Toro 41235 Operator's Manual
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Toro 41235 Operator's Manual

Spray system heavy-duty vehicles
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Workman
®
Heavy-Duty Workman
Model No. 41235—Serial No. 312000001 and Up
The installation of the Workman
interdependent kits. Contact your Authorized Toro Dealer for more information.
Form No. 3372-914 Rev A
200 Spray System
®
Vehicles
®
200 Spray System requires the installation of one or more
G011763
Original Instructions (EN)

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Summary of Contents for Toro 41235

  • Page 1 200 Spray System requires the installation of one or more interdependent kits. Contact your Authorized Toro Dealer for more information. To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN)

  • Page 2: Table Of Contents

    Before Operating ............ 4 you are responsible for operating the product properly and While Operating............5 safely. You may contact Toro directly at www.Toro.com for Maintenance ............6 product and accessory information, help finding a dealer, or Safety and Instructional Decals ......... 7 to register your product.

  • Page 3: Safety

    Safety Maintenance ..............37 Recommended Maintenance Schedule(s) ......37 Daily Maintenance Checklist ........37 Improper use or maintenance by the operator or owner can Notation for Areas of Concern.........38 result in injury. To reduce the potential for injury, comply Premaintenance Procedures ........38 with these safety instructions and always pay attention to the Accessing the Machine ..........38 safety alert symbol, which means CAUTION, WARNING, or Lubrication ...............40...

  • Page 4: Chemical Safety

    Chemical Safety Before Operating • Operate the machine only after reading and understanding WARNING the contents of this manual. Chemical substances used in the spray system may • Never allow children to operate the sprayer. be hazardous and toxic to you, bystanders, animals, •...

  • Page 5: While Operating

    • Use only an approved non-metal, portable fuel container. – Avoid sudden stops and starts. Do not go from Static electric discharge can ignite gasoline vapors in a reverse to forward or forward to reverse without first ungrounded fuel container. Remove the fuel container coming to a complete stop.

  • Page 6: Maintenance

    • • Gross Vehicle Weight (GVW) has a major impact on your When operating with a heavy load, reduce your speed and ability to stop and/or turn. Heavy loads and attachments allow for sufficient braking distance. Do not suddenly make a vehicle harder to stop or turn. The heavier the apply the brakes.

  • Page 7: Safety And Instructional Decals

    Authorized TORO Distributor check death. Such use could void the product warranty of The maximum engine speed with a tachometer. Toro® Company. • • If major repairs are ever needed or assistance is required, This vehicle should not be modified without contact an Authorized Toro Distributor.
  • Page 8 106-1434 93-0688 1. Crushing hazard, sprayer tank assembly—read the 1. Warning—read the Operator's Manual. Operator's Manual before performing maintenance. 2. Caustic liquid/chemical burn and toxic gas inhalation hazards—wear hand, skin, eye, and respiratory protection. 93-7814 1. Entanglement hazard, belt—stay away from moving parts. 114-9576 1.
  • Page 9 108-3309 108-3307 1. Total area 8. Width 2. Boom select 9. Distance 3. Speed 10. Speed calibration 4. Units of measure 11. Sub volume 5. Select units 12. Total volume 6. Application rate 13. Flowmeter calibration 7. Sub area 119-9413 1.

  • Page 10: Setup

    Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. – No parts required Remove the existing bed. – No parts required Prepare the Workman®. Cover assembly Gear tooth assembly Install the vehicle speed sensor. Screw (M6 x 1 inch x 12) Spring washer (M6) Install the PTO kit.

  • Page 11: Removing Existing Bed

    Procedure Description Qty. Center boom assembly Bolt (3/8 x 1-1/4 inches) Lock nut (3/8 inch) Boom transport cradle Install the boom assembly. Bolt (1/2 x 1-1/4 inches) Flange nut (1/2 inch) Left boom extension Right boom extension Hose clamps R-clamp Shoulder bolt Install boom hoses.

  • Page 12: Preparing The Workman

    Installing the Vehicle Speed Sensor (for Workman ® 3000, 4000 series only) Parts needed for this procedure: Cover assembly Gear tooth assembly Screw (M6 x 1 inch x 12) Figure 4 Spring washer (M6) 1. Left rear corner of bed 4.

  • Page 13: Installing The Power Take-Off (Pto) Kit(For Workman ® 3000, 4000 Series Only)

    Installing the Electrical Harness Parts needed for this procedure: Fuse block Fuse (10 amp) Thermal breaker (30 amp) Figure 6 Hex screw (#10-24 x 3/4 inch) 1. Cover 4. Geartooth sensor Phillips screw (#10-24 x 3/4 inch) 2. Screw (M6 x 1.00 x 12) 5.
  • Page 14 (#10-24 x 3/4 inch) and two locknuts (#10-24) as shown in Figure 8. 8. Remove any dirt, grease from the existing fuse block decal and make sure the surface is clean and dry. Place the decal 9. Install the fuses and thermal breakers: A.
  • Page 15 Figure 11 1. Wire harness 7. Black ground wire 2. New fuse block 8. Foam marker fuse slot 3. Yellow wire 9. Left boom actuator slot 10. Right boom actuator slot 4. Orange wire 5. Red wire 11. Spray system power fuse slot 6.

  • Page 16: Installing The Control Box Mount

    11. Locate a suitable location near the fuse box to install the fuse decal. Make sure the surface is clean and dry, G012932 then place the decal 12. Install the fuses and thermal breakers: A. Install the two 30 amp thermal breakers to the left and right boom lift fuse slots (Figure 12).

  • Page 17: Installing The Attachment Hold-Down Brackets

    is mounted. If the hand throttle kit is installed it must be separated from the dashboard in order to install the control mount plate. Refer to the Hand Throttle Kit Operator’s Manual for directions in removing and installing the hand throttle assembly.

  • Page 18: Installing The Radiator Cover(For Workman ® 3000, 4000 Series Only)

    Installing the Radiator Cover (for Workman ® 3000, 4000 series only) Parts needed for this procedure: Radiator cover assembly G011748 Bolt (1/4 x 3/4 inch) Figure 17 Procedure Left hand side shown The radiator cover is shipped with an additional panel 1.

  • Page 19: Installing The Tank Skid

    Installing the Tank Skid Parts needed for this procedure: Tank and skid assembly Clevis pins Lynch pins Bolt (1/2 x 1-1/2 inches) G011759 Washers (1/2 inch) Figure 20 Nuts (1/2 inch) 1. Support straps 4. Clevis pin 5. Lynch pin 2.

  • Page 20: Installing The Control Box

    10. Check the alignment of the tank skid and the vehicle 14. Line up the front mounting brackets with the hold frame. If necessary, loosen the bolts securing the pivot down brackets installed previously. lug to the tank skid frame slightly (Figure 21). Raise the 15.

  • Page 21: Installing The Boom Assembly

    4. Install the Spray Pro Decal to the monitor (Figure 25). G011762 Figure 27 Figure 25 1. Drill hole (1/4 inch) 2. 20 inches 1. Spray pro monitor 3. Decal, Lower half 2. Decal, Upper half 8. Secure the control box harness to the console and ROPS cover using the J-clips.
  • Page 22 6. Remove the four bolts, four washers and four nuts on the hinge plate. 7. Install the extension boom to the center boom at the hinge plate using four bolts, four washers and four nuts removed in step 6 as shown in Figure 30. Note: Ensure all spray turrets are facing to the rear.

  • Page 23: Installing Boom Hoses

    Installing Boom Hoses Parts needed for this procedure: Hose clamps R-clamp Shoulder bolt Washer Procedure 1. Route the boom hoses as shown in Figure 31. G012928 Figure 31 4. Nut 1. Boom hose, left extension 7. Shoulder bolt 2. Boom hose, center 5.

  • Page 24: Installing The Nozzles

    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. To obtain the correct nozzles for your needs, contact your Authorized Toro Distributor and be prepared to give them then following information:...

  • Page 25: Product Overview

    Product Overview Figure 33 1. Power switch, Spray Pro™ 4. Rate lockout key switch 7. Center boom switch 10. Right boom lift switch monitor 2. Spray Pro™ monitor 5. Master boom switch 8. Right boom switch 3. Application rate switch 6.
  • Page 26 Sonic Boom and Foam Marker Switch Agitation Control Valve Locations (Optional) This valve is located on the right side of the tank (Figure 35). Turn the knob on the valve to the 9 o'clock position to turn If you install the sonic boom and/or the foam marker kit, you on the tank agitation and to the 3 o'clock position to turn will add switches to the control panel for controlling their off the tank agitation.
  • Page 27 Figure 36 1. Tank drain handle Tank Cover The tank cover is located in the center of the top of the tank (Figure 37). 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.
  • Page 28 Spray Pro™ Monitor The monitor has an LCD screen that displays the data you select, a selection dial, and 4 buttons for calibrating the The Spray Pro monitor displays and monitors various system monitor (Figure 38). performance data such as vehicle speed and application rates. It does not control the application rate.

  • Page 29: Specifications

    Optional Equipment Increases values displayed on the screen during calibration. The Toro® Company has optional equipment and accessories that you can purchase separately and install on your Workman. Calibration Settings Contact your Authorized Service Dealer for a complete list of optional equipment that is currently available for your sprayer.

  • Page 30: Operation

    Operation 5. Tighten the bolt and nut to lock the bumpers into the adjusted position. Torque the fasteners to 135-165 ft-lbs (183-223 N-m). Note: Determine the left and right sides of the machine Note: The bumper may experience some compression over from the normal operating position.

  • Page 31: Operating The Booms

    label; it should indicate if it is not compatible). Using a spray position without leaving the Operator's seat. It is chemical that is not compatible with Viton will degrade recommended to change boom positions while the machine the O-rings in the sprayer, causing leaks. is stationary.

  • Page 32: Spraying Tips

    5. Turn the Spray Pro selection dial to the Application Rate position and use the application rate switch to achieve the desired rate. To do this: A. Ensure the pump is On. B. Select the desired gear range and begin driving. C.
  • Page 33 Important: If you used wetable powder chemicals, clean the strainer after each tank. 13. Using a garden hose, spray off the outside of the sprayer with clean water. 14. Remove the nozzles and clean them by hand. Replace damaged or worn nozzles.

  • Page 34: Calibrating The Spray Pro Monitor

    Calibrating the Spray Pro Monitor Figure 42 1. LCD screen 6. Application rate 11. Reset, calibration button 16. Select units 2. Selection dial 7. Sub Area 12. Calibrate, calibration button 17. Width 3. Total area 8. Distance 13. Decrease, calibration 18.
  • Page 35 1. Stop the sprayer and set the parking brake. The display will alternate between the total volume reading (“HOLD” shown) and the flow calibration 2. Set the master boom switch to the Off position. The value (“CAL HOLD” shown). monitor displays “HOLD”. 10.

  • Page 36: Calibrating The Boom Bypass Valves

    14. With the selection dial set to the Distance position, 12. Adjust the boom bypass valve (Figure 43) on the boom press and hold the Calibrate button until the monitor control valve for the boom you turned off until the displays “CAL HOLD”...

  • Page 37: Maintenance

    • Inspect the pressure dampener bladder and replace if necessary. (see an Authorized Every 400 hours Toro Service Distributor) • Inspect the pump check valves and replace if necessary. (see an Authorized Toro Service Distributor) • Check boom actuator hydraulic oil for air bubbles.

  • Page 38: Notation For Areas Of Concern

    Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check toe-in. Lubricate all grease fittings. Touch up and damaged paint. Immediately after every washing, regardless of the interval listed Notation for Areas of Concern Inspection performed by: Item Date Information...
  • Page 39 Figure 45 Left side shown 1. Front mounting bracket 4. Washer (1/2 inch) 2. Hold-down bracket 5. Locknut (1/2 inch) 3. Bolt (1/2 x 1-1/2 inches) Figure 47 1. Bed support 3. Bed 4. Fold the boom extensions forward, alongside the tank 2.

  • Page 40: Lubrication

    Lubrication Greasing the Boom Hinges Service Interval: Every 100 hours Greasing the Sprayer System Important: If the boom hinge is washed with water, all water and debris must be cleared from the hinge Service Interval: Every 50 hours assembly and fresh grease must be applied. Every 100 hours Grease Type: No.
  • Page 41 8. Repeat the procedure for each actuator rod bearing. G002016 Figure 50 1. Actuator 4. Cotter 2. Actuator rod 5. Pin 3. Boom pivot pin housing 3. Lift up on the boom and remove the pin (Figure 50). Slowly lower the boom to the hardstop. 4.

  • Page 42: Electrical System Maintenance

    Pump Maintenance Inspecting the Pump Service Interval: Every 400 hours/Yearly (whichever comes first)—Inspect the pump diaphragm and replace if necessary. (see an Authorized Toro Service Distributor) Every 400 hours/Yearly (whichever comes first)—Inspect the pressure dampener bladder and replace if...

  • Page 43: Adjusting The Boom Actuator

    1. Actuator, right boom 2. Manual relief valve Refer to the Service Manual for instructions on how to bleed air from the actuators or contact an Authorized Toro Service Distributor. Note: Due to the opposing orientation of actuators in respect to each other the manual relief valve is on the...

  • Page 44: Inspecting The Nylon Pivot Bushings

    Cleaning 3. Once the original position of the actuator is recovered, close the manual relief valve. Torque the valve to 1.1-2.1 ft-lb (1.5-2.9 N⋅m). Cleaning the Flowmeter Inspecting the Nylon Pivot Service Interval: Every 200 hours/Yearly (whichever comes first) (More often when using wettable Bushings powders) Service Interval: Every 400 hours/Yearly (whichever comes...

  • Page 45: Storage

    Storage 2. Remove the retainer from the red fitting attached to the large hose on the top of the tank (Figure 55). 1. Position the sprayer on a level surface, set the parking brake, disengage the PTO, stop the engine, and remove the ignition key.

  • Page 46: Removing The Sprayer

    E. Clean the pistons and replace any worn O-rings. frame. This prevents the assembly from shifting when the fasteners securing the tank assembly to the frame F. Coat all piston O-rings with vegetable oil and are loosened. reinstall in the valve assembly with the screws previously removed.

  • Page 47: Troubleshooting

    Troubleshooting Troubleshooting the Spray System Problem Possible Cause Corrective Action A boom section does not spray. 1. The electrical connection on the boom 1. Turn the valve off manually. Disconnect valve is dirty or disconnected. the electrical connector on the valve and clean all leads, then reconnect it.
  • Page 48 Problem Possible Cause Corrective Action The Area is inaccurate. 1. The sprayer width is not correctly 1. Check and set the appropriate Width in entered. the calibration mode. 2. The speed sensor is not calibrated 2. Calibrate the speed sensor. correctly.

  • Page 49: Schematics

    Schematics G011797 Electrical, spray system (Rev. A)
  • Page 50 Notes:...
  • Page 51 Notes:...
  • Page 52 Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor's service or have difficulty obtaining guarantee information, contact the Toro importer.

This manual is also suitable for:

Workman 200

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