Toro 41229, 41235 User Manual
PART NO. 03124SL (Rev. C)
Service Manual
(Models 41229 and 41235)
Workman
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Workman 200 Spray System (Models 41229 and
41235).
REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE, AND ADJUSTMENT
INSTRUCTIONS. Keep the Operator’s Manual, Installation Instructions and Parts Catalog for your machine
with this Service Manual. Replacement Operator’s
Manuals and Parts Catalogs are available on the internet at www.Toro.com.
The T oroCompany reserves the right to change product
specifications or this publication without notice.
R
200 Spray System
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
E The Toro Company -- 2003, 2005, 2011, 2014
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Workman 200 Spray System
Table Of Contents
Chapter 1 -- Safety and Product Records
Safety Instructions 1 -- 2..........................
Safety and Instruction Decals 1 -- 3................
Product Records 1 -- 3...........................
Chapter 2 -- Electrical System
Electrical Schematic and Electrical Harness and Con-
nector Drawings 2 -- 2..........................
Special Tools 2 -- 3..............................
Component Testing 2 -- 4.........................
Chapter 3 -- Spray System
Specifications 3 -- 2..............................
General Information 3 -- 3........................
Spray System Flow Diagram 3 -- 4.................
Spray System Operation 3 -- 5....................
Troubleshooting 3 -- 6............................
Service and Repairs 3 -- 8........................
Chapter 3.1 -- Sonic Boom System (Optional Kit)
General Information 3.1 -- 2......................
Special Tools 3.1 -- 3............................
Electrical Schematic 3.1 -- 4......................
Sonic Boom System Operation 3.1 -- 6.............
Troubleshooting 3.1 -- 16.........................
Service and Repairs 3.1 -- 22.....................
Chapter 3.2 -- Ultra Sonic Boom System (Optional
Kit)
Safety andElectrical
System
Spray
System
System
Sonic Boom
Product Records
General Information 3.2 -- 2......................
Special Tools 3.2 -- 3............................
Electrical Schematic 3.2 -- 4......................
Sonic Boom System Operation 3.2 -- 6.............
Troubleshooting 3.2 -- 17.........................
Service and Repairs 3.2 -- 26.....................
Chapter 4 -- Electrical Diagrams
Electrical Schematics 4 -- 3.......................
Wire Harness Drawings 4 -- 6.....................
Ultra Sonic
Boom System
Electrical
Diagrams
Workman 200 Spray System
Rev. C
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Workman 200 Spray System
Safety and Product Records
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 3
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1
Safety and
Product Records
Workman 200 Spray System Page 1 – 1 Safety and Product Records
Safety Instructions
The Workman 200 Spray System is designed and
tested to offer safe service when operated and maintained properly . Although hazard control and accident
prevention are partially dependent upon the design and
configuration of the machine, these factors are also dependent upon the awareness, concern, and proper
training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury
or death. To reduce the potential for injury or death,
comply with the following safety instructions.
Before Op erating
WARNING
To reduce the potential for injury or death,comply with the following safety instructions.
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become familiar with the controls and know how to stop the
machine and engine quickly. A replacement Operator’s
Manual is available on the Internet at www.Toro.com.
While Operating
1. Sit on the seat when starting and operating the machine.
2. Before starting the engine:
A. Engage the parking brake.
B. Make sure drive system is in the NEUTRAL position and the pump switch is OFF.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
4. Do not touch engine, radiator, muffler or exhaust
pipe while engine is running or soon after it is stopped.
These areas could be hot enough to cause burns.
2. Keep all shields, safety devices, and decals in place.
If a shield, safety device, or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
5. Before getting off the seat:
A. Ensure that drive system is in the NEUTRAL
position.
B. Set parking brake.
C. Turn pump switch OFF.
D. Stop engine and remove key from ignition switch.
E. Do not park on slopes unless wheels are chocked
or blocked.
6. Follow spray chemical manufacturer ’s recommendations for handling precautions, protective equipment,
and mixing proportions.
Rev. B
Workman 200 Spray SystemPage 1 -- 2Safety and Product Records
Maintenance and Service
1. Before servicing or making adjustments, turn PTO
off, put shift lever in neutral, stop engine, set parking
brake, and remove key from the switch.
2. Prior to servicing sprayer components, determine
what chemical(s) have been used in the sprayer. Follow
precautions and recommendations printed on chemical
container labels or Material Safety Data Sheets when
servicing sprayer components. Use appropriate protec
tive equipment: protective clothing, chemical resistant
gloves, and eye protection.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside
where there is an open flame, such as near a water heat
er or furnace.
5. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
6. If engine must be running to perform maintenance or
an adjustment, keep clothing, hands, feet, and other
parts of the body away from moving parts. Keep by
standers away.
-
-
-
7. Disconnect battery before servicing the machine.
Disconnect negative (–) battery cable first and positive
(+) cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the
battery. Reconnect positive (+) cable first and negative
(–) cable last.
8. Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes, and clothing. Protect your
face, eyes, and clothing when working with a battery.
9. Battery gases can explode. Keep cigarettes, sparks,
and flames away from the battery.
10.To assure optimum performance and continued
safety of the machine, use genuine Toro replacement
parts and accessories. Replacement parts and acces
sories made by other manufacturers may result in nonconformance with safety standards, and the warranty
may be voided.
-
Safety and
Product Records
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Workman 200 Spray System. If any decal becomes
illegible or damaged, install a new decal. Part numbers
are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
Product Records
Insert Operator’s Manual, Installation Instructions and
Parts Catalog for your Workman 200 Spray System at
the end of this Chapter. Refer to Operator’s Manual for
recommended maintenance intervals. Additionally, in
sert Installation Instructions, Operator’s Manuals, and
Parts Catalogs for other accessories (e.g. Foam Mark
ing Kit, Hose Reel Kit) that have been installed on your
Workman vehicle at the end of this Chapter.
-
-
Workman 200 Spray System Page 1 – 3 Safety and Product Records
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Safety and Product Records Page 1 – 4 Workman 200 Spray System
Table of Contents
ELECTRICAL SCHEMATIC and ELECTRICAL
HARNESS and CONNECTOR DRAWINGS 2.....
SPECIAL TOOLS 3.............................
COMPONENT TESTING 4.......................
Master Boom Switch 4.........................
Rate Control and Boom Actuator Switches 5......
Supervisor Key Switch 6.......................
Boom Control and Monitor Power Switches 7.....
Hold and Boom Actuator (Serial Numbers
Above 260000000) Relays 8..................
Traction Speed Sensor 9.......................
Chapter 2
Electrical System
System
Electrical
Workman 200 Spray System Page 2 -- 1 Electrical System
Rev. B
Electrical Schematic and Electrical Harness and
Connector Drawings
The electrical schematic and other electrical drawings
for the Workman 200 Spray System are located in Chap
ter 4 – Electrical Diagrams.
-
Electrical System
Page 2 – 2
Workman 200 Spray System
Special Tools
Multimeter
The multimeter can test electrical components and circuits for current, resistance, or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt–
Ohm–Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital me
ter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
-
Figure 1
System
Electrical
Workman 200 Spray System
Page 2 – 3
Electrical System
Component Testing
Master Boom Switch
The master boom switch is located on the spray control
enclosure faceplate (Fig. 2).
Testing
1. Remove spray control enclosure faceplate, locate
master boom switch and unplug wire harness connector
from switch.
2. The switch terminals are marked as shown in Figure
3. In the ON position, continuity should exist between
terminals 2 and 3 and also between terminals 5 and 6.
In the OFF position, continuity should exist between ter
minals 1 and 2 and also between terminals 4 and 5.
3. Reconnect the harness connectors to the switch after testing. Install console panel to machine.
1
-
Figure 2
1. Master boom switch
4 5 6
1 2 3
BACK OF SWITCH
Figure 3
Electrical System
Page 2 – 4
Workman 200 Spray System
Rate Control and Boom Actuator Switches
The rate control (increase/decrease) switch is located
on the spray control enclosure faceplate (Fig. 4).
On machines equipped with the electric boom lift, this is
the same switch that is used to operate the boom actuators.
2
Testing
1. Remove spray control enclosure faceplate, locate
switch to be tested and unplug wire harness connector
from switch.
2. The switch terminals are marked as shown in Figure
5. In the INCREASE or boom raise position, continuity
should exist between terminals 2 and 3 and also between terminals 5 and 6. In the neutral, center position,
there should be no continuity between any switch terminals. In the DECREASE or boom lower position, continuity should exist between terminals 2 and 1 and also
between terminals 5 and 4.
3. Reconnect the harness connector to the switch after
testing. Install console panel to machine.
1
Figure 4
1. Rate control switch
2. Boom actuator switch
56
1243
BACK OF SWITCH
System
Electrical
Figure 5
Workman 200 Spray System Page 2 -- 5 Electrical System
Rev. B
Supervisor Key Switch
The supervisor key switch (rate lockout) is located on
the spray control enclosure faceplate (Fig. 6). When the
supervisor key switch is in the OFF (locked) position, the
application rate switch is disabled.
The supervisor key switch used on sprayers with serial
numbers below 270000000 is shown in Figure 7. The
key switch used on s prayers with serial numbers above
270000000 is shown in Figure 8.
Testing
1. Remove spray control enclosure faceplate, locate
supervisor k ey switch and removewire harness connectors from switch.
2. Test switch for continuity as follows:
A. For sprayers with serial numbers below
270000000 (Fig. 7), when the key is in the ON position, continuity should exist between the two switch
terminals. In the OFF position, there should be no
continuity between the switch terminals.
B. For sprayers with serial numbers above
270000000 (Fig. 8), when the key is in the ON position, continuity should exist between switch terminals A and D. In the OFF position, there should be no
continuity between switch terminals A and D. Switch
terminals B and C are not used on the Workman 200
sprayer.
1
Figure 6
1. Supervisor key switch
SERIAL NUMBER BELOW 270000000
OFF
o
60
ON
3. Reconnect the harness connectors to the switch after testing. Install console panel to machine.
FRONTOFSWITCH
BACK OF SWITCH
Figure 7
SERIAL NUMBER ABOVE 270000000
OFF (LOCKED)
o
45
ON (UNLOCKED)
FRONTOFSWITCH
BACK OF SWITCH
Figure 8
Rev. B
Workman 200 Spray SystemPage 2 -- 6Electrical System
Boom Control and Monitor Power Switches
The three boom control (on/off) and monitor power
switches are located on the spray control enclosure
faceplate (Fig. 8).
Testing
1. Remove spray control enclosure faceplate, locate
boom control switch and unplug wire harness connector
from switch.
2. The switch terminals are marked as shown in Figure
9. In the ON position, continuity should exist between
terminals 2 and 3 and also between terminals 5 and 6.
In the OFF position, continuity should exist between ter
minals 1 and 2 and also between terminals 4 and 5.
3. Terminals 7 (–) and 8 (+) are used for the indicator
light in the switch. The light should be illuminated when
the switch is in the ON position.
4. Reconnect the harness connector to the switch after
testing. Install console panel to machine.
-
2
1
Figure 8
1. Boom control switch 2. Monitor power switch
7 4 5 6
System
Electrical
8 1 2 3
BACK OF SWITCH
Figure 9
Workman 200 Spray System
Page 2 – 7
Electrical System
Hold and Boom Actuator (Serial Numbers Above 260000000) Relays
Workman sprayers with serial numbers below
260000000 use a single relay for the sprayer hold function. Sprayers with serial numbers above 260000000
use the hold relay and four (4) additional relays for the
boom actuators. The hold and boom actuator relays are
located in the spray control enclosure.The relays can be
identified by a tag at the relay wire harness connector.
SERIAL NUMBER BELOW 260000000
87
1
3
868587A 87
4
The relay used on sprayers with serial numbers below
260000000 (Fig. 11) has a different terminal layout than
relays used on sprayers with serial numbers above
260000000 (Fig. 12). Relay operation and circuit logic is
the same regardless of serial number.
Testing
1. Remove spray control enclosure faceplate, locate
relay that is to be tested and unplug wire harness connector from relay.
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
87A
86
85
30
1
Figure 11
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open term.
SERIAL NUMBER ABOVE 260000000
1
868587A 87
1
30
2
3
30
4
2
5. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to machine wire harness and install spray control enclosure faceplate.
1. Coil terminal
2. Common terminal
Rev. B
Figure 12
3. Normally closed term.
4. Normally open term.
Workman 200 Spray SystemPage 2 -- 8Electrical System
Traction Speed Sensor
The traction speed sensor is attached to the upper
transaxle cover (Fig. 13). It uses a magnetically based,
Hall Effect integrated circuit. As the differential in the
transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the
sensor. The red striped connector wire is the positive
lead, the black wire is the ground lead, and the gray
striped wire is the signal output.
Testing
6. Locate traction speed sensor on the transaxle assembly. Disconnect the wire harness connector from the
traction speed sensor.
7. Remove cap screw and lock washer that secure
speed sensor to transaxle. Remove speed sensor from
transaxle.
2
1
System
Electrical
8. Connect positive multimeter test lead to the sensor
connector gray striped wire terminal and the negative
multimeter lead to the connector black wire terminal
(Fig. 14). Set multimeter to ohms setting.
IMPORTANT: Incorrect jumper wire connections
during testing can damage the sensor.
9. Using a +12 VDC battery, a multimeter, a 1K ohm resistor and appropriate jumper wires, connect the battery
and multimeter to the speed sensor using Figure 14 as
a guide.
10.Set multimeter to DC volts setting.
11. The multimeter should display very low voltage when
a metal object is held near the sensor tip. The multimeter
should display battery voltage when the metal object is
moved away from the sensor tip.
12.After testing is complete, remove jumper wires, resistor and multimeter leads from sensor connector.
13.Replace speed sensor if necessary.
14.After testing is complete, remove jumper wires and
multimeter leads from sensor connector. Reinstall
speed sensor into transaxle and secure with cap screw
and lock washer. Reconnect speed sensor to wire harness.
Figure 13
1. Transaxle assembly 2. Traction speed sensor
1K ohm
resistor
+
12 VDC
6
4
BAC
5
3
1
2
Figure 14
1. Speed sensor
2. Sensor tip
3. Sensor connector
4. Red striped wire
5. Gray striped wire
6. Black wire
--
Workman 200 Spray System Page 2 -- 9 Electrical System
Rev. B
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Electrical System
Page 2 – 10
Workman 200 Spray System
Table of Contents
Chapter 3
Spray System
SPECIFICATIONS 2.............................
GENERAL INFORMATION 3.....................
Precautions Concerning Chemicals Used in
Spray System 3.............................
Precautions for Removing or Adjusting Spray
System Components 3.......................
O--Ring Seal Kit 3.............................
SPRAY SYSTEM FLOW DIAGRAM 4..............
SPRAY SYSTEM OPERATION 5..................
TROUBLESHOOTING 6.........................
SERVICE AND REPAIRS 8......................
Suction Dampener 8..........................
Pressure Dampener 9.........................
Spray Pump 10...............................
Spray Pump Service 12........................
Agitation Control Valve 16......................
Agitation Nozzles (Tank Mounted) 18............
Pressure Relief Valve (Tank Mounted) 20.........
Spray Control (Serial Numbers Below
290999999) 22..............................
Spray Control (Serial Numbers Above
310000000) 23.1............................
Flowmeter (Serial Numbers Below 290999999) 24.
Flowmeter (Serial Numbers Above 310000000)25.1
Rate Control Motor (Serial Numbers Below
290999999) 26..............................
Regulating Valve Assembly (Serial Numbers
Above 310000000) 27.1.....................
Boom Valve Motor (Serial Numbers Below
290999999) 28..............................
Boom Valve Manifold Assembly (Serial Numbers
Above 310000000) 31.1.....................
Boom Bypass 32..............................
Tank Suction 34..............................
Tank Drain 36................................
Turret Bodies 38..............................
Turret Body Service 39........................
Boom Frame Breakaway Pivot Assembly
(Machines with Serial Numbers Below
260000000) 40..............................
Boom Hinge (Machines with Serial Numbers
Above 260000000) 42.......................
Boom Actuator (Optional) (Machines with
Serial Numbers Below 260000000) 44.........
Boom Actuator Service (Machines with Serial
Numbers Below 260000000) 46...............
Boom Actuator (Machines with Serial Numbers
Above 260000000) 48.......................
Boom Actuator Service (Machines with Serial
Numbers Above 260000000) 50...............
Spray
System
Workman 200 Spray System Page 3 -- 1 Spray System
Rev. B
Specifications
Item Description
Spray Pump Diaphragm Pump, 29 GPM
Spray Pressure Relief Valve Poppet Style, 220 PSI Maximum
Sprayer Tank 200 Gallon (757 Liter), Polyethylene
Suction Strainer 50 Mesh, Stainless Steel, Tank Mounted
(30 Mesh and 90 Mesh Optional)
Spray System
Page 3 – 2
Workman 200 Spray System
General Information
Precautions Concerning Chemicals Used in Spray System
Chemicals can injure persons, animals, plants, soil, or
other property. To eliminate environmental damage and
personal injury:
1. Select the proper chemical for the job.
2. Carefully read the directions printed on the chemical
manufacturer’s labels before handling chemicals. Instructions on chemical manufacturer’s container labels
regarding mixing proportions should be read and strictly
followed.
3. Keep spray material away from skin. If spray material
comes in contact with a person, wash it off immediately
in accordance with manufacturer’s recommendations
(container labels and Material Safety Data Sheets).
4. Always wear protective clothing, chemical resistant
gloves, eye protection, and other personal protective
equipment as recommended by the chemical manufacturer.
5. Properly dispose of chemical containers, unused
chemicals, and chemical solution.
Precautions for Removing or Adjusting Spray System Components
1. Stop the vehicle and set the parking brake.
2. Shut off the vehicle’s engine and remove the key
from the ignition switch.
3. Disengage all power and wait until all moving parts
have stopped.
4. Remove chemicals from pump, hoses, and other
spray components. Thoroughly neutralize and rinse
spray system before loosening or removing any spray
system component(s).
5. Make sure line pressure is relieved before loosening
any system component.
Spray
System
O--Ring Seal Kit (Serial Numbers Below 310000000)
Part Number: 106 --4846
The O--Ring Seal Kit includes an assortment of O--rings
used for sealing the spray c ontrol valves on Workman
sprayers with serial numbers below 310000000. It is
recommended that O--rings be replaced every two (2)
years or whenever a valve is loosened.
SPRAYER
O--RING SEAL KIT
PART NO. 106--4846
Figure 1
Workman 200 Spray System Page 3 -- 3 Spray System
Rev. B
Spray System Flow Diagram
PRESSURE
PRESSURE DAMPENER
& SCREEN
TOP MOUNTED SUCTION
TOP MOUNTED TANK
DRAIN VALVE
BOOM BY–PASS
PRESSURE
GAUGE
PRESSURE
RELIEF
BOOM CONTROL
VALVES
VALVE
BOOM SUPPLY
PRESSURE
FLOWMETER
PRESSURE CONTROL
VALVE
DIAPHRAGM PUMP
CONNECTED TO PTO
Spray System
SUCTION
DAMPENER
SUCTION
PRESSURE
AGITATION
BOOM SUPPLY
FLOW DIRECTION
CONTROL
AGITATION
VALVE
TANK
AGITATION
Page 3 – 4
AGITATORS (4)
Workman 200 Spray System
Spray System Flow Diagram
Workman 200 Spray System
Spray System Operation
The Workman 200 Spray System uses a positive displacement diaphragm pump to move spray solution
from the spray tank to the boom nozzles. The spray
pump is self–priming and has a dry crankcase. The
pump is driven by the transaxle PTO kit output shaft at
a speed that is proportional to the ground speed of the
vehicle. It should be noted that pump rotation will stop
whenever the vehicle clutch pedal is depressed.
The downward stroke of the pumps’ connecting rods
and diaphragms create suction to allow fluid to be drawn
from the spray tank to the pump through the suction
tube, suction strainer, hoses, and connectors. A suction
dampener placed in the suction line dampens suction
pulses to smooth suction flow. Suction valves positioned
in the pump valve chamber prevent fluid from being
pumped back into the suction line when the connecting
rods change direction. Leaks in the suction line will
cause system problems and often will be indicated by er
ratic suction line jumping and pump noise.
Once to the pump, the fluid is pushed by the upward
stroke of the pumps’ connecting rods and diaphragms
to the pressure side of the spray system through hoses,
connectors, control valves, and spray nozzles. A pres
sure dampener at the pump outlet smooths system
pressure pulsation. Pressure valves positioned in the
pump head prevent fluid from being drawn back into the
pump. Maximum pressure in the system is limited by a
pressure relief valve located in the tank. A pressure
gauge indicates system pressure.
-
-
The spray system is controlled electrically and consists
of a rate control valve and three boom control valves. A
manually adjustable boom bypass valve exists in each
of the boom control valves to prevent system pressure
changes when a boom section is shut off. Flow in excess
of control valve settings is directed back to the spray
tank.
An inline flowmeter in the pressure side of the system directly before the boom control valves measures flow to
the spray booms. The Spray Pro Monitor displays infor
mation regarding application rate based on input from
the flowmeter and the ground speed sensor in the trans
axle.
Flow for tank agitation comes from flow that is bypassed
by the rate control valve. A manual agitation control
valve directs flow to four agitation nozzles in the spray
tank.
-
-
Spray
System
Workman 200 Spray System
Page 3 – 5
Spray System
Troubleshooting
Problem Possible Cause
Spray system leaks fluid. Fitting(s), hose(s), or tube(s) are loose or damaged.
O--ring(s) or seal(s) are missing or damaged.
Spray tank drain valve is leaking.
Fluid leaking from bottom of spray
pump.
Excessive suction hose vibration. Suction screen in tank is plugged.
Spray pressure is low. Suction line is restricted.
Faulty diaphragm(s) in spray pump.
Spray pump suction line has an air leak.
Suction tube in spray tank has air leak.
Suction line is restricted.
Suction dampener diaphragm is damaged.
Suction screen in tank is plugged.
Spray nozzles worn or damaged.
Pressure line or component is loose or leaking.
Engine speed is low.
Pressure relief valve in tank is stuck.
Spray pump is damaged.
Single spray boom nozzle leaks
when boom is turned off.
Nozzles on one spray boom leak
when boom is switched off.
Spray pump doesn’t rotate. Vehicle clutch pedal is depressed.
Diaphragm in turret body is leaking or damaged.
Diaphragm in turret body is leaking or damaged.
Boom valve motor for affected boom not seating.
Key on spray pump shaft is sheared.
Auxiliary PTO not engaged or faulty.
Auxiliary PTO output shaft damaged.
PTO drive shaft damaged or missing.
Workman 200 Spray SystemPage 3 -- 6Spray System
Erratic spray operation from booms. Clogged strainer.
Damaged suction dampener.
Damaged pressure dampener.
Console boom switch(es) dirty, corroded, or damaged.
Rate control motor worn or sticking.
Boom valve motor seat loose or damaged.
Boom valve motor actuating cam worn or sticking.
No spray output from one spray
Hoses on boom are pinched or kinked.
boom.
Boom valve motor for affected boom not opening.
Console boom switch dirty, corroded, or damaged.
Check for 12 volts at affected boom valve motor in both directions
(on and off).
Low spray rate from one nozzle. Clogged or damaged spray nozzle(s).
Spray nozzles are different sizes.
Boom valve motor for affected boom not seating.
Spray
System
Workman 200 Spray System Page 3 -- 7 Spray System
Service and Repairs
Suction Dampener
The suction dampener is mounted to the suction line at
the spray pump (Fig. 2) and is used to dampen suction
pulses and smooth suction flow. During pump operation,
the suction dampener diaphragm will move.
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components.
A damaged suction dampener diaphragm will allow a
suction leak and will cause improper pump operation. If
the diaphragm is damaged, remove diaphragm from
dampener housing and replace it (Fig. 3).
1
1. Spray pump
2. Suction dampener
2
3
Figure 2
3. Suction hose
1
1. Spray pump
2. O–ring
3
4
2
Figure 3
3. Dampener housing
4. Diaphragm
Spray System
Page 3 – 8
Workman 200 Spray System
Pressure Dampener
The pressure dampener is mounted to the pressure line
at the spray pump (Fig. 4) and is used to smooth system
pressure pulsation. Adjust air pressure on the pressure
dampener from 12 to 15 PSI (.82 to 1.03 bar).
IMPORTANT: Any fluid in the pressure dampener
will include spray system chemicals so take necessary precautions when working with the dampener.
Use appropriate protective equipment: protective
clothing, chemical resistant gloves, and eye protection.
If fluid is present when pressure in the dampener is
checked, the diaphragm in the pressure dampener is
damaged and should be replaced.
2
1
Dampener Service (Fig. 5)
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components.
1. Loosen and remove cap screws and nuts that secure
diaphragm between housings.
2. Remove diaphragm from dampener.
3. Replace diaphragm and reassemble dampener.
Figure 4
1. Spray pump 2. Pressure dampener
4
5
8
7
1
2
3
6
Figure 5
1. Spray pump
2. O–ring
3. Hex nut (12 used)
4. Rear housing
5. Diaphragm
6. Front housing
7. Cap screw (12 used)
8. Air valve
Spray
System
Workman 200 Spray System
Page 3 – 9
Spray System
Spray Pump
p
FRONT
RIGHT
Loctite #242
Loctite #242
17
16
15
13
16
Anti–seize
Lubricant
18
19
13
Apply thread sealant
12
14
22
11
10
9
8
7
4
6
5
3
2
1
28
27
26
25
24
5
23
1. Spray pump assembly
2. Elbow (pressure)
3. Gasket
4. Pressure tee fitting
5. O–ring
6. Pressure dampener
7. O–ring
8. Hosebarb
9. Nut
10. Hose clam
20
21
Figure 6
11. Pressure hose
12. Flange head screw (4 used)
13. Pump drive shroud
14. Shroud bracket
15. Square key
16. Set screw
17. PTO driveshaft
18. Flange nut (4 used)
19. Flange nut (4 used)
Apply thread sealant
20. Pump mount bracket
21. Flange head screw (4 used)
22. Suction tee fitting
23. Suction dampener
24. Gasket
25. Hosebarb
26. Nut
27. Hose clamp
28. Suction hose
Spray System
Page 3 – 10
Workman 200 Spray System
Removal (Fig. 6)
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components.
1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition
switch.
2. Loosen hose clamp that secures suction hose (item
28) to hosebarb (item 25). Pull suction hose from hose
-
barb.
3. Loosen hose clamp that secures pressure hose
(item 11) to hosebarb (item 8). Pull pressure hose from
hosebarb.
4. Remove PTO driveshaft (item 17) from output shaft
of transaxle PTO assembly.
5. Remove four (4) flange head screws and flange nuts
that secure pump assembly to pump mount bracket.
3. Install elbow (pressure), pressure tee fitting, and
pressure dampener to pump outlet. Orientate elbow to
-
ward right side of machine (Fig. 7).
4. Remove set screws (item 16) from PTO driveshaft.
Clean threads of set screws and set screw threads in dri
-
veshaft.
5. Apply anti–seize lubricant to pump shaft. Position
square key in pump shaft and slide PTO driveshaft fully
onto pump shaft.
6. Apply Loctite #242 (or equivalent) to threads of set
screws. Install set screws into PTO drive shaft to secure
PTO shaft to pump shaft.
7. Position pump drive shrouds (item 13) to shroud
bracket (item 14). Install four (4) flange head screws and
flange nuts to secure shrouds to bracket.
8. Position pump on pump mount bracket. Install flange
head screws and flange nuts to pump and mount brack
-
et. Secure pump to mount bracket.
6. Remove pump assembly (with PTO driveshaft and
drive shrouds attached) from machine.
7. Remove four (4) flange head screws and flange nuts
that secure pump drive shrouds (item 13) to shroud
bracket (item 14). Remove pump drive shrouds.
8. Loosen two (2) set screws (item 16) that secure PTO
drive shaft to pump shaft. Separate PTO drive shaft from
pump. Locate and remove key from pump shaft.
9. As needed, remove pressure and suction components from pump using Figure 6 as a guide. Discard any
removed o–rings and gaskets.
Installation (Fig. 6)
NOTE: Coat all o–rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
1. Apply thread sealant to threads of pressure tee fitting, elbow (pressure), and suction tee fitting. Position
new o–rings and gaskets on suction and pressure fit
-
tings that were removed during disassembly.
2. Install suction tee fitting and suction dampener to
pump inlet. Orientate tee toward right side of machine
(Fig. 7).
9. Attach PTO driveshaft to output shaft of transaxle
PTO assembly.
10.Install pressure and suction hoses to correct barb fittings. Secure hoses with hose clamps.
1
2
Figure 7
1. Elbow (pressure) 2. Suction hose
Spray
System
Workman 200 Spray System
Page 3 – 11
Spray System
Spray Pump Service
15
28
14
13
11
60 ft–lb
(81 N–m)
12
1
2
25
3
4
9
4
5
6
7
8
7
8
9
10
23
22
26
2
5
18
6
21
20
25
12
60 ft–lb
(81 N–m)
3
13
55 ft–lb
(75 N–m)
16
24
14
32 ft–lb
(43 N–m)
27
17
1. Valve chamber
2. Valve (inlet position)
3. O–ring
4. Diaphragm cover
5. Hex bolt
6. Washer
7. Diaphragm
8. Diaphragm back disc
9. Nylon washer
10. Lock washer
Spray System
20
21
25 ft–lb
(34 N–m)
18
10
19
Figure 8
11. Hex bolt
12. Ball bearing (crankshaft)
13. Dust plate
14. Pump casing
15. Hex bolt (30 mm long) (3 used)
16. Hex bolt (4 used per cover)
17. Hex bolt (55 mm long) (2 used)
18. Felt seal
19. Hex nut
Page 3 – 12
20. Connecting rod
21. Ball bearing (connecting rod)
22. Grease fitting
23. Crankshaft
24. Hex nut (5 used)
25. Valve (outlet position)
26. Hex bolt (2 used)
27. Washer (2 used)
28. Poly o–ring
Workman 200 Spray System
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