. Install front and rear tank saddles to the frame. 2. Secure with fasteners removed previously 3. Install tank assembly. 4. Secure assembly with straps and long bolts. Figure 7 1. 19-1/4 inches 2. Boom upright 3. 4. Retaining bolt Jam nut 4. Tighten the boom frame bolts (Figure 8). Torque the bolts to 75 ± 8 ft-lbs (102 ± 11 N⋅m). Figure 8 1.
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Step 3. Remove and retain any fasteners securing the valve assembly to the cross bar between the uprights. 8 4. Remove valve assembly from the cross bar between the uprights. Transferring the Valve Assembly (1250 and 5700 Turf Sprayers Only) Removing the Valve Assembly from 5700 Turf Sprayers 1. Remove hose clamps securing boom supply hoses from the valve assembly.
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Installing the Valve Assembly on 1250 Turf Sprayers Installing the Valve Assembly on 5700 Turf Sprayers 1. Install new cross bar to the valve uprights using the fasteners removed previously (Figure 9). 1. Install lower crossbar removed from the old boom uprights using existing fasteners. Instal the new valve bracket support to the lower cross bar using existing carriage bolts and fasteners (Figure 10). Figure 9 1. 2. 3. 4. Crossbar Valve assembly Bolt, existing Bolt (5/16 x 3/4 inch) 5. 6. 7.
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Step 9 Installing the Boom Assembly Parts needed for this step: 1 2 14 8 14 4 4 1 1 2 1 Procedure Figure 11 1. 2. 3. 4. Valve assembly Upper valve bracket Foam strip Bolt 5. 6. 7. 8. Center boom assembly Boom transport cradle Bolt (3/8 x 1-1/4 inches) Spacer Lock nut (3/8 inch) Flange bolt (1/2 x 1-1/4 inches) Flange nut (1/2 inch) Left boom extension Right boom extension Extension boom supply hose Center boom supply hose 1.
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2. Use the graphic to locate the set of mounting holes the center boom will be installed to for your machine (Figure 13). 4. Make electrical connections for boom actuators to newly routed connectors. 5. Power on the system and use the boom lift switches to extend the boom actuator rods. This is to allow the left and right boom extensions to be installed. 6. Remove the four bolts, four washers and four nuts on the hinge plate. 7.
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Step secure it to the hose barbs in the boom extensions. 10 Connecting the Boom Hoses 5. Secure the boom hoses to the boom frame using the r-clamp on the front side of the pivot bracket. Leave enough slack in the hose to keep the hoses from kinking when the booms are raised to the transport position. Parts needed for this step: 5700 Turf Sprayers 6 1. Connect the center boom supply hose in loose parts to the center hose barb in the valve assembly. Secure it with a hose clamp.
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Step Before operating the machine, the springs must be adjusted to the correct compression. 12 1. Support the booms while they are extended to the spray position. 2. At the boom hinge, measure the compression of the upper and lower springs while the booms are in their extended position (Figure 16). Completing the Setup Parts needed for this step: A. All springs must be compressed until they measure 1.56 inches. 1 B. Use the jam nut to compress any spring that measure greater than 1.56 inches.
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Operation Operating the Booms The boom lift switches on the sprayer control panel allows you to move the booms between transport position and spray position without leaving the Operator’s seat. It is recommended to change boom positions while the machine is stationary. To change the boom position: 1. Stop the sprayer on level ground. 2. Use the boom lift switches to lower booms. Wait until the booms reach the full, extended spray position. 3.
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Maintenance 1. Extend the booms to the spray position. 2. Remove the cotter pin from the pivot pin (Figure 18). Greasing the Boom Hinges Important: If the boom hinge is washed with water, all water and debris must be cleared from the hinge assembly and fresh grease must be applied. Grease Type: No. 2 general-purpose lithium base grease. 1. Wipe the grease ﬁttings clean so that foreign matter cannot be forced into the bearing or bushing. 2. Pump grease into the bearing or bushing at each ﬁtting Figure 17.
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0.085-0.100 inch (2.16-2.54 mm), you may wish to bleed the air from the hydraulic oil. Refer to the Service Manual for instructions on how to bleed air from the actuators or contact an Authorized Toro Service Distributor. Emergency Manual Operation of the Boom Actuators Note: Determine the left and right sides of the machine from the normal operating position. Figure 19 Use of the manual relief valve may cause the boom to move suddenly and cause injury to you or others. Right boom 1.
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Figure 20 1. Actuator, right boom 2. Manual relief valve Note: Due to the opposing orientation of actuators in respect to each other the manual relief valve is on the forward face of the left boom actuator and the rear face of the right boom actuator. Figure 21 1. Pivot pin 2. Bolt 3. Nut 2. Use a hexagonal wrench to loosen the manual relief valve no more than 2-3 turns. The cylinder should start stroking manually or by external pressure at this time. 4. 5. Nylon bushing Pivot bracket 4.
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Troubleshooting Troubleshooting the Spray System Problem Possible Cause Corrective Action A boom section does not spray. 1. The electrical connection 1. Turn the valve off on the boom valve is manually. Disconnect dirty or disconnected. the electrical connector on the valve and clean all leads, then reconnect it. 2. Blown fuse 2. Check the fuses and replace them as necessary. 3. Pinched hose 3. Repair or replace the hose. 4. A boom by-pass valve is 4. Adjust the boom by-pass improperly adjusted. valves.
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Problem Boom actuator is not operating properly. Possible Cause Corrective Action 1. A thermal breaker in the 1. Wait for the system fuse block responsible for to cool down before powering the actuator resuming operation. has tripped due to If the thermal breaker overheating. trip repeatedly, contact your Authorized Service Dealer. 2. A thermal breaker in 2. Contact your Authorized the boom actuator Service Dealer. responsible for powering the actuator has tripped or malfunctioned.