Form No. 3351–160 Rev A Workman 200 Spray System Heavy Duty Workman Vehicles Model No. 41229—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . . . . . . Chemical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supervisor’s Responsibilities Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. • Make sure that operators are thoroughly trained and familiar with the Operator’s Manual, Training Video, Engine Manual, and all labels on the Workman vehicle. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention.
• Use only an approved non–metal, portable fuel container. Static electric discharge can ignite gasoline vapors in a ungrounded fuel container. Remove the fuel container from the bed of the vehicle and place on the ground away from the vehicle before filling. Keep nozzle in contact with container while filling. • Follow all local/state/federal requirements for the spraying of chemicals.
– Remove key from ignition. – Use caution when operating vehicle on a steep slope. Normally travel straight up and down slopes. Reduce speed when making sharp turns or when turning on hillsides. Avoid turning on hillsides whenever possible. Note: Block wheels if machine is on an incline. – Use extra caution when operating vehicle on wet surfaces, at higher speeds or with a full load. Stopping time will increase with a full load. Shift into a lower gear before starting up or down a hill.
damage. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Warning Sudden changes in terrain may cause abrupt steering wheel movement, possibly resulting in hand and arm injuries. • Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relieved by stopping engine, cycling dump valve from raise to lower and/or lowering box and attachments.
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. 106-5065 1. On 2. Tank drain 100-8577 1. On 2. Agitation 3. Off 3. Off 106-5016 1. Warning—read the Operator’s Manual. 2. Electric shock hazard, overhead power lines—stay away from overhead power lines. 3. Crushing hazard, boom—keep bystanders a safe distance from the machine. 106-1374 1. Foam marker 2.
93-7814 1. Entanglement hazard, belt—stay away from moving parts. 106-1355 1. Warning—do not enter the tank. 106-1354 1. 540 RPM 106-1365 1. Crushing hazard, sprayer tank—keep bystanders a safe distance from the sprayer tank and read the Operator’s Manual.
107-2825 1. 2. 3. 4. 5. Monitor On Off Application rate Increase 6. 7. 8. 9. 10. Decrease Locked-rate switch Unlocked-rate switch Master boom spray Left boom 11. 12. 13. 14. 15. 9 Center boom Right boom Spray on Spray off Automatic 16. 17. 18. 19. 20. Manual Left boom foam marker Right boom foam marker Lower the boom. Raise the boom.
Specifications Note: Specifications and design are subject to change without notice.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Note: You will need to purchase RTV silicone sealant before installing this kit. Contact your Authorized Toro Distributor for information on the available accessories. After you install the booms and nozzles and before using the sprayer for the first time, adjust the boom bypass valves so that the pressure and application rate remains the same for all booms with one or more booms turned off.
Description Qty. Use Hold-down brackets 2 Installing the attachment hold-down brackets. Radiator cover 1 Radiator panel 1 Bolts, 3/8 x 1 inch 4 Bolts, 1/4 x 3/4 inch 3 Tank and skid assembly 1 Clevis pins 2 Lynch pins 4 Bolts, 1/2 x 1-1/2 inch 2 Washers, 1/2 inc 4 Nuts, 1/2 inch 2 Knob 1 J–clips 3 Bolt, 1/4 x 3/4 inch 1 Flange nut, 1/4 inch 1 Boom holder assembly, left 1 Boom holder assembly, right 1 Operator’s Manual 1 Read before operating the machine.
Installing the Vehicle Speed Sensor 3. Remove the clevis pins securing the cylinder rod ends to the bed mounting plates by pushing the pins toward the inside (Fig. 2). 3 Important The speed sensor must be installed prior to the installation of the Power Take Off (PTO) kit. If a PTO kit was previously installed it must be removed at this time. See the Installation Instructions from the PTO kit for more information on removing and installing the PTO kit. 1 1.
4. Install the geartooth sensor using the screw (M6 x 1.00 x 12) and spring washer (M6) as shown in figure 5. 4. Install the fuse block and harness to the frame along side the existing fuse block, using the two screws (#10-24 x 3/4 inch), two washers (7/32 inch), and two locknuts (#10-24) as shown in figure 7. 5. Install the PTO kit. Refer the Installation Instructions for more information. 5. Install the 10 amp fuse to the spray system fuse slot and attach new fuse block decal (Fig. 7).
Installing the Adapter Plate 7. At the ROPS cover, rear of the seat assembly, route the wiring harness up from under the seat and above the frame. Make sure the spray system power connector is out from underneath the vehicle (Fig. 8). If you are installing the spray system on a Workman vehicle with a serial number of 239999999 or lower, you will need to use the adapter plate, bolts, and nuts included in the loose parts. 1.
Installing the Prop Rod Assembly 3. Install the prop rod assembly on the inside of the rear, lefthand side of the tank skid frame at the yoke using a clevis pin and cotter pin (Fig. 13). 1. Install the strut support assembly to the inside of the left frame rail using two socket head bolts (3/8 x 1 inch) and two lock nuts (3/8 inch) as shown in figure 11 and 12. Torque the nuts to 30 ± 3 ft⋅lb (30 ± 4 N⋅m). 5, 6 3 2 4 1 3 2 1 Figure 13 3 1. Prop rod 2. Jam nut 3. Yoke Figure 11 4.
Installing the Tank Skid 3. Repeat steps to install the hold-down bracket on the opposite side. Installing the Radiator Cover 1. Using a lift, raise the tank skid assembly and position over the vehicle frame with the pump and valve assemblies facing rearward. 1. Locate the spray system power connector on the wiring harness installed previously. 2. Turn the prop rod 90° and guide it through the prop rod support (Fig 16) as the tank skid is slowly lowered. 2.
Attaching Pump Drive 5. Use the access panels on both sides of the tank skid to check for pinching of any hoses or wiring (Fig 17). 9. Pull rearward on the rubber cowling of the front of the PTO drive shaft and install the drive shaft onto the PTO output shaft (Fig. 19). 2 Important Verify the PTO shaft is secured by making sure the locking balls are seated in the groove of the output shaft. 1 1 2 Figure 17 2 Right side shown 1. Access panel door 2.
Installing the Control Box Note: If a hole is not present, one must be drilled. Drill a 1/4 inch hole in the top surface of the cover on the centerline approximately 20 inches from the edge on the operator ’s side (Fig. 22). The control box is mounted on the tank skid by a clevis pin, hair pin and hand knob. It is located on the left side toward the back. 1. Remove the clevis pin, and hair pin securing the control box to the tank skid. 2.
Installing Boom Holders Before Operating Install the boom holder assemblies included with the Spray System when installing the Boom Kit. Use the Boom Kit Installations Instructions for more information on installing the boom extensions. Filling the Fresh Water Tank The sprayer is equipped with a fresh water tank (Fig. 24) for you to wash chemicals off of your skin, eyes, or other surfaces in the case of accidental exposure.
Operation Think Safety First This section covers the operation of the spray system only. See your Workman Operator’s Manual for information on vehicle operation. Please carefully read all of the safety instructions and decals in the safety section of both this manual and your vehicle manual. Knowing this information could help you or bystanders avoid injury. Note: Determine the left and right sides of the machine from the normal operating position. 2 1 3 4 5 6 7 8 Figure 25 1.
Application Rate Switch Flowmeter The application rate switch is located on the left side of the control panel (Fig. 25). Press and hold the switch upward to increase the spray system application rate, or press and hold it downward to decrease application rate. The flowmeter measures the flow rate of the fluid for use by the Spray Pro system (Fig. 26). Rate Lockout Key Switch These valves turn the three booms on or off (Fig. 26).
Pressure Gauge Tank Cover The pressure gauge is located to the right of the tank (Fig. 27). This gauge shows the pressure of the fluid in the system in psi and bar. The tank cover is located in the center of the top of the tank (Fig. 30). To open it, turn off the engine and set the parking brake, then turn the front half of the cover to the left and swing it open. You can remove the strainer inside for cleaning.
Spray Pro Monitor • App. Rate Displays the application rate in US gallons per acre (US), liters pre hectare (SI), or US gallons per 1000 sq ft (TURF). The Spray Pro monitor displays and monitors various system performance data such as vehicle speed and application rates. It does not control the application rate. • Total Volume The monitor has an LCD screen that displays the data you select, a selection dial, and 4 buttons for calibrating the monitor (Fig. 31).
Calibrating the Spray Pro Monitor 7. Use the [+] or [–] buttons to change the boom width as needed. 8. Repeat steps 4 through 7 for the other booms as needed. The Spray Pro monitor has a calibration mode that allows you to change various settings to customize the display and calibrate the monitor to your needs. You can calibrate or change the following settings: 9. Press [CAL] until the red light turns off. You can also exit calibration mode by driving the sprayer.
12. When the calibration volume is displayed, use the [+] or [–] buttons to change it to the amount of water you put in the tank. 14. With the selection dial set to the Distance position, press and hold [CAL] until the monitor displays “CAL HOLD” and the red light on the monitor illuminates. 13. When the display begins alternating again, the flowmeter calibration value will have changed; write this number down and save it. This is the calibration value for your vehicle.
Filling the Spray Tank 11. Adjust the boom bypass valve (Fig. 26) under the boom control valve for the boom you turned off until the pressure reading on the gauge is the same as it was in step 8. Important Ensure that the chemicals you will be using are compatible for use with Viton (see the manufacturer’s label; it should indicate if it is not compatible). Using a chemical that is not compatible with Viton will degrade the o-rings in the sprayer, causing leaks. 1.
5. Turn the Spray Pro selection dial to the Application Rate position and use the application rate switch to achieve the desired rate. 5. With the shift lever in the Neutral position, engage the PTO, and set the hand throttle. 6. Ensure that the agitation control valve is in the On position. Note: The vehicle must be moving for the Spray Pro to calculate the application rate. 7. Set the master boom switch and boom switches to the On positions to begin spraying. 6.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval 8 hours 100 hours 1More often Maintenance Procedure • Clean the suction strainer1 • Grease the spray system when using wetable powers Important Refer to your Workman and engine operator’s manual for additional maintenance procedures. Daily Maintenance Checklist Duplicate this page for routine use.
Notation for Areas of Concern Inspection performed by: Item Date Information 1 2 3 4 5 6 7 8 9 10 11 12 Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark plug(s).
Cleaning the Flowmeter Cleaning the Suction Strainer Occasionally, the flowmeter may need to be cleaned to remove an obstruction, as follows: Clean the suction strainer daily. If you are using wetable powders, clean it after every tank. 1. Remove the retaining cap from the flowmeter body (Fig. 33). 1. Remove the retainer from the red fitting attached to the large hose on the top of the tank. 2. Carefully pull the paddle wheel assembly from the body. 3.
Greasing the Spray System Lubricate all bearings and bushings after every 100 hours or once a year, whichever occurs first. Grease Type: No. 2 General Purpose Lithium Base Grease 1. Wipe the grease fitting clean so that foreign matter cannot be forced into the bearing or bushing. 2. Pump grease into the bearing or bushing. Important Only a few pumps of grease are required to lubricate the system. Do not over grease. Grease will not purge from the system. 3. Wipe off excess grease.
Storage 8. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 1. Position the sprayer on a level surface, set the parking brake, disengage the PTO, stop the engine, and remove the ignition key. 9. Check the condition of all spray hoses, replacing any that are damaged or worn. 2. Clean dirt and grime from the entire machine. 11. Paint all scratched or bare metal surfaces. 10. Tighten all hose fittings.
Problem A pressure drop occurs when you turn on a boom. Possible Causes Corrective Action 1. The boom bypass valve is improperly adjusted. 1. Adjust the boom bypass valve. 2. There is an obstruction in the boom valve body. 2. Remove the inlet and outlet connections to the boom valve and remove any obstructions. 3. A nozzle is missing. 3. Inspect all nozzles and replace any if necessary. Troubleshooting the Spray Pro Monitor Problem The monitor does not function.
Problem Possible Causes Corrective Action The monitor is erratic in operation. 1. A two-way radio is too close to the monitor or its cables. 1. Keep two-way radios away from the monitor and its cables. The displayed measurements do not make sense. 1. The Units of Measurement is set to a system other than what you expect. 1. Check the Units of Measurement to ensure that it is set correctly. The monitor reads “OFL.” 1. The data has exceeded the maximum allowed. 1.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.