Boom Mounting Kit Form No. 3356-122 Rev B For Workman 200 Spray Systems Model No. 41229, Model Year 2004-5 Model No. 41324—Serial No. 260000001 and Up Installation Instructions Note: The installation of existing sprayer kits (Foam Marker Kit, Hose Reel Kit, etc.) to the newly modified boom system may require additional parts or updated kits. Please contact your Authorized Toro Dealer for additional information.
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 Qty. Description Use No parts required – Preparing the machine. No parts required – Remove the installed boom system Decal 106-1434 2 Install the decals. Prop rod assembly 1 Change the prop rod assembly. No parts required – Removing the existing boom supports.
Note: Determine the left and right sides of the machine from the normal operating position. Step 2 Note: The following procedure, at times, will require two people to perform. An overhead hoist can be used as well. Removing Installed Boom System Note: The installation of this kit can be aided by referencing the Parts Catalog and Service Manual. Step No Parts Required 1 Procedure Prepare the boom assembly for removal by securing it with an over head hoist.
Figure 2 Left side shown 1. Tank skid frame 2. Access door 3. Hold down bracket assembly Figure 1 Left side shown 1. Bolt (1/2 x 1-1/4 inches) 2. Bolt (1/2 x 3 inches) 3. Lock nut (1/2 inch) 4. 5. 6. Boom mount bracket Boom mount angle Center boom assembly Decal 106-1434 Install area Step 4 5. Remove the boom assembly and place it aside to allow installation of the new boom assembly.
skid frame to the machine frame. Use a lift to control the movement of the assembly. 7. Using the overhead lift, lower the tank skid frame slightly to allow the prop rod to find the support. 3. Tilt the assembly up but do not engage the prop rod. Use the over head lift to keep the spray tank assembly up lifted and stationary to allow the prop rod to be changed. 8. Turn the prop rod 90 degrees and guide it through the prop rod support as the tank skid is slowly lowered. 4.
boom mount angles from the side of the tank skid frame (Figure 5). Remove the boom mount angles. pump brackets to the pump support bracket (Figure 5). 6. Remove the four bolts (1/2 x 3 inches) and four lock nuts (1/2 inch) securing the pump brackets to the tank skid frame (Figure 5). Remove the pump brackets. 5. Remove the four bolts (1/2 x 1-1/4 inches) and four lock nuts (1/2 inch) securing the Figure 5 1. 2. Bolt (1/2 x 1 inch) Boom mount bracket 3. 4. Boom mount angles Lock nut (1/2 inch) 5.
Step 3. Use two bolts (1/2 x 1 inch) and two lock nuts (1/2 inch) removed previously to secure the left pump support bracket to pump bracket (Figure 6). 6 4. Repeat steps 2 and 3 for the right side pump support bracket. Installing the New Boom Supports 5. Install the left boom angle behind the left pump support bracket face and inside the tank skid frame bracket. Use two bolts (1/2 x 1 inch) and two lock nuts (1/2 inch) removed previously to secure the angle to the tank skid frame bracket (Figure 7).
3. Remove the screws in the front cover and remove the cover. 4. Disconnect the connectors from the existing wiring harness to left and right boom lift switches in the front cover. 5. Remove the grommet in the base of the control box. 6. Route the connectors labeled left and right actuator on the new wiring harness up through the hole in the bottom of the control box. Install the grommet removed previously. 7.
Step 2. Install center boom assembly to the uprights using four flange bolts (1/2 x 1-1/4 inches) and four flange nuts (1/2 inch) (Figure 10). 8 Installing the Boom Assembly Parts needed for this step: 1 2 14 8 14 4 4 1 1 2 1 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 Figure 10 Procedure 1.
Figure 11 1. Center boom assembly 2. Boom extension 3. Hinge plate 4. 5. 6. Bolt (3/8 x 1-1/4 inches) Spacer Lock nut (3/8 inch) 6. Repeat step 5 on the other side of the center boom assembly with the opposing boom extension. Note: Ensure all spray turrets are facing to the rear.
Step 2. Install the hoses to the valve assembly. Use the fittings to attach the hose to a valve assembly. 9 3. Route the boom hoses as shown in Figure 12. 4. Use the R-clamps to secure the right and left boom hoses to the front side of the center boom assemblies. Secure the hoses and R-clamps with a shoulder bolt, a washer and a nut as shown in Figure 12.
Step 5. Use liquid soap to coat the hose barb of the tee connections on both extension booms (Figure 13). Install the boom extension hose over the barb and secure it with a clamp. 10 Checking the Boom Hinge Springs No Parts Required Procedure Important: Operating the spray system with the boom hinge springs under the incorrect compression could damage the boom assembly. Measure the springs and use the jam nut to compress the springs to 1.56 inches if necessary.
4. The old boom system represents a contaminated metal. Dispose of it according to local and state regulations. 5. Keep the following documents to reference the modifications: • The Parts Catalog for this kit. • The Operation, Maintenance and Troubleshooting sections of this Installation Instructions. Figure 14 1. Boom hinge spring 2. Jam nut 3. Repeat the procedure for each spring on both boom hinges. 4. Move the booms into the transport “X” position.
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.
Maintenance 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. Accessing the Machine Rasing the Tank Assembly 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 15.
Figure 17 Right boom Figure 16 1. Actuator 2. Actuator rod 3. Boom pivot pin housing 4. 5. 1. Grease bearing Cotter Pin 6. Raise the boom to align the pivot with the actuator rod. While holding the boom, insert the pin through both boom pivot and actuator rod (Figure 16). 7. With the pin in place, release the boom and secure the pin with the cotter removed previously. 8. Repeat the procedure for each actuator rod bearing. 3. Lift up on the boom and remove the pin (Figure 16).
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 18 1. Use of the manual relief valve may cause the boom to move suddenly and cause injury to you or others. Actuator, right boom 2.
Figure 19 1. Pivot pin 2. Bolt 3. Nut 4. 5. Nylon bushing Pivot bracket 4. Remove the boom and pivot bracket assembly from the center frame to access the nylon bushings. 5. Remove and inspect the nylon bushings from the front and back sides of the pivot bracket (Figure 19). Replace any damaged bushings. 6. Place a small amount of oil on the nylon bushings and install them into pivot bracket. 7. Install the boom and pivot bracket assembly into the center frame, aligning the openings (Figure 19). 8.
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.
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.
