Form No. 3351-915 Rev B Workman 200 Spray System Heavy Duty Workman Vehicles Model No. 41229—Serial No. 240000127 and Up Operator’s Manual Register your product at www.Toro.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . . . . . . Chemical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions. TO REDUCE THE POTENTIAL FOR INJURY OR DEATH, COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS. Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Supervisor’s Responsibilities Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.
• Chemicals and fumes in the tanks are dangerous; never enter the tank or place your head over or in the opening. – Fill fuel tank outdoors and to about one inch below top of tank (bottom of filler neck). Do not overfill. – Wipe up any spilled gasoline. • Follow all local/state/federal requirements for the spraying of chemicals. • Use only an approved non–metal, portable fuel container. Static electric discharge can ignite gasoline vapors in a ungrounded fuel container.
• If the machine ever vibrates abnormally, stop immediately, turn engine off, wait for all motion to stop and inspect for damage. Repair all damage before resuming operation. – Use extreme caution, reduce speed and maintain a safe distance around sand traps, ditches, creeks, ramps, and any unfamiliar areas or other hazards. – Watch for holes or other hidden hazards. • Before getting off the seat: – Use caution when operating vehicle on a steep slope. Normally travel straight up and down slopes.
• Never work under a sprayer without using tank support prop rod. • Avoid stopping on hills, especially with a load. Stopping while going down a hill will take longer than stopping on level ground. If the vehicle must be stopped, avoid sudden speed changes, which may initiate tipping or rolling of the vehicle. Do not slam on the brakes when rolling backward, as this may cause the vehicle to overturn.
• Refer to your vehicle’s Operator’s manual for other maintenance.
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 107-8621 1. Agitation on 2. Continuous variable setting 3. Off 3. Agitation 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.
3-7814 1. Entanglement hazard, belt—stay away from moving parts. 106-1354 108-3312 1. 540 RPM 1. LCD screen 2. Selection dial 3. Reset 4. Calibrate 5. Decrease 6. Increase 106-1355 1. Warning—do not enter the tank. 108-3309 106-1365 1. 2. 3. 4. 5. 6. 7. 1. Crushing hazard, sprayer tank—keep bystanders a safe distance from the sprayer tank and read the Operator’s Manual. 108-3307 9 Total area Boom select Speed Units of Measure Select units Application rate Sub area 8. 9. 10. 11. 12. 13.
7-2825 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. 10 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 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.
Removing Existing Bed Caution 1. Start the engine. Engage the hydraulic lift lever and lower the bed until cylinders are loose in slots. Release the lift lever and the turn off engine. The full bed weighs approximately 210 pounds, so do not try to install or remove it by yourself. Get the help of two or three other people or use an overhead crane. 2. Remove the lynch pins from the outer ends of the cylinder rod clevis pins (Fig. 2). 6. Store the cylinders in storage clips.
3. Install the new cover assembly to the transaxle using the four bolts removed in step 1 (Fig. 5). The correct orientation of the cover will have the seal facing up and positioned toward the left hand side of the vehicle. 2 3 1 7 4 2 8 3 9 4 5 5 10 6 1 m–7218 Figure 6 1. 2. 3. 4. 5. 6 m–7150 Wiring harness New fuse block Red/black wire Red/white wire Red wire 6. 7. 8. 9. 10. Black ground wire Foam marker fuse slot Boom lift fuse slot Spray system fuse slot Open slot, not used Figure 5 1.
Installing the Adapter Plate 9. Route the wiring harness through the opening in the floor, under the seat base, and rearward along with the existing wiring. 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. 10. At the ROPS cover, rear of the seat assembly, route the wiring harness up from under the seat and above the frame.
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.
Important If any hoses or wiring on the tank skid assembly are being pinched or bent, raise the assembly up, adjust its positioning, and tie items back. 1 2 5. Line up the pivot lug at the rear of the tank skid assembly with the opening at the end of the vehicle frame (Fig 18). 2 1 Figure 19 3 1. Rubber cowling 2. PTO drive shaft 2 4 3. PTO output shaft Finishing the Tank Skid Installation 9. Line up the front mounting brackets with the hold down brackets installed previously. 10.
Installing the Control Box 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 1. Remove the clevis pin, and hair pin securing the control box to the tank skid. 20 inches 2. Install the control box, with the controls facing the driver, to the control mount using the clevis pin and hair pin removed previously. 3. Install the hand knob to stabilize the control box. Tighten by hand. 4.
8 9 4 7 6 6 3 6 5 2 7 3 m–7427 4 6 1 Figure 23 1. Center boom frame 2. Tank sprayer frame brackets 3. Bolt, 1/2 x 3 inch 4. Frame mounting bracket 5. Spacer 6. Flange nut, 1/2 inch 7. Bolt, 1/2 x 1-1/4 inch 4. Adjust the position of the center boom frame so that is is level. Adjust the boom holders’ height if necessary. 8. Left boom holder assembly 9. Right boom holder assembly 7. Install the center boom to the center frame at the boom mounting brackets (Fig.
Installing Boom Hoses Greasing the Pivot Arms 1. Use liquid soap to coat the hose barb of the center boom’s right nozzle turret (Fig. 25). The boom pivot arms are not greased at the time of factory assembly and must be greased before use. Refer to Greasing the Pivot Arms, page 36, for more information. 2. Connect the center boom supply hose to the soaped barb and fasten it with a hose clamp (Fig. 25). Adjusting Extension Booms 1.
Installing Nozzles 4. With the boom actuator at full extension, the break-away pivot gusset should just touch the center boom frame slot (Fig. 28). The nozzles you use to apply your chemicals vary depending on the rate of application that you need; therefore, nozzles are not supplied with the kit.
Operation Think Safety First 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. This section covers the operation of the spray system only. See your Workman Operator’s Manual for information on vehicle operation. Note: Determine the left and right sides of the machine from the normal operating position. 2 9 1 10 3 4 5 6 7 8 Figure 30 1.
Application Rate Switch 1 3 2 The application rate switch is located on the left side of the control panel (Fig. 30). Press and hold the switch upward to increase the spray system application rate, or press and hold it downward to decrease application rate. Rate Lockout Key Switch The rate lockout key switch is located on the lower, left corner of the control pane (Fig. 30).
Pressure Gauge 1 The pressure gauge is located to the right of the tank (Fig. 32). This gauge shows the pressure of the fluid in the system in psi and bar. Pump The pump is located near the rear of the vehicle (Fig. 33). 1 3 Figure 34 1. Tank drain handle Tank Cover 2 The tank cover is located in the center of the top of the tank (Fig. 35). 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.
Spray Prot Monitor 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. The monitor has an LCD screen that displays the data you select, a selection dial, and 4 buttons for calibrating the monitor (Fig. 36). 20 US English 20 CE Symbol m–XXXX Figure 36 1. 2. 3. 4. 5. LCD screen Selection dial Reset, calibration button Calibrate, calibration button Decrease, calibration button 6. 7. 8. 9. 10.
4. Turn the selection dial to the Units of Measure position. setting, without affecting the Total Volume display. If you press the Reset calibration button, the Sub Area also resets. 5. Use the Increase or Decrease calibration buttons to select desired units of measure. • Total Volume 6. Press the Calibrate button until the red light turns off. You can also exit calibration mode by driving the sprayer.
4. Select a straight, flat track of ground that is similar to your turf conditions. Note: If you park the vehicle on a flat, level surface and fill the tank until the water over flows out of the top of the tank, you will have 200 US gallons (760 L). Note: Using a road or other paved surface could cause an inaccurate reading when you later drive the sprayer on turf. Note: Do not rely on the marks on the side of the tank for measuring the water for this procedure.
Resetting an OFL Condition If the monitor reads “OFL”, it indicates that you have exceeded the monitor screen dimensions. Press and hold the Reset calibration button to set the display to 0. Adjusting the Boom Bypass Valves After you install your 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 when you turn one or more booms off. 1.
Filling the Spray Tank 5. Turn the Spray Pro selection dial to the Application Rate position and use the application rate switch to achieve the desired rate. 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.
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. 7. Set the master boom switch and boom switches to the On positions to begin spraying. 8. Allow all of the water in the tank to spray out though the nozzles. 9. Check the nozzles to ensure that they are all spraying correctly. 10. Set the master boom switch to the Off position, disengage the PTO, and stop the engine. 11.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure 8 hours • Clean the suction strainer1 50 hours • Lubricate the pump. 100 hours • • • • • 200 hours • Check all hoses for wear/cracking. • Inspect all hose connections for proper attachment. 1More often Grease the spray system Inspect the pump diaphragm and replace it if necessary.
For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the accelerator operation. Clean the suction strainer. Check toe-in. Lubricate all grease fittings.1 Touch up and damaged paint.
4. Clean the strainer with clean running water. Important The paddle wheel assembly will only fit into the body one way. Align the pin of the paddle wheel assembly with the hole in the flowmeter body. Do not force the paddle wheel assembly into the body in any other orientation. 5. Replace the strainer, seating it fully into the hole. 6. Connect the hose to the top of the tank and secure it with the retainer. 5. Install the retaining cap. 3 1 2 Figure 38 1. Retaining cap 2. Paddle wheel assembly 3.
Greasing the Spray System 2. Pump grease into the fitting located below the spring until grease can be seen coming out of the bottom of the pivot assembly (Fig. 41). 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 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.
Storage 1. Position the sprayer on a level surface, set the parking brake, disengage the PTO, stop the engine, and remove the ignition key. 2. Clean dirt and grime from the entire machine. Important You can wash the machine with mild detergent and water. Do not use high pressure water to wash the machine. Pressure washing may damage the electrical system or wash away necessary grease at friction points. Avoid excessive use of water, especially near the control panel, lights, engine, and the battery. 3.
Troubleshooting Troubleshooting the Spray System Problem A boom section does not spray. Possible Causes Corrective Action 1. Pinched hose 1. Repair or replace the hose. 2. A boom by-pass valve is improperly adjusted. 2. Adjust the boom by-pass valves. 3. Damaged boom valve 3. Contact your Authorized Service Dealer. A boom section does not turn off. 1. The valve is damaged. 1. Stop the spray system and pump and turn off the sprayer.
Problem The Distance is inaccurate. Possible Causes Corrective Action 1. The speed sensor is not calibrated correctly. 1. Calibrate the speed sensor. 2. The speed sensor is damaged. 2. Contact your Authorized Service Dealer. 1. The monitor cable is loose. 1. Connect the monitor cable. 2. The flowmeter is dirty or clogged. 2. Clean the flowmeter. 3. The flowmeter is not calibrated correctly. 3. Calibrate the flowmeter 4. The flowmeter is damaged. 4. Contact your Authorized Service Dealer. 5.
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.