Operator's Manual

ManualsBrandsToro ManualsSprayersPro Control Spray System, Workman

Model No. 41080-80001 & UP

Model No. 41021-80001 & UP

Model No. 41031-80001 & UP

Model No. 41220-80001 & UP

Model No. 41223-80001 & UP

Model No. 41230-80001 & UP

OPERATOR’S

INSTRUCTIONS

PRO CONTROL

SPRAY SYSTEM

for the WORKMAN

Vehicle

FORM NO. 95-9300

©The TORO Company - 1998

To assure maximum safety, optimum

performance, and to gain knowledge of the

product, it is essential that you or any other

operator of this Vehicle read and understand

the contents of this manual and the vehicle’s

manuals before the engine is ever started. Pay

particular attention to the SAFETY

INSTRUCTIONS highlighted by the triangular

safety alert symbol.

2. Learn how to operate the Sprayer and how to

use the controls properly. DO NOT let anyone

operate this equipment without first receiving

thorough instructions.

3. Keep all shields, safety devices and decals in

place. If a shield, safety device or decal is

malfunctioning, illegible or damaged, repair or

replace it before operating the machine.

4. Chemicals can injure persons, animals, plants,

soils or other property. To eliminate environmental

damage and personal injury:

A. Select the proper chemical for the job.

B. Follow manufacturer’s instructions on

chemical container labels. Apply and handle

chemicals as recommended.

C. Handle and apply chemicals with care.

Wear goggles and other necessary protective

equipment. Handle chemicals in well

ventilated areas. Never smoke while handling

chemicals.

D. Properly dispose of chemical container

and unused chemicals.

The safety alert symbol means CAUTION,

WARNING or DANGER - personal safety

instruction. Failure to comply with the

instruction may result in personal injury.

SAFETY INSTRUCTIONS

Keep this and all Operator’s Manuals in the plastic tube behind the operator seat.

It is very important that all persons operating this equipment have easy access to these instructions at all

times!

Carefully read and follow the “Set-Up” Instructions that are provided with this equipment and the Safety

Instructions in the WORKMAN

Operator’s Manual.

RECOGNIZE SAFETY INFORMATION

This safety-alert symbol is used to call

attention to a dangerous situation, which

could result in serious injury or death to the

operator or a bystander.

Safety, mechanical and some general information

in this manual are emphasized. DANGER,

WARNING and CAUTION identify safety

messages. Whenever the triangular safety symbol

appears, it is followed by a safety message that

must be read and understood. For more details

concerning safety, read the Safety Instructions on

this page and page 2. IMPORTANT identifies

special mechanical information and NOTE

identifies general information worthy of special

attention.

These instructions are provided as a guide for the

safe operation and maintenance of this equipment.

However, the operator’s personal safety, as well

as those persons in the work area, will depend on

the careful actions and good judgement of the

operator. To reduce the potential for injury or

death, comply with the following safety

instructions.

BEFORE OPERATING:

1. Operate this machine only after reading and

understanding the contents of this manual. A

replacement manual is available by sending

complete model and serial number to: Hahn

Equipment Co., 1625 N. Garvin, Evansville, IN 47711.

Summary of content (36 pages)

PAGE 1
FORM NO. 95-9300 Model No. 41080-80001 & UP Model No. 41021-80001 & UP Model No. 41031-80001 & UP Model No. 41220-80001 & UP Model No. 41223-80001 & UP Model No.
PAGE 2
SAFETY INSTRUCTIONS WHILE OPERATING: 5. Drive the Vehicle safely. A. Always SLOW the Vehicle when aproaching and while making a turn. B. Always SLOW the Vehicle when driving in unfamiliar areas or over rough terrain. C. Always SLOW the Vehicle when changing the direction of travel or preparing to stop. D. When turning or driving on slopes, always SLOW the Vehicle, then turn the vehicle to prevent loss of control and possible upset. E. DO NOT make sudden or sharp turns.
PAGE 3
SAFETY & INSTRUCTION DECALS The following safety and instruction decals are installed on the PRO CONTROLTM. 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 4
INTRODUCTION TM The Toro Pro-Control Spray System is designed to improve the accuracy and uniformity of spray applications. Its performance relies on the installation and preventive maintenance of the complete Sprayer. This Manual provides a simple step-by-step procedure for installing and operating the Toro Pro-ControlTM Spray System. The Toro Pro-Control™ System consists of a computer based Control Console, a Speed Sensor, Turbine Type Flow Meter and a Motorized Control Valve.
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CONSOLE FEATURES 1129 Sioux Falls, SD PART No. SERIAL No. R E V P G M IMPORTANT: This Console requires selection of area measurement in US (acres); SI [hectares] or TU {1,000 sq. ft.} and type of speed sensor SP1 (wheel drive, etc.), SP2 (radar) speed sensor, or SP3 (wheel drive). (The Toro Workman ® Pro-Control uses the SP1 wheel drive sensor.) Console PGM (Program) can be determined by letter stamped in PGM box on label. Selects Manual or fully Automatic control. Can automaticlly control two rates.
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BEFORE SPRAYING CONSOLE CALIBRATION: CALCULATING “BOOM CAL” (Boom 1, Boom 2, Boom 3) Boom cal is calculated by multiplying the number of spray tips times the tip spacing. For the Toro Pro-ControlTM , having nozzles at 20" [50 cm] spacing, the Console should be programmed as follows: “Boom 1 (left)” - 80 [204]: “Boom 2 (center)” - 60 [152]: “Boom 3 (right)” - 80 [204]. CALCULATING “SPEED CAL” NOTE: This measurement is critical to the performance of the Toro Pro-Control ™ Spray System. MEASURE CAREFULLY.
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BEFORE SPRAYING CONSOLE CALIBRATION (CONT’D): NOTE: For new installations you must first perform the “Initial Console Programming” on page 10. CALCULATING “RATE 1” AND “RATE 2” Refer to the Chemical Manufacturer’s instructions on the chemical container label to determine the application rate of the chemical to be sprayed. Enter the application rate (noting decimal) in RATE 1 and RATE 2. Enter the rates in gallons per acre (US mode), gallons per 1000 sq. ft.
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Gallons Per Acre Application Rates TORO Nozzle Part No. Number Pressure Capacity 1 Nozzle (GPM) 20 30 0.14 0.17 40 50 0.20 0.22 23.8 26.1 19.8 21.8 17.0 18.7 14.9 16.3 13.2 14.5 11.9 13.1 10.8 11.9 9.9 10.9 Red 20 30 0.28 0.35 33 42 28 35 24 30 21 26 18 23 17 21 15 19 14 17 Brow n 40 50 20 30 0.40 0.45 0.35 0.43 48 53 42 51 40 45 35 43 34 38 30 36 30 33 26 32 26 30 23 28 24 27 21 26 22 24 19 23 20 22 17 21 Gray 40 50 20 30 0.50 0.56 0.42 0.
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Liters Per Hectare Application Rates TORO Nozzle Pressure Capacity Part No. Number (kPa) 1 Nozzle (L/min) Yellow 150 200 0.53 0.64 4 km/h 159 192 5 km/h 127 154 6 km/h 106 128 7 km/h 91 110 8 km/h 80 96 Red 275 350 150 200 0.76 0.83 1.06 1.32 228 249 318 396 182 199 254 317 152 166 212 264 130 142 182 226 114 125 159 198 101 111 141 176 91 100 127 158 83 91 116 144 1.51 1.70 1.40 1.61 1.89 2.13 1.67 1.
PAGE 10
BEFORE SPRAYING 2. Selecting US, SI or TU CONSOLE PROGRAMMING: After all installation procedures have been completed and Console power is turned “ON”, the Console will flash “CAL” in the RATE display. This means you must calibrate or program the Console before it can be operated. This is a one-time operation which does not have to be repeated. NOTE: Turning the POWER ON/OFF switch to “OFF” does not affect the Console memory. All data is retained.
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BEFORE SPRAYING CONSOLE PROGRAMMING (Cont’d): You may also want to enter data in the keys VOL TANK 9. To display US, TI or TU and SP1, SP2 or SP3 after being selected, depress and hold . These TIME labeled: 9 and 0 although it is not required for operation of the system. VOL TANK 13. 9 (Optional) - Enter the amount of material in the Tank. This number must be re-entered each time the Tank is refilled. The function monitors Tank volume while spraying, based on application rate. TIME 14.
PAGE 12
BEFORE SPRAYING The DATA LOCK CODE may be cleared by entering a code of “0” or by turning off console power and turning console on while depressing key. the POWER DOWN DELAY FEATURE: To conserve the Vehicle’s 12-volt battery, the Power Down Delay should be set. In this “power down” mode, all data will be retained, but the time of day clock will not operate. The Power Down Delay is initially set at 10 days. 2.
PAGE 13
BEFORE SPRAYING INITIAL SYSTEM SET-UP: 1. Fill the Tank with water and open the Suction Line Valve. See FIG. 6. IMPORTANT! The pump will be damaged if it is activated before it is completely filled with liquid. Be certain the suction line valve is open and liquid has reached the pump. 13. Adjust ball valve in Agitator Line for desired agitation. Verify that maximum pressure is still present at the Pressure Gauge. 14. Hold the MAN. ADJ. switch in DECR. position for approximately 12 seconds.
PAGE 14
BEFORE SPRAYING INITIAL SYSTEM FIELD TEST(Cont’d): FILL THE CLEAN WATER WASH TANK. 5. At the end of each swath sprayed, switch the MASTER ON/OFF to “OFF” to shut off flow. This also shuts off the acreage totalizer. NOTE: Fill Clean Water Wash Tank with clean water only. Check to assure tank is full before each operation. 6. Verify acres covered and gallons used. In case of chemical contact with skin or eyes, a fresh water wash tank has been installed on the R.H. side of the vehicle. See FIG. 7.
PAGE 15
For future reference, pencil in your calibrations numbers in the spaces below. VOL TANK 1 2 3 4 5 6 7 8 9 BOOM WIDTHS 1124 SELF TEST TIME 0 FOR TESTING, ENTER NORMAL OPERATING SPEED RATE 2 CAL MILITARY TIME RATE 1 CAL VOLUME-IN-TANK VALVE CAL APPLICATION RATE 2 METER CAL APPLICATION RATE 1 SPEED CAL 2611 BOOM 3 CAL CALIBRATION # FROM FLOW METER BOOM 2 CAL SPEED CAL NUMBER BOOM 1 CAL OPERATION USING THE SPRAYER: AFTER SPRAYING: IMPORTANT! Check all of your equipment...
PAGE 16
Preventative maintenance is most important to assure long life of the Pro-Control Spray System. The following maintenance procedures should be followed on a regular basis: Flush the entire spraying system as described on page 15 after each use. Failure to clean the system can result in a chemical residue which can plug the Flow Meter, Solenoids, Control Valve, Hoses and/or Nozzle Tips, and seriously damage the Centrifugal Pump. Wash spray nozzles thoroughly with water. Blow out orifice, clean and dry.
PAGE 17
MAINTENANCE Preventive maintenance will pay off many times over in peak performance and efficient operation. FLOW METER: Once per season the Flow Meter should be flushed and cleaned. Perform this procedure more often if suspension type products are being sprayed. 1. Thoroughly rinse and drain the entire spraying system. 2. Remove Flow Meter from Sprayer and flush with clean water to remove any chemicals. 3. Remove flange bolts from the Flow Meter. See FIG. 9. 8.
PAGE 18
MAINTENANCE PROCEDURE TO RE-CALIBRATE FLOW METER: PROCEDURE TO TEST SPEED SENSOR TO CONSOLE CONNECTION: 1. Enter a METER CAL number of 10 [38] in key Disconnect the Speed Sensor Switch Assembly Cable from the back of the Control Console. See diagram of Console receptacle in FIG. 9. METER CAL labeled: 5 10 O’CLOCK 2. Enter a TOTAL VOLUME of 0 in key labeled: TOTAL VOLUME 3. Switch OFF Boom 2 and Boom 3. 4. Remove Boom 1 hose at boom connection and place the hose in a 5 gallon [19 liter] container.
PAGE 19
MAINTENANCE TROUBLESHOOTING GUIDE NO. PROBLEM CORRECTIVE ACTION 1 NO DISPLAY LIGHTS WITH POWER ON 1 2 3 4 Check fuse on back of Console. Check battery connections Check operation of POWER ON/OFF switch. Return Console to Raven, Inc. to replace Processor Board Assembly. 2 ALL KEYBOARD LIGHTS ON AT SAME TIME 1 Return Console to Raven, Inc. to replace Processor Board Assembly. 3 A DIGIT CAN NOT BE ENTERED VIA KEYBOARD 1 Return Console to Raven, Inc. to replace Face Plate Sub-assembly.
PAGE 20
MAINTENANCE TROUBLESHOOTING GUIDE (Cont’d) NO. PROBLEM CORRECTIVE ACTION 11 SPEED INACCURATE OR UNSTABLE 1 2 12 RATE READS “0000” 1 2 13 RATE INACCURATE OR UNSTABLE 1 2 3 4 20 Run speed check on hard surface road. If SPEED is not accurate, verify the clearance gap between the Wheel Magnets and the Switch Assembly. The gap should be 1/4 to 1". Adjust switch bracketry if required. Remove one red magnet and one black magnet from the wheel.
PAGE 21
MAINTENANCE TROUBLESHOOTING GUIDE (Cont’d) NO. PROBLEM CORRECTIVE ACTION 14 CAN NOT VARY RATE IN MANUAL OPERATION OR IN AUTO 1 2 3 4 15 SPRAYER PRESSURE IS CORRECT BUT RATE IS LOW 1 2 3 16 TOTAL VOLUME DOES NOT REGISTER 1 2 3 17 TOTAL VOLUME REGISTERS FLOW INACCURATELY 1 Check cabling to motorized Control Valve for breaks. Check connections in cabling for cleanliness.
PAGE 22
MAINTENANCE CENTRIFUGAL PUMP SEAL PROBLEM TROUBLESHOOTING 22 Trouble Probable Cause Remedy 1. Cracked or broken stationary seat (Ceramic) Seal ran dry and heated up. When liquid reached seal faces it was cooler, causing thermal cracks. Check to insure seal chamber is full of liquid before starting pump. On high temperature application insure proper flushing at seal faces. 2. Carbon washer scored Dirty System. Have system cleaned and flushed. grooved. 3.
PAGE 23
MAINTENANCE Always flush pump with water, or neutralizing agent before servicing. Refer to the illustrated Parts List for part ordering information. Pump Housing Disassembly In most cases, seal replacement requires disassembly of only the pump half of the unit. 1. Remove the four casing cap screws with 9/16" box end wrench. Tap pump casing on discharge port with rubber hammer, if necessary, to break loose from mounting flange. Check inside of pump casing including suction port.
PAGE 24
MAINTENANCE 4. To install the rotary portion of the mechanical seal, place it over the shaft with the carbon side facing in, and press until it bottoms out against the stationary portion. Install rubber spacer. See FIG. 13. 5. Insert key into shaft key slot. Place impeller on shaft. Put impeller nut on shaft end using a large screwdriver or file in the impeller vanes for support, tighten impeller nut securely. 6. Install O-ring on mounting flange. Replace O-ring. 7.
PAGE 25
MAINTENANCE TROUBLESHOOTING THE 95-9237 SOLENOID VALVE CONDITION 1. Valve won’t open POSSIBLE CAUSES A. No electrical power to valve B. Stem restricted 2. Valve won’t shut off movement HOW TO CHECK Manually activate valve. If stem moves freely, check and clean electrical connections. Inspect electrical system. Manually activate stem by pushing on lower diaphragm piston. If more than 5 lbs. of force is required to move stem, disassemble valve, inspect and clean all parts. A.
PAGE 26
MAINTENANCE SOLENOID VALVE: IMPORTANT: Before performing any maintenance, make sure electrical power to the coil is shut off and line pressure is relieved. • Keep all electrical connections and coil clean at all times. • A protective coating may be applied to the completed electrical connections if desired. • Do not apply lubricating oils or other petroleum products to the valves, as this may cause swelling of the rubber parts.
PAGE 27
MAINTENANCE SOLENOID VALVE (Cont’d) 5. Position valve body subassembly and coil subassembly together. 6. Replace lower diaphragm housing (14). Secure coil assembly (1), body subassembly and lower diaphragm housing (14) using four screws (15). Care must be exercised to uniformly tighten the retaining screws (15). 7. Replace electrical connections. There is no positive or negative terminal.
PAGE 28
PERFORMANCE VERIFICATION Refer to the preceding information in this manual for complete and detailed instructions. Follow all Safety Instructions . Gallons Per 1,000 sq. ft. Gallons Per Acre Determine Desired Application Rate From Manufacturers Labeling ________ G.P.A. Determine a Vehicle Application Speed _____ M.P.H. Determine Desired Application Rate From Manufacturers Labeling ________ G.P. 1,000 sq. ft. Determine a Vehicle Application Speed _____ M.P.H.
PAGE 29
Rate Check (Cont’d) Park Vehicle. SET PARKING BRAKE. Engage pump, turn on all booms and maintain the same engine RPM used to drive the test course to maintain the application rate pressure. Set Pro Control in Self Test Mode (enter your application speed). Hold a graduated cylinder under the far left nozzle on the left boom. Collect the output for the same amount of time that it took to travel 204 ft. Each ounce of fluid collected equals a 1 gallon per acre application rate.
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CONTENTS SAFETY INSTRUCTIONS ....................................................................................................................... 1&2 RECOGNIZE SAFETY INFORMATION ............................................................................................. 1 BEFORE OPERATING: ..................................................................................................................... 1 WHILE OPERATING:................................................................................
PAGE 31
Helping you put quality into play.
PAGE 32
WORKMAN® PRO CONTROL SPRAY SYSTEM INITIAL CONSOLE PROGRAMMING When you first turn on Console power, after all installation procedures have been completed, the Console will flash "CAL" in the RATE display. This means you must "calibrate" or program the Console before it can be operated. (This is a one-time operation which does not have to be repeated. Turning OFF the POWER ON/OFF Switch does not affect the Console memory. All data is retained.
PAGE 33
* * Use 80” [204 cm] Number of nozzles x spacing in inches [cm] of right boom. Use 690 For 23” Tires, 720 For 24” Tires. Consult Operator’s Manual For Detailed Instructions. Use number stamped on Yellow Label on Flow Meter or White Tag on the Flow Meter’s cable. * 6 VALVE CAL Use 2611. Sets system response: Consult Operator’s Manual to modify number. RATE 2 CAL Second rate. If only one rate is used, use same value here, that was used in Rate 1.
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NOTES: 34
PAGE 35
NOTES: 35
PAGE 36
The Toro Commercial Products Two Year Limited Warranty The Toro Company warrants your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for the period of time listed below. Where a warrantable condition exists, Toro will repair the Product at no cost to you including diagnosis, labor , parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.