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.

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

This page is intentionally blank.

Workman 200 Spray System

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

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

This page is intentionally blank.

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.

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.

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.

Figure 4

1. Rate control switch

2. Boom actuator switch

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.

Figure 6

1. Supervisor key switch

SERIAL NUMBER BELOW 270000000

OFF

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)

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.

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

868587A 87

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

Figure 11

1. Coil terminal

2. Common terminal

3. Normally closed term.

4. Normally open term.

SERIAL NUMBER ABOVE 260000000

868587A 87

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.

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

BAC

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.

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. Spray pump

2. Suction dampener

Figure 2

3. Suction hose

1. Spray pump

2. O–ring

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.

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

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

FRONT

RIGHT

Loctite #242

Anti–seize

Lubricant

Apply thread sealant

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

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.

Figure 7

1. Elbow (pressure) 2. Suction hose

Spray

System

Workman 200 Spray System

Page 3 – 11

Spray System

Spray Pump Service

60 ft–lb

(81 N–m)

60 ft–lb

(81 N–m)

55 ft–lb

(75 N–m)

32 ft–lb

(43 N–m)

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

25 ft–lb

(34 N–m)

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

Disassembly (Fig. 8)

IMPORTANT: Make sure to remove and neutralize chemicals from pump before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during pump repair.

NOTE: Many pump components can be easily re-

versed. During disassembly, make note of component position (e.g. crankshaft, valve chamber) to assure cor

rect assembly.

1. Remove two (2) hex bolts that retain valve chamber to pump. Separate valve chamber from pump.

2. Remove inlet and outlet valves and o–rings from each diaphragm cover. Note orientation of valves. Dis

card valves and o–rings. Clean valve and o–ring seats in the valve chambers and diaphragm covers.

3. Remove hex bolts that secure diaphragm covers to pump. Remove diaphragm covers.

D. Position dust plate and felt seal on both ends of crankshaft.

IMPORTANT: If connecting rod position is incorrect, pump will not operate properly.

E. Slide crankshaft assembly into pump casing. The rear connecting rod should be positioned to the left side and the connecting rod closest to you to the right side (Fig. 9).

2. Place second pump casing onto assembly. Pump casing surfaces should mate together.

3. Install three (3) shorter (30 mm) bolts and two (2) longer (55 mm) bolts with washers into pump casing assembly (Fig. 10). Thread hex nuts onto bolts but do not fully tighten. Check that crankshaft turns freely.

4. Remove hex bolt, washer, nylon washer, diaphragm, and diaphragm back disc from each connecting rod. Discard diaphragms.

5. Remove five (5) hex bolts and nuts that secure pump casing halves together. Note location of two (2) longer hex bolts with washers. Carefully separate pump casing halves.

6. Clean grease from bottom of housing and check condition of bearings on crankshaft. If bearings require replacement, remove and disassemble crankshaft:

A. Remove crankshaft assembly from pump casing.

B. Slide felt seal and dust plate from both ends of crankshaft.

C. Loosen hex bolt and hex nut that secure connecting rods to crankshaft. Slide connecting rods from crankshaft. Press ball bearings from crankshaft.

Assembly (Fig. 8)

1. If disassembled, reassemble crankshaft.

A. Hand pack new bearings with #2 general purpose lithium base grease.

Figure 9

1. Closest connecting rod (to right side)

2. Rear connecting rod (to left side)

Spray

System

B. Pressing on bearing inner race, install two connecting rod and two crankshaft ball bearings onto crankshaft.

C. Slide connecting rods onto connecting rod bearings. Offsets of the connecting rods should face each other. Install hex bolt, flat washers, and hex nut to each connecting rod. Torque hex nuts to 25 ft–lb (34 N–m) to secure connecting rods to crankshaft.

Workman 200 Spray System

1. Hex bolt (30 mm long) 2. Hex bolt (55 mm long)

Page 3 – 13

Figure 10

Spray System

4. Place diaphragm back disc and new diaphragm onto each connecting rod. The connecting rods should ex

tend above the diaphragms when correctly installed (Fig. 11). Position nylon washer and washer on each connecting rod and then thread hex bolt into connecting rod. Torque bolt to 60 ft–lb (81 N–m).

5. Make sure that pump casings align and then secure pump casing assembly by torquing five (5) bolts to 32 ft– lb (43 N–m).

6. Secure diaphragm covers to pump using hex bolts (4 per cover). Torque bolts to 55 ft–lb (75 N–m).

7. Place new o–rings and valves into diaphragm cover openings (Fig. 12). Inlet valves should be installed with the spring down into the cover and should be on the same side of the pump as the crankshaft grease fitting. Outlet valves should be installed with the spring up and away from cover and should be on the same side of the pump as the crankshaft extension.

8. Place valve chamber over valves noting orientation of chamber inlet and outlet. Secure valve chamber with two (2) hex bolts. Torque bolts 60 ft–lb (81 N–m).

Figure 11

1. Diaphragm 2. Connecting rod

Figure 12

1. Inlet (suction) 3. Outlet valve

2. Inlet valve

Spray System

Page 3 – 14

Workman 200 Spray System

This page is intentionally blank.

Spray

System

Workman 200 Spray System

Page 3 – 15

Spray System

Agitation Control Valve

FRONT

RIGHT

1. Agitation control valve

2. Fork

3. Hosebarb/hose (to agitation nozzles)

Spray System

Figure 13

4. O–ring

5. O–ring

6. Hosebarb/hose (from spray control)

Page 3 – 16

NOTE: ARROWS SHOW FLUID FLOW DIRECTION

7. Connector

8. Pump suction hose

Workman 200 Spray System

Removal (Fig. 13)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disas sembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Label disconnected hoses for proper installation after repairs are completed.

3. Remove agitation control valve using Figures 13 and 14 as guides.

4. Disassemble agitation valve as required (Fig 15).

Installation (Fig. 13)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Assemble agitation control valve (Fig 15). Align arrow on valve handle with large hole in valve ball during assembly (Fig. 16).

2. Install agitation valve using Figures 13 and 14 as guides.

3. Check spray system for leaks.

Figure 14

1. Agitation control valve 3. Suction hose (from tank)

2. Control bypass hose 4. Suction hose (to pump)

Figure 15

1. Valve housing

2. Ball seat

3. O–ring

4. O–ring

5. Washer (8 used)

6. Cap screw (4 used)

7. End cover

8. Screw (4 used)

9. Screw

10. Button

11. Valve handle

12. Disc

13. O–ring

14. Spindle

15. Valve ball

16. Lock nut (4 used)

Spray

System

Workman 200 Spray System

1. Valve handle arrow 2. Valve ball large hole

Page 3 – 17

Figure 16

Spray System

Agitation Nozzles (Tank mounted)

FRONT

RIGHT

1. Agitation supply

2. Tee fitting

3. Hosebarb/hose

4. O–ring

5. Connector

6. Bulkhead nut

7. Gasket

8. Bulkhead fitting

Figure 17

9. Hosebarb

10. Agitation nozzle

11. Nut

12. Fork (12 used)

13. Hosebarb/hose

14. Hosebarb/hose

15. Hosebarb/hose

16. Agitation nozzle

NOTE: ARROWS SHOW FLUID FLOW DIRECTION

17. Hosebarb/hose

18. Tee fitting

19. Nipple

20. Adapter

21. O–ring

22. Elbow

23. Hosebarb/hose

Spray System

Page 3 – 18

Workman 200 Spray System

Disassembly (Fig. 17)

Assembly (Fig. 17)

IMPORTANT: Make sure to remove and neutralize chemicals from tank and other components before disassembly. Wear protective clothing, chemical re sistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Drain spray tank (see Operator’s Manual).

3. Label hoses for proper installation after repairs are completed.

4. Remove agitation nozzles as required using Figure 17 as a guide. Discard all removed o–rings and gaskets.

NOTE: Coat all o–rings with vegetable oil before installation to reduce the chance of damage during assembly.

1. Install agitation nozzles using Figure 17 as a guide. Replace all removed o–rings and gaskets.

2. Check spray system for leaks.

Spray

System

Workman 200 Spray System

Page 3 – 19

Spray System

Pressure Relief Valve (Tank Mounted)

FRONT

RIGHT

1. Hosebarb/hose

2. Ringnut

3. Pressure relief valve

Figure 18

4. Gasket

5. Hosebarb/hose

6. O–ring

NOTE: ARROWS SHOW FLUID

FLOW DIRECTION

7. Fork

8. Hosebarb/hose (from spray pump)

Spray System

Page 3 – 20

Workman 200 Spray System

Removal (Fig. 18)

IMPORTANT: Make sure to remove and neutralize chemicals from tank and other components before disassembly. Wear protective clothing, chemical re sistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Drain spray tank (see Operator’s Manual).

3. Label disconnected hoses for proper installation after repairs are completed.

4. Remove pressure relief valve from spray tank using Figure 18 and 19 as guides. Discard all removed o–rings and gaskets.

5. Disassemble pressure relief valve using Figure 20 as a guide.

Assembly (Fig. 18)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Assemble and install pressure relief valve using Figure 18, 19 and 20 as guides. Replace all removed o– rings and gaskets.

2. Check spray system for leaks.

Figure 19

1. Hose to pressure relief 3. Control supply hose

2. Hose from spray pump

Spray

System

Figure 20

1. Nut 4. Cone

2. Seat 5. Relief valve housing

3. Spring

Workman 200 Spray System

Page 3 – 21

Spray System

Spray Control (Serial Numbers Below 290999999)

FRONT

71 in--lb (8 N--m)

RIGHT

NOTE: ARROWS SHOW FLUID FLOW DIRECTION

71 in--lb (8 N--m)

Figure 21

1. Nut

2. Threaded rod

3. Washer

4. Bushing

5. O--ring

6. Cap

7. O--ring

8. Tee piece

9. Hose: control supply (1”)

10. Hose clamp

11. Fork

12. Screw

13. Control valve bracket

14. Rate control valve housing

15. Rate control motor

16. Screw (4 used)

17. Screw

18. O--ring

19. Lock washer

20. Handgrip

21. Flowmeter assembly

22. Flowmeter housing

23. Hose: control bypass (1”)

24. Hosebarb

25. O--ring

26. End cap

27. Hose: boom bypass (1”)

28. Hosebarb

IMPORTANT: Rate control and boom valve motors may have a fuse for circuit protection. Make sure that correct fuse is installed in the in--line fuse holder located in the motor harness.

29. Fork

30. Joiner

31. LH boom valve motor/manifold

32. O--ring

33. End cap

34. Joiner

35. Boom valve bracket

36. O--ring (3 used)

37. Hosebarb: boom supply (3 used)

38. Nut (3 used)

39. Coupler (pressure gauge)

40. Center boom valve motor/manifold

41. RH boom valve motor/manifold

Rev. B

Workman 200 Spray SystemPage 3 -- 22Spray System

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disas sembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

Removal (Fig. 21)

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Label hoses for proper installation after repairs are completed. Loosen hose clamps and disconnect hoses from spray control.

3. Unplug electrical connectors from rate control motor, flowmeter, and three (3) boom valve motors from ma chine electrical harness.

4. Remove pressure gauge tube from coupler on back of flowmeter housing (Fig. 23).

5. Remove three (3) flange head screws that secure spray control assembly to valve mounting bar. Remove spray control assembly from machine.

6. Remove spray control components as required using Figure 21 as a guide. Discard all removed o–rings and gaskets.

Assembly (Fig. 21)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Rate control motor 4. Center boom valve motor

2. Flowmeter 5. RH boom valve motor

3. LH boom valve motor 6. Valve mounting bar

Figure 22

Spray

System

1. Install spray control components using Figure 21 as a guide. Replace all removed o–rings and gaskets.

2. Before installing rod (Item 2) into assembly, thread nut (item 1) fully onto rod end that has fewer threads. Make sure that o–ring (Item 3) is not damaged during installation over rod. To secure assembly, torque nut 71 in–lb (8 N–m).

3. Position spray control assembly to valve mounting bar and secure with three (3) flange head screws.

4. Install hoses to correct locations on spray control assembly. Secure hoses with hose clamps.

5. Install pressure gauge tube to coupler on back of flowmeter housing (Fig. 23).

6. Plug electrical connectors from rate control motor, flowmeter, and three (3) boom valve motors to machine electrical harness.

7. Operate spray system and check for leaks.

Figure 23

1. Flowmeter 3. Coupler

2. Pressure gauge tube

Workman 200 Spray System

Page 3 – 23

Spray System

Spray Control (Serial Numbers Above 310000000)

FRONT

RIGHT

NOTE: ARROWS SHOW FLUID FLOW DIRECTION

1. Flange nut (2 used)

2. Flange nut (8 used)

3. Flange head screw (2 used)

4. Valve mount

5. Flange head screw (8 used)

6. Gasket (2 used)

7. Flowmeter

Figure 23.1

8. Clamp (2 used)

9. Boom valve manifold

10. Pressure gauge tube

11. Coupler (pressure gauge)

12. Hose clamp (3 used)

13. Hose clamp (3 used)

14. Hose: boom bypass

15. Hose: RH boom supply

16. Hose: center boom supply

17. Hose: LH boom supply

18. Regulating valve assembly

19. Hose: control bypass

20. Hose: control supply

Page 3 -- 23.1 Workman 200 Spray SystemSpray System

Rev. B

Disassembly (Fig. 23.1)

IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Label all spray control assembly hoses for proper installation after repairs are completed. Loosen hose clamps and disconnect hoses from spray control.

3. Label all wire harness leads for assembly purposes. Disconnect wire harness connectors from regulating valve, flowmeter and three (3) boom valve motors.

4. Remove pressure gauge tube (item 10) from coupler on pressure gauge port on right side of boom valve manifold assembly.

3. Using labels placed during disassembly, install hoses to correct locations on spray control assembly. Secure hoses with hose clamps.

4. Install pressure gauge tube (item 10) to coupler on pressure gauge port on right side of boom valve manifold assembly.

5. Using labels placed during disassembly, secure wire harness connectors to regulating valve, flowmeter and three (3) boom valve motors.

6. Operate spray system and check for leaks. Repair all leaks before returning the sprayer to service.

5. Support spray control assembly to prevent it from falling.

6. Remove eight (8) flange head screws, flat washers and flange nuts that secure spray control assembly to valve mount. Remove spray control assembly from machine.

IMPORTANT: Before removing flowmeter from spray control assembly, note direction of arrow on top of flowmeter (Fig. 23.3). The arrow should point toward boom valve manifold assembly.

7. Separate spray control assembly as required using Figure 23.1 as a guide. Discard all removed gaskets.

Assembly (Fig. 23.1)

NOTE: Coat all gaskets and o--rings with vegetable oil

before installation to reduce the chance of damage during assembly.

1. Assemble spray control using Figure 23.1 as a guide. Replace all removed gaskets. Make sure that arrow on flowmeter body points toward boom valve manifold assembly (Fig. 23.3).

2. Position spray control assembly to valve mounting bar and secure with eight (8) flange head screws, flat washers and flange nuts.

Figure 23.2

1. Boom valve manifold

2. Flowmeter

NOTE ARROW

DIRECTION

FROM

REGULATING

VALV E

Figure 23.3

3. Regulating valve

TO BOOM

VALV E

MANIFOLD

Spray

System

Page 3 -- 23.2Workman 200 Spray System Spray System

Rev. B

Flowmeter (Serial Numbers Below 290999999)

71 in--lb (8 N--m)

FRONT

RIGHT

71 in--lb

(8 N--m)

1. Nut

2. Threaded rod

3. Washer

4. Bushing

5. O--ring

6. Cover

7. O--ring

8. Tee piece

9. Hose: control supply (1”)

10. Hose clamp

Figure 24

11. Fork

12. Screw

13. Control valve bracket

14. Rate control motor/housing

15. O--ring

16. Hosebarb

17. Hose: control bypass (1”)

18. Coupler (pressure gauge)

19. Flowmeter housing

NOTE: ARROWS SHOW FLUID FLOW DIRECTION

20. O--ring

21. Flowmeter rotor shaft

22. Flowmeter rotor

23. Flow sensor

24. Nut

25. End cap

26. LH boom control motor

27. Center boom control motor

28. RH boom control motor

Rev. B

Workman 200 Spray SystemPage 3 -- 24Spray System

Removal and Inspection (Fig. 24)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disas sembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Loosen and remove nut that secures flow sensor to flowmeter housing. Carefully remove flow sensor from housing.

3. Inspect for worn rotor shaft and/or bushings. Make sure that rotor magnets are not missing or damaged.

4. Clean rotor, rotor shaft, and flowmeter sensor if required (see Operator’s Manual).

5. With the flow sensor harness connected to the machine and the ignition key in the ON position, slowly spin the flowmeter rotor. The flowmeter LED should illumi

nate as a rotor magnet passes the flow sensor and should go out as the next magnet passes the sensor.

NOTE: When using a magnet to check the flowmeter, make sure to alternately use both north and south poles of the magnet.

6. If the flowmeter LED does not flash, remove rotor and rotor shaft from sensor. With the flowmeter harness connected to the machine and the ignition key in the ON position, slowly pass alternate poles of a magnet past the flow sensor. If the flowmeter LED flashes as the magnet poles pass the sensor, replace the rotor and ro

tor shaft. If the flowmeter LED does not flash as the magnet poles pass the sensor, replace the flow sensor.

7. If necessary, remove flowmeter housing using Figures 24 and 26 as guides (also see Spray Control) in this section). Discard all removed o–rings and gaskets.

Figure 25

1. Rotor shaft 2. Rotor

Figure 26

1. Rate control motor 4. Center boom valve motor

2. Flowmeter 5. RH boom valve motor

3. LH boom valve motor

Spray

System

Assembly (Fig. 24)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

NOTE: When installing flow sensor into housing, make sure to align locating pin on sensor flange with hole in housing.

1. Reassemble flowmeter using Figures 24 and 26 as guides. Replace all removed o–rings and gaskets.

2. Operate spray system and check for leaks.

Workman 200 Spray System

Page 3 – 25

Spray System

Flowmeter (Serial Numbers Above 310000000)

NOTCH

NOTE ARROW

DIRECTION

NOTCH

1. Flowmeter body

2. Rotor/magnet assembly

3. Upstream hub with bearing

THREAD

SEALANT

Figure 26.1

4. Downstream hub

5. Retaining ring (2 used)

6. Turbine stud with bearing

7. Sensor assembly

8. Cable clamp

9. Screw

Page 3 -- 25.1 Workman 200 Spray SystemSpray System

Rev. B

Removal and Inspection (Fig. 26.1)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Remove spray control assembly from machine and separate flowmeter from spray control (see Spray Control Assembly (Serial Numbers Above 310000000) Removal in this section).

2. Disassemble flowmeter as required using Figures

26.1 and 26.3 as guides.

3. Clean rotor (item 2), both hubs (items 3 and 4) and flowmeter body to remove any metal filings, spray chemicals or other materials.

Figure 26.2

1. Boom valve manifold

2. Flowmeter

3. Regulating valve

Assembly (Fig. 26.1)

1. Assemble flowmeter using Figures 26.1 and 26.3 as guides. Check the following items during flowmeter assembly.

A. If turbine stud (item 6) was removed from upstream hub, apply thread sealant to threads of stud before installation.

B. Check that rotor spins freely with very little drag. If necessary, loosen the turbine stud 1/16 of a turn and check rotor drag. Continue the process of loosening stud until rotor spins freely.

C. When installing hubs (items 3 and 4) into housing, make sure to align locating notch on each hub with boss in housing bore.

D. If sensor (item 7) was removed from flowmeter body, thread sensor into housing so that it lightly bottoms in the housing. Secure sensor in position by tightening jam nut.

E. Make sure that retaining rings are fully seated in grooves of flowmeter housing.

1. Flowmeter body

2. Retaining ring

3. Upstream hub

Figure 26.3

4. Rotor

5. Downstream hub

6. Sensor

Spray

System

2. Attach flowmeter assembly to spray control and then install spray control assembly to machine (see Spray Control Assembly (Serial Numbers Above 310000000) Installation in this section).

Page 3 -- 25.2Workman 200 Spray System Spray System

Rev. B

Rate Control Motor (Serial Numbers Below 290999999)

Figure 27

1. Phillips head screw (5 used)

2. Lock washer

3. Hand grip

4. O--ring

5. Phillips head screw (4 used)

6. Rate control motor assembly

7. Gasket

8. Phillips head screw (4 used)

9. Rate valve spindle section

10. Rate control valve housing

The rate control motor allows the operator to vary the spray application rate. The pressure increase/decrease switch on the spray console energizes the rate control motor which adjusts the valve opening and allows some flow to bypass the spray booms.

NOTE: The rate control motor affects flow to all spray booms. Therefore, a problem with the rate control motor will affect all booms and nozzles.

Disassembly and Inspection (Fig. 27)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

11. O - -ring

12. Cone

13. Control valve

14. Seal

1. To remove the rate control motor:

A. Adjust the rate control to maximum to allow the rate control motor spring to relax. This can be done with either the increase/decrease switch on the spray console or by rotating the hand grip on the motor fully in a clockwise direction.

B. Unplug rate control motor electrical connector from machine electrical harness.

C. Loosen four (4) phillips head screws (item 5) evenly to allow removal of the rate control motor.

D. The inside of motor housing should be free of excessive moisture, corrosion, and dirt.

Rev. B

Workman 200 Spray SystemPage 3 -- 26Spray System

2. Remove four (4) phillips head screws (item 8) that secure spindle section to housing. Remove spindle sec tion.

3. Locate, remove, and discard o–ring (item 11) and seal (item 14).

4. Remove valve (item 13) and inspect for wear and/or damage. Replace if needed.

5. If needed, the spindle shaft can be removed by removing lock nut that secures cone (item 12) to shaft.

NOTE: Many individual components for the rate control motor and spindle section are not available separately. If individual components are worn or damaged, assem blies must be replaced. Refer to Parts Catalog.

6. If necessary, remove rate control valve housing from machine (see Spray Control in this section).

Assembly (Fig. 27)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

Figure 28

1. Rate control motor 4. Center boom valve motor

2. Flowmeter 5. RH boom valve motor

3. LH boom valve motor

Spray

System

1. If removed, install rate control valve housing to machine (see Spray Control in this section).

2. If spindle shaft was removed, assemble by reversing disassembly process. Make sure that spindle shaft sup port aligns with notches in housing during assembly. Secure spindle assembly with lock nut.

3. Align control valve with tabs in spindle section and install control valve. Rotate spindle to fully retract control valve.

4. Install new o–ring (item 11) and seal (item 14) to spindle section.

5. Position spindle section to rate control valve housing. Secure spindle section with four (4) phillips head screws (item 8).

6. To ease assembly of the motor, rotate spindle shaft so the post is about 1/2” (13 mm) from the spindle sec tion housing. Align slot in motor with post in spindle and install motor.

7. Secure motor to assembly by evenly tightening four (4) phillips head screws (item 5).

Workman 200 Spray System

Page 3 – 27

Spray System

Regulating Valve Assembly (Serial Numbers Above 310000000)

Figure 28.1

1. Regulating valve motor

2. Hose barb

3. Flange

4. Adaptor

5. Flynut

6. Elbow fitting

7. Mounting bracket (2 used)

8. Fork

9. Washer (4 used)

10. Cap screw (4 used)

The regulating valve allows the operator to vary the spray application rate. The pressure increase/decrease switch on the spray console energizes the regulating valve motor which adjusts the valve opening and allows some flow to bypass the spray booms.

NOTE: The r egulating valve affects flow to all spray booms. Therefore, a problem with the regulating valve will affect all booms and nozzles.

Removal and Inspection (Fig. 28.1)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Remove spray control assembly from machine and separate regulating valve assembly from spray control (see Spray Control Assembly (Serial Numbers Above

310000000) Removal in this section).

11. Lock nut (4 used)

12. O--ring (2 used)

13. O--ring

14. O--ring

2. Disassemble regulating valve assembly as needed using Figure 28.1 as a guide. Discard all removed O-rings and gaskets.

NOTE: There are limited replacement parts available for regulating valve motor assembly. Check your parts catalog for parts that are available.

3. To remove valve motor cover from regulating valve motor (Fig. 28.3):

A. Loosen three (3) screws that secure valve motor cover to valve motor assembly.

B. Carefully lift and rotate cover from valve motor.

C. Unplug wire connections and remove cover.

D. Make sure that screws that secure valve motor are tight.

Page 3 -- 27.1 Workman 200 Spray SystemSpray System

Rev. B

Assembly (Fig. 28.1)

1. To install valve motor cover to regulating valve motor (Fig. 28.3):

A. Connect cover wires to motor wires. Make sure that cover wire c olor is the same as the motor wire color when connecting wires.

B. Carefully rotate cover onto valve motor taking care to not damage wires.

C. Tighten screws to secure cover to valve motor.

NOTE: Coat all O--rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

2. Assemble regulating valve assembly using Figure

28.1 as a guide.

3. Attach regulating valve assembly to spray control and then install spray control assembly to machine (see Spray Control Assembly (Serial Numbers Above

310000000) Installation in this section).

Piston Valve Service (Fig. 28.4)

1. Remove hosebarb from bottom of valve motor to allow access to piston valve.

2. Make sure that valve is closed. If valve is not closed, spring above piston valve will be under compression and may damage valve motor or piston valve during disassembly. End of piston valve will extend into bottom of valve motor housing when valve is closed. If necessary, reconnect motor to machine wire harness and close valve before removing piston valve.

3. Use 3mm allen wrench to loosen and remove piston valve assembly from valve motor. Locate and retrieve spring from above piston valve.

Figure 28.2

1. Boom valve manifold

2. Flowmeter

Figure 28.3

1. Valve motor assembly

2. Valve motor cover

3. Wire connector

3. Regulating valve

4. Socket screw (4 used)

5. Phillips screw (2 used)

Spray

System

4. Inspect seals on piston valve assembly.O--ring in top groove of piston valve assembly is available separately. If lower two (2) seals in piston valve are worn or damaged, replace piston valve assembly. The piston valve is not designed to be disassembled.

5. Apply silicone grease to seals on piston valve assembly.

6. Position spring into valve motor housing. Use 3mm allen wrench to secure piston valve assembly to valve motor.

7. Secure hosebarb to bottom of valve motor.

Page 3 -- 27.2Workman 200 Spray System Spray System

Figure 28.4

1. Valve motor assembly

2. Piston valve assembly

3. Valve seal

Rev. B

4. Spring

5. Valve motor cover

Boom Valve Motor (Serial Numbers Below 290999999)

70 in--lb

(8 N--m)

Figure 29

1. Housing cover

2. Cover seal

3. Boom valve motor

4. Phillips head screw (5 used)

5. O--ring

6. Lock washer

7. Hand grip

8. Roller

9. Roller pin

10. Spindle

11. Spr in g

12. Spring seat

13. O--ring

14. Spindle housing

15. Phillips head screw (4 used)

16. O--ring

17. O--ring

18. Flat washer

19. Seat outer o-- ring

20. Seat

21. Seat inner o-- ring

22. Seat base

The Workman 200 Sprayer (serial numbers below

290999999) uses three boom valve motor assemblies to control the spray booms. Each boom valve motor assembly includes a motor section (Fig. 29, Items 1 through 7), a spindle section (Fig. 29, Items 8 through

27), and a manifold assembly (Fig. 29, Items 28 through

33).

Disassembly and Inspection (Fig. 29)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Remove spray control from machine. Separate spray control components to allow boom valve motor disassembly (see Spray Control in this section).

23. Flat washer

24. Spring

25. Flat washer

26. Cone

27. Screw

28. Boom valve manifold housing

29. Fork

30. O--ring

31. Balancing valve

32. Roll pin

33. Balancing valve knob

2. To remove the motor and spindle section assembly from the manifold assembly:

A. Remove the fork (item 29) that secures the motor and spindle sections to the manifold assembly.

B. Lift the motor and spindle section assembly from the manifold.

3. To allow easier separation of the motor and spindle sections, make sure that boom valve motor is in the closed position (green indicator is recessed into the spindle housing). Remove four phillips head screws (item 15) and separate spindle section from motor section.

Rev. B

Workman 200 Spray SystemPage 3 -- 28Spray System

4. Remove rear housing cover from boom valve motor to inspect motor components.

A. Cam should be tight on shaft. Cam surface should be free of wear and/or scoring.

B. The inside of motor housing should be free of excessive moisture, corrosion, and dirt.

C. The cam bearing surface in the housing cover should be inspected for excessive wear.

5. Inspect and disassemble spindle section (Fig. 31).

A. Inspect spindle roller surface for wear or scoring. Check that spindle roller rotates freely on roller pin. Replace roller and/or pin as required.

B. The spindle can be disassembled by removing the screw at the bottom of the spindle shaft. Take note of washer, spring, seat, and o–ring locations as spindle is removed.

C. Inspect the cone located at the bottom of the spindle. The cone should be free of nicks or worn spots. A damaged cone will allow flow to the boom bypass rather than to the spray boom.

D. The seat o–rings allow the spindle to shut off flow to the spray boom. If boom nozzles leak when the boom is shut off, the seat and seat o–rings should be inspected carefully.

Figure 30

1. Rate control motor 4. Center boom valve motor

2. Flowmeter 5. RH boom valve motor

3. LH boom valve motor

Spray

System

6. If leakage occurs from balancing valve knob at bottom of boom valve manifold (Fig. 32):

A. Carefully remove roll pin that secures balancing valve to knob.

B. Remove knob from manifold. Remove and discard o–ring.

C. Inspect seating surfaces of manifold and balancing valve. Clean or replace components as needed.

Assembly (Fig. 29)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Replace all removed o–rings.

2. If boom valve manifold was disassembled (Fig. 32):

A. Install o–ring, balancing valve, and knob to manifold.

B. Secure balancing valve to knob by carefully installing roll pin.

Figure 31

1. Spindle roller 3. Seat

2. Cone

Figure 32

1. Boom valve manifold 3. Balancing valve knob

2. Balancing valve 4. Roll pin

Workman 200 Spray System

Page 3 – 29

Spray System

3. Assemble spindle section by reversing disassembly process. Align green indicator tab on spindle to slot in spindle housing. Install screw into bottom of spindle to secure assembly. Torque screw 70 in–lb (8 N–m).

4. Position spindle section on motor section so that green indicator on spindle section is opposite the motor hand grip. Secure spindle section to motor section with four phillips head screws (item 15).

5. Replace rear housing to boom valve motor.

6. Position the motor and spindle section assembly to the manifold assembly. The motor hand grip and boom supply hosebarb on manifold should be on the same side of the assembly. Install the fork (item 29) to secure the motor and spindle sections to the manifold.

7. Assemble spray control assembly. Install spray control to machine (see Spray Control in this section).

8. Operate spray system and check for leaks.

Spray System

Page 3 – 30

Workman 200 Spray System

This page is intentionally blank.

Spray

System

Workman 200 Spray System

Page 3 – 31

Spray System

Boom Valve Manifold Assembly (Serial Numbers Above 310000000)

NOTE: ARROWS SHOW FLUID FLOW DIRECTION

Figure 32.1

1. Boom valve motor (3 used)

2. Hose barb (3 used)

3. Pressure gauge port

4. Flange

5. Flynut

6. Elbow fitting

7. Mounting bracket (2 used)

8. Balancing valve assembly

9. Flange

10. Fork (3 used)

11. Fork(6used)

12. O--ring (4 used)

13. O--ring (4 used)

The sprayer system for serial numbers above 310000000 uses three (3) boom valve motor assemblies to control the spray booms. Each boom valve motor assembly includes a motor section and a balancing valve assembly.

The boom control switches on the operator spray console are used to energize the boom valve motors and open the boom valves. The open boom valvesallow system flow to reach the appropriate boom section (right, center or left).

Disassembly (Fig. 32.1)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

14. O--ring (3 used)

15. Balancing valve assembly (2 used)

16. Washer (4 used)

17. Cap screw (4 used)

18. Lock nut (4 used)

19. Cap

1. Remove spray control assembly from machine and separate boom valve manifold assembly from spray control (see Spray Control Assembly (Serial Numbers Above 310000000) Removal in this section).

2. Disassemble boom valve manifold assembly as needed using Figure 32.1 as a guide. Discard all removed O--rings and gaskets.

NOTE: There are limited replacement parts available for boom valve motor assembly. Check your parts catalog for parts that are available.

3. To remove cover from boom valve (Fig. 32.3):

A. Loosen three (3) screws that secure valve motor cover to valve motor assembly.

B. Carefully lift and rotate cover from valve motor.

Page 3 -- 31.1 Workman 200 Spray SystemSpray System

Rev. B

C. Unplug wire connections and remove cover.

D. Make sure that screws that secure valve motor are tight.

Assembly (Fig. 32.1)

1. To install cover to boom valve motor (Fig. 32.3):

A. Connect cover wires to motor wires. Make sure that cover wire c olor is the same as the motor wire color when connecting wires.

B. Carefully rotate cover onto valve motor taking care to not damage wires.

C. Tighten screws to secure cover to valve motor.

NOTE: Coat all O--rings with vegetable oil before installation to reduce the chance of damage during assembly.

2. Assemble boom valve manifold assembly using Figure 32.1 as a guide.

3. Attach boom valve manifold assembly to spray control and then install spray control assembly to machine (see Spray Control Assembly (Serial Numbers Above

310000000) Installation in this section).

Piston Valve Service (Fig. 32.4)

1. Remove hosebarb from bottom of valve motor to allow access to piston valve.

3. Use 3mm allen wrench to loosen and remove piston valve assembly from valve motor. Locate and retrieve spring from above piston valve.

Figure 32.2

1. Boom valve manifold

2. Flowmeter

Figure 32.3

1. Valve motor assembly

2. Valve motor cover

3. Wire connector

3. Regulating valve

4. Socket screw (4 used)

5. Phillips screw (2 used)

Spray

System

5. Apply silicone grease to seals on piston valve assembly.

6. Position spring into valve motor housing. Use 3mm allen wrench to secure piston valve assembly to valve motor.

7. Secure hosebarb to bottom of valve motor.

Page 3 -- 31.2Workman 200 Spray System Spray System

Figure 32.4

1. Valve motor assembly

2. Piston valve assembly

3. Valve seal

Rev. B

4. Spring

5. Valve motor cover

Boom Bypass

FRONT

RIGHT

1. Boom bypass elbow

2. O–ring

3. Bulkhead fitting

Figure 33

4. Gasket

5. Fork

6. Bulkhead nut

NOTE: ARROW SHOWS FLUID FLOW DIRECTION

7. Hosebarb/hose

8. Hosebarb/hose

Spray System

Page 3 – 32

Workman 200 Spray System

Disassembly (Fig. 33)

IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical re sistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Drain spray tank (see Operator’s Manual).

3. Disassemble boom bypass using Figures 33 and 34 as guides. Discard all removed o–rings and gaskets.

Assembly (Fig. 33)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Assemble boom bypass using Figures 33 and 34as guides. Replace all removed o–rings and gaskets.

2. Check spray tank for leaks.

Figure 34

1. Boom bypass elbow 2. Tank suction tube

Spray

System

Workman 200 Spray System

Page 3 – 33

Spray System

Tank Suction

FRONT

RIGHT

1. Suction hosebarb

2. O–ring

3. Screen vane

4. Suction screen

5. Fork

6. Filter housing

Spray System

Figure 35

7. Expansion pin

8. Bulkhead gasket

9. Bulkhead nut

10. O–ring

11. Hosebarb

12. Hose clamp

Page 3 – 34

NOTE: ARROW SHOWS FLUID FLOW DIRECTION

13. Suction hose

14. Suction tube

15. Suction tube foot

16. Spray tank

17. Hose clamp

18. Suction hose (1 1/2”)

Workman 200 Spray System

NOTE: If suction tube in tank develops an air leak, spray performance will diminish when tank level reaches the leak.

Removal (Fig. 35)

IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical re sistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Remove suction strainer from spray tank (see Operator’s Manual).

3. Raise tank lid and remove strainer basket to gain access to suction tube inside spray tank (Fig. 36).

4. Remove suction tube assembly from spray tank and disassemble tube using Figure 35 as a guide. Discard all removed o–rings and gaskets.

Assembly (Fig. 35)

Figure 36

1. Suction strainer 3. Tank lid

2. Tank drain

Spray

System

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Assemble and install suction tube assembly using Figure 35 as a guide. Replace all removed o–rings and gaskets.

2. Check spray tank for leaks.

Figure 37

1. Tank suction tube 2. Tank drain

Workman 200 Spray System

Page 3 – 35

Spray System

Tank Drain

FRONT

RIGHT

1. Drain handle

2. Nut

3. O–ring

4. Bulkhead

Figure 38

5. Gasket

6. Ringnut

7. Chain

8. Drain assembly

9. Hose clamp

10. Drain hose

11. Spray tank

Spray System

Page 3 – 36

Workman 200 Spray System

Disassembly (Fig. 38)

IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Drain spray tank (see Operator’s Manual).

3. Raise tank lid and remove strainer basket to gain access to chain (item 7) that connects drain handle (item

1) to plunger in drain assembly (item 8). Disconnect chain from drain handle.

4. If necessary, remove drain handle and bulkhead using Figure 38 as a guide.

5. If necessary, remove drain assembly from tank:

A. Loosen hose clamp and slide drain hose from drain assembly hosebarb.

B. Remove fork from drain assembly to allow hosebarb to be removed from drain assembly.

C. Remove bulkhead nut that secures drain assembly to spray tank.

D. Lift drain assembly from bottom of tank.

6. Disassemble drain assembly using Figure 40 as a guide.

7. Discard all removed o–rings and gaskets.

1. Tank drain

2. Suction strainer

Figure 39

3. Tank lid

Spray

System

Assembly (Fig. 38)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Assemble drain tube using Figures 38 and 40 as guides. Replace all removed o–rings and gaskets.

2. Hosebarb of drain assembly should be orientated toward the rear of the spray tank. Make sure that clearance exists between drain assembly and sprayer frame.

3. Check spray tank for leaks.

Workman 200 Spray System

Page 3 – 37

1. Adapter

2. Plunger holder

3. Spring

4. Drain plunger

5. O–ring

6. Drain seat

7. O–ring

Figure 40

8. Drain bulkhead

9. Fork

10. Gasket

11. Bulkhead nut

12. O–ring

13. Hosebarb

Spray System

Turret Bodies

1. Turret body (w/90o elbow)

2. 90

elbow (1 used)

3. Screw

LEFT

BOOM

SUPPLY

CENTER

BOOM

SUPPLY

RIGHT BOOM SUPPLY

Figure 41

4. Turret body (w/double hose barb)

5. Turret body (w/single hose barb)

6. Single hose barb (3 used)

7. Double hose barb (7 used)

8. Turret body clamp

9. Hose barb (for 90

elbow)

Removal (Fig. 41)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch.

2. Loosen hose clamp(s) and remove supply hose(s) from turret body.

3. Remove screw that secures turret body clamp to spray boom. Separate clamp halves and remove turret body from machine.

Spray System

Page 3 – 38

Installation (Fig. 41)

NOTE: The type of hose barb on turret body deter-

mines turret location on spray boom. Refer to Figure 41 for turret position on booms.

1. Position turret body clamp halves to spray boom and turret body. Slide clamp halves together. Position turret so that spray nozzle and nozzle fan slot are parallel to ground. Tighten clamp screw to secure turret body.

2. Install supply hose(s) to turret body. Tighten hose clamp(s).

Workman 200 Spray System

Turret Body Service

Disassembly (Fig. 42)

1. Pull e–clip from body and slide plug with o–ring from body.

2. Disassemble turret body using Figure 42 as a guide.

3. Discard all removed seals, gaskets, o–rings, and diaphragms.

Assembly (Fig. 42)

NOTE: Coat all o–rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.

1. Replace all removed seals, gaskets, o–rings, and diaphragms.

2. Assemble turret body using Figure 42 as a guide.

A. The turret (item 8) end with slightly larger bore and detent grooves needs to be orientated toward detent posts on body (item 4) (Fig. 43).

B. Make sure to align notch on plug (item 10) with groove in body (item 4) as plug is installed.

C. Install e–clip (item 5) into body to secure assembly.

1. Upper clamp

2. O–ring

3. Pivot pin

4. Body

5. E–clip

6. Gasket (3 used)

7. Dust cap (2 used)

8. Turret

9. O–ring

Figure 42

10. Plug

11. Nozzle

12. Nozzle cap

13. O–ring

14. Seal

15. Screw

16. End cap

17. Diaphragm

18. Hose barb

Spray

System

Figure 43

1. Body 3. Detent groove

2. Detent post

Workman 200 Spray System

Page 3 – 39

Spray System

Boom Frame Breakaway Pivot Assembly (Serial Numbers Below 260000000)

1. Hinge

2. Breakaway pivot

3. Spring

4. Washer

5. Roll pin

6. Hex nut

7. Support bracket

Figure 44

8. Carriage screw

9. Flat washer

10. Cotter pin

11. Clevis pin

12. Clevis pin

13. Main boom frame

14. Breakaway pivot assembly

Rev. A

15. Cap screw

16. Boom support

17. Boom extension pipe

18. Lock nut (4 used per side)

19. Flat washer (4 used per side)

20. Cap screw (4 used per side)

Workman 200 Spray SystemPage 3 -- 40Spray System

Disassembly (Fig. 44)

1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch.

2. Support boom to prevent it from falling. Remove cap screw and hex nut that secure boom support to break away assembly.

3. Remove hex nut, flat washer, and carriage screw that secure support bracket to breakaway pivot. Slide support bracket from breakaway assembly.

CAUTION

Spring in breakaway pivot is under tension. To prevent possible personal injury, compress spring before removing roll pin. Wear eye protection when removing roll pin.

Figure 45

1. Breakaway pivot 3. Boom support

2. Support bracket 4. Boom extension pipe

4. Compress spring in breakaway assembly slightly. Drive roll pin from hinge (Fig. 46). Remove flat washer and spring from assembly.

5. Complete disassembly as required using Figures 44 and 45 as guides.

Assembly (Fig. 44)

1. Assemble breakaway pivot using Figures 44 and 45 as guides.

2. Lubricate grease fitting on breakaway pivot after assembly is complete (see Operator’s Manual).

Figure 46

1. Roll pin 2. Spring

Spray

System

Workman 200 Spray System

Page 3 – 41

Spray System

Boom Hinge (Serial Numbers Above 260000000)

FRONT

RIGHT

Figure 47

1. Hinge (2 used per boom)

2. Rubber boot (2 used per hinge)

3. Backing plate (4 used per hinge)

4. Flange nut (4 used per hinge)

5. Boom (RH shown)

6. Tee fitting

7. Flange hd screw (4 used per hinge)

8. Lock nut

9. Cap screw

10. Flat washer

11. Pivot bracket

12. Bushing (2 used per pivot bracket)

13. Flange head screw

14. Pivot pin

Disassembly (Fig. 47)

IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair.

1. Park machine on a level surface, lower spray booms, stop engine, engage parking brake and remove key from the ignition switch.

2. Loosen hose clamp and remove supply hose from tee fitting (item 6) on spray boom.

3. Support spray boom to prevent it from falling.

15. Flange nut

16. Boom frame

17. Tube (2 used per boom)

18. Spring retainer (2 used per boom)

19. Breakaway spring (2 used per boom)

20. Grease fitting (2 used per hinge)

4. Loosen two (2) cap screws (item 9) and lock nuts (item 8) to allow breakaway springs (item 18) to fully extend.

5. Complete disassembly as required using Figure 47 as a guide. If pivot bracket (item 11) is to be removed from machine, disconnect boom actuator (not shown) from pivot bracket (see Boom Actuator Removal (Machines with Serial Numbers Above 260000000) in this section).

6. Clean all removed components. If pivot bracket was removed, inspect bushings and pivot pin for damage or wear.

Rev. A

Workman 200 Spray SystemPage 3 -- 42Spray System

Assembly (Fig. 47)

1. If pivot bracket (item 11) was removed from machine, lightly lubricate bushings (item 12) with motor oil before assembly. Connect boom actuator (not shown) to pivot bracket (see Boom Actuator Installation (Machines with Serial Numbers Above 260000000) in this section).

2. Make sure that hinges (item 1) are securely fastened to pivot bracket (item 11) and boom (item 5). The boom hinge uses four (4) backing plates between the boom and flange nuts.

3. Position boom hinge to pivot bracket hinge. Make sure that rubber boots (item 2) are placed at hinge junc tions and that rib on boots are toward the top of the boom (Fig. 48).

4. Insert two (2) cap screws (item 9) through flat washers (item 10) and hinges. Place tube (item 17), breakaway spring (item 19), spring retainer (item 18) and lock nut (item 8) on each cap screw. Make sure that shoulder on spring retainer fits into breakaway spring.

5. Tighten lock nuts so there is 1.560” (39.6 mm) between the face of the spring retainer and the hinge casting (Fig. 49).

Figure 48

1. Rubber boot 2. Rib

1.560”

(39.6 mm)

Spray

System

6. Connect supply hose to tee fitting on spray boom and secure with hose clamp.

7. Lubricate grease fittings on boom hinge (see Operator’s Manual).

Figure 49

Workman 200 Spray System

Page 3 – 43

Rev. A

Spray System

Boom Actuator (Optional) (Serial Numbers Below 260000000)

FRONT

RIGHT

Figure 50

1. Cotter pin

2. Clevis pin

3. Boom actuator

4. Wire harness

Removal (Fig. 50)

1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch.

2. Label actuator electrical leads to ease reassembly. Unplug boom actuator connector wires from machine harness.

3. Support boom to prevent it from falling. Remove cotter pins and clevis pins that attach boom actuator to center and side boom.

4. Pull boom actuator from machine.

5. Adjustable clevis

Installation (Fig. 50)

1. Position boom actuator to clevis attachment points on center and side booms.

2. Install clevis pins and cotter pins to secure actuator to boom assembly.

3. Plug actuator connector wires into machine harness. Make sure that operator switches engage correct actuator.

A. Left side actuator connector has orange and blue wires.

B. Right side actuator connector has yellow and green wires.

Rev. A

Workman 200 Spray SystemPage 3 -- 44Spray System

Adjustment

1. Loosen end nut that secures adjustable clevis to boom frame (Fig. 51). Position jam nut as close as pos

sible to adjustable clevis. Tighten end nut to secure clevis.

2. Fully raise side boom with the boom actuator. The boom actuator should fully extend and ratchet.

3. With the boom actuator at full extension, the breakaway pivot gusset should just touch the center boom frame slot (Fig. 52).

4. If needed, loosen end nut that secures adjustable clevis and readjust jam nut on clevis to allow correct boom actuator extension. Tighten end nut to secure clevis adjustment.

Figure 51

1. Boom actuator 3. Jam nut

2. Adjustable clevis 4. End nut

Figure 52

1. Breakaway pivot gusset 3. Boom actuator

2. Boom frame slot

Spray

System

Workman 200 Spray System

Page 3 – 45

Spray System

Boom Actuator Service (Serial Numbers Below 260000000)

20 in--lb

(2.3 N--m)

70 in--lb

(7.9 N--m)

15 16

70 in--lb

(7.9 N--m)

1. Screw

2. Rear housing

3. Washer

4. Woodruff key

5. Clutch

6. Thin washer

7. Intermediate gear

8. Thick washer

Figure 53

9. Hex nut (2 used)

10. Motor gear

11. Housing gasket

12. Front housing

13. Cover tube gasket

14. Motor seal

15. Motor assembly

16. Ball screw and brake assembly

17. Washer head screw (4 used)

18. Cover tube

19. O--ring

20. O--ring

Rev. A

Workman 200 Spray SystemPage 3 -- 46Spray System

Disassembly (Fig. 53)

Assembly (Fig. 53)

1. Remove four (4) washer head screws that secure cover tube. Remove one (1) screw (item 1) that retains rear housing. Slide rear housing and housing gasket from assembly.

2. Slide thin washer, intermediate gear, and thick washer from front housing support pin.

3. In order, remove washer, clutch, woodruff key, and second washer from ball screw shaft.

4. Pull cover tube from front housing. Remove cover tube gasket.

5. Loosen and remove two (2) hex nuts that secure motor to front housing. Slide motor, motor gear, and motor seal from front housing.

6. Remove ball screw and brake assembly from front housing.

7. Clean actuator components. Replace worn or damaged parts.

8. Discard and replace all removed gaskets and o– rings.

1. Position ball screw and brake assembly to front housing. Take care to not disturb brake components.

2. Slide motor, motor gear, and motor seal to front housing. Secure motor with two (2) hex nuts. Torque nuts to 70 in–lb (7.9 N–m).

3. Install new o–rings into rear of cover tube. Slide cover tube gasket and cover tube over ball screw.

4. Place washer on ball screw shaft. Position woodruff key and then slide clutch and second washer onto shaft.

5. Place thick washer, intermediate gear, and thin washer onto front housing support pin. Make sure that intermediate gear engages both motor gear and clutch.

6. Position housing gasket to front housing. Slide rear housing over gears.

7. Secure rear housing:

A. Thread one (1) screw (item 1) through rear housing and into front housing.

B. Install four (4) washer head screws through cover tube.

Spray

System

C. Torque screw (item 1) to 20 in–lb (2.3 N–m). Torque four washer head screws to 70 in–lb (7.9 N–m).

Workman 200 Spray System

Page 3 – 47

Spray System

Boom Actuator (Serial Numbers Above 260000000)

1. Boom actuator (2 used)

2. Carriage screw (4 used)

3. Boom frame

4. Washer plate

Figure 54

5. Lock nut (4 used)

6. Flange nut (2 used)

7. Flange head screw (2 used)

8. Pivot pin (2 used)

Rev. A

9. Clevis strap (2 used)

10. Boom pivot bracket

11. Clevis pin (2 used)

12. Cotter pin (2 used)

Workman 200 Spray SystemPage 3 -- 48Spray System

Removal (Fig. 54)

Installation (Fig. 54)

1. Park machine on a level surface, place spray booms in the transport (raised) position, stop engine, engage parking brake and remove key from the ignition switch.

2. Disconnect boom actuator from machine wire harness.

3. Remove pivot pin (item 8) that secures actuator to clevis strap (item 9) on boom frame.

4. Remove cotter pin (item 11) from clevis pin (item 12). Support boom actuator and slide clevis pin from boom pivot bracket. Remove actuator from machine.

1. Position boom actuator to boom frame and boom pivot bracket.

2. Secure actuator to boom pivot bracket with clevis pin and cotter pin.

3. Secure actuator to clevis strap on boom frame with pivot pin.

4. Connect boom actuator to machine wire harness.

Spray

System

Workman 200 Spray System

Page 3 – 49

Rev. A

Spray System

Boom Actuator Service (Serial Numbers Above 260000000)

IMPORTANT: Do not dismantle, repair or modify the boom actuator. Internal components are not available for the actuator. If an actuator is damaged or worn, replace actuator.

CAUTION

During and after operation, the actuator may be very hot. To avoid possible burns, allow the actuator to cool before working on it.

Actuator Circuit Protection

Each boom actuator is protected internally by a thermal circuit breaker.In case of actuator overheating, the thermal breaker will trip, causing the actuator to cease functioning. Once the actuator cools to appropriate operating temperature, the actuator thermal breaker will reset to allow actuator operation to resume.

A separate 30 amp thermal breaker also protects each boom actuator circuit. These thermal breakers are located at the machine fuse panel and will prevent circuit operation if overloaded. The thermal breakers reset automatically.

Actuator Freeplay Inspection

Actuator Air Bleeding

If actuator freeplay is excessive, air bleeding of the actuator should be performed using the following procedure:

1. Thoroughly clean the exterior of the actuator to prevent contaminates from entering the actuator.

2. Make sure that the actuator cylinder is fully retracted.

IMPORTANT: To prevent actuator damage, use vise with protective jaws when clamping actuator.

3. Place the actuator in a vise making sure that actuator is clamped in the area identified in Figure 55. Use just enough clamping force to hold the housing securely. Make sure that the reservoir plug is orientated up.

CAUTION

The actuator reservoir is pressurized. If the reservoir plug is removed too quickly, oil under pressure can be ejected from the actuator.

4. Slowly loosen and remove the reservoir plug at the top of the reservoir.

Over time, actuator operation may be affected by air captured in the reservoir oil. An excessive amount of air in the actuator oil will allow excessive actuator freeplay. Excessive freeplay will allow spray boom bouncing when driving over severe terrain.

Measure actuator freeplay using the following procedure:

1. Move the vehicle to an open area and lower thespray booms to the spray position.

2. Lift up on the boom at the last triangular gusset with a 25 pound (11.4 kg) force. Support boom in that position.

3. Using a non--permanent felt tipped marker, mark the cylinder rod at the outside of the cylinder seal.

4. Release the spray boom and allow it to return to the spray (fully lowered) position.

5. Determine the actuator freeplay by measuring the distance from the mark on the cylinder rod to the cylinder seal. The freeplay should be less than 0.100” (2.5 mm). If excessive freeplay is found, bleed air from actuator.

5. Using a light through the plug hole, confirm that the reservoir oil is clear. If the oil appears milky, air is entrained in the reservoir oil. Keep the actuator vertical with the plug removed for approximately 15 minutes to allow the air to separate from the oil.

6. When oil appears clear, use a 12 volt DC power supply to power the actuator and extend the cylinder completely.

IMPORTANT: To ensure proper reservoir pressure, make sure that cylinder is extended before installing reservoir plug.

7. Install the reservoir plug and torque from 45 to 60 in-lb (5.1 to 6.8 N--m).

8. If reservoir oil was milky, use power supply to contract and extend the actuator cylinder 3 times. Repeat steps 2 through 7 until oil is clear.

9. When actuator oil is clear and plug has been installed, use power supply to fully contract the actuator cylinder. Remove actuator from vise and install on machine.

Rev. A

Workman 200 Spray SystemPage 3 -- 50Spray System

Actuator Oil Level

Under normal conditions, actuator oil level should remain constant. If any oil is spilled from the reservoir during air bleeding, the oil level in the actuator should be checked and adjusted.

1. Thoroughly clean the exterior of the actuator to prevent contaminates from entering the actuator.

2. Make sure that the actuator cylinder is fully retracted.

IMPORTANT: To prevent actuator damage, use vise with protective jaws when clamping actuator.

RESERVOIR

PLUG

RESERVOIR

VISE

CLAMPING

AREA

CYLINDER

CAUTION

The actuator reservoir is pressurized. If the reservoir plug is removed too quickly, oil under pressure can be ejected from the actuator.

4. Slowly loosen and remove the reservoir plug at the top of the reservoir.

5. Using a light through the plug hole, confirm that the reservoir oil is clear. If the oil appears milky, perform ac tuator air bleeding procedure.

6. Use a clean rod to identify the level of oil in reservoir. Distance from plug fitting to oil level should be .984” (25 mm). If necessary, add ISO VG 32 mineral oil to actuator reservoir to adjust oil level.

ELECTRIC

MOTOR

DOWN

Figure 55

Spray

System

0.984”

(25 mm)

7. When oil level is correct, use a 12 volt DC power supply to power the actuator and extend the cylinder completely.

IMPORTANT: To ensure proper reservoir pressure, make sure that cylinder is extended before instal ling reservoir plug.

8. Install the reservoir plug and torque from 45 to 60 in– lb (5.1 to 6.8 N–m).

Actuator Disposal

If actuator disposal is necessary, remove hydraulic oil from actuator before disposal.

1. Open actuator reservoir (see Steps 1 through 4 in Actuator Air Bleeding).

2. Drain oil from actuator.

Workman 200 Spray System

Page 3 – 51

Figure 56

Rev. A

Spray System

This page is intentionally blank.

Spray System

Page 3 – 52

Workman 200 Spray System

Table of Contents

Chapter 3.1

Sonic Boom System

GENERAL INFORMATION 2.....................

Installation Instructions 2......................

Precautions Concerning Chemicals Used in

Spray System 2.............................

Precautions for Removing or Adjusting Spray

System Components 2.......................

SPECIAL TOOLS 3.............................

ELECTRICAL SCHEMATIC 4....................

SONIC BOOM SYSTEM OPERATION 6...........

Sprayer Operation on Level Turf 6..............

Turf Depression Encountered 8.................

Rise in Turf Encountered 10....................

Boom Level Changed by Operator During

Automatic Operation 12......................

Manual Boom Operation 14....................

TROUBLESHOOTING 16........................

Sonic Boom Light 16..........................

Sonic Boom Calibration 16.....................

Diagnostic Display 17.........................

Troubleshooting Chart 20......................

SERVICE AND REPAIRS 22.....................

Sonic Mode Switch 22.........................

Relays 23....................................

Electronic Control Unit (ECU) 24................

Sonic Sensor 25..............................

System

Sonic Boom

Workman 200 Spray System Page 3.1 -- 1 Sonic Boom System (Optional Kit)

Rev. C

General Information

Installation Instructions

The Sonic Boom Kit Installation Instructions provides information regarding the installation, operation and general maintenance for your Sonic Boom System. Refer to that publication for additional information when servicing the machine.

Precautions Concerning Chemicals Used in Spray System

Chemicals can injure persons, animals, plants, soil and other property. To eliminate environmental damage and personal injury:

1. Select the proper chemical for the job.

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 (refer to 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. Park vehicle on a level surface and apply 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 spray system pressure is relieved before loosening any system component.

Rev. B

Workman 200 Spray SystemPage 3.1 -- 2Sonic Boom System (Optional Kit)

Special Tools

Diagnostic Display

The Diagnostic Display (Fig. 1) can be connected to the Sonic Boom wire harness communication connector to verify correct electrical functions of the Sonic Boom System. Electronic control unit (ECU) inputs and outputs for the Sonic Boom System can be checked using the Diagnostic Display.

Toro Part Number for Diagnostic Display: 85--4750

Toro Part Number for Overlay (English): 94--8604

IMPORTANT: The Diagnostic Display must not be left connected to the machine. It is not designed to withstand the environment of the machine’s every day use. When use of Diagnostic Display is completed, disconnect it from the machine and reconnect loopback connector to wire harness communication connector. Machine will not operate without loopback connector installed on wire harness. Store Diagnostic Display in a dry, secure, indoor location and not on machine.

Figure 1

Figure 2

Workman 200 Spray System Page 3.1 -- 3 Sonic Boom System (Optional Kit)

Rev. B

Electrical Schematic

ACTUATOR

LEFT BOOM

RIGHT BOOM

ACTUATOR

Rev. B

RIGHT BOOM

ACTUATOR SWITCH

LEFT BOOM

ACTUATOR SWITCH

Sonic Boom System

Workman 200 Spray SystemPage 3.1 -- 4Sonic Boom System (Optional Kit)

This page is intentionally blank.

Workman 200 Spray System Page 3.1 -- 5 Sonic Boom System (Optional Kit)

Rev. B

Sonic Boom System Operation

ACTUATOR

LEFT BOOM

(STATIONARY)

RIGHT BOOM

ACTUATOR

(STATIONARY)

(NOT ENERGIZ ED)

(IN AUTO POSITION)

Rev. B

RIGHT BOOM

ACTUATOR SWITCH

Workman 200 Spray SystemPage 3.1 -- 6Sonic Boom System (Optional Kit)

LEFT BOOM

ACTUATOR SWITCH

Power Current

Sonic Boom System

Sprayer Operation on Level Turf

Sonic Mode Switch in Automatic

Control Current

Indicator Light Current

Sprayer Operation on Level Turf

During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo. As long as the sensor height remains the same as the calibrated height, the spray boom will remain at a fixed height from the ground for spraying accuracy.

On level turf, the boom sensors continually send signals and receive echoes that determine that the booms sections are at the calibrated height. Thus, there is no need to change boom height. The boom actuators will not be energized and the boom sections remain at the correct, level position.

CONSISTENT BOOM HEIGHT

SO ACTUATOR MOVEMENT

IS NOT NECESSARY

LEVEL GROUND

Figure 3

Workman 200 Spray System Page 3.1 -- 7 Sonic Boom System (Optional Kit)

Rev. B

LEFT BOOM

ACTUATOR

(EXTENDING)

RIGHT BOOM

ACTUATOR

(STATIONARY)

(NOT ENERGIZED)

(ENERGIZED)

(NOT ENERGIZ ED)

(IN AUTO POSITION)

Rev. B

RIGHT BOOM

ACTUATOR SWITCH

Workman 200 Spray SystemPage 3.1 -- 8Sonic Boom System (Optional Kit)

LEFT BOOM

ACTUATOR SWITCH

Power Current

Sonic Boom System

Downward Slope in Turf Encountered (Left Boom Shown)

Sonic Mode Switch in Automatic

Control Current

Indicator Light Current

Downward Slope in Turf Encountered

During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo. As long as the sensor height remains the same as the calibrated height, the spray boom section will remain at a fixed distance from the ground for spraying accuracy.

When a spray boom section encounters a downward slope in the turf, the time necessary for the sensor to receive the signal echo is longer than the calibrated timeframe. This change in time causes the ECU to energize the appropriate power switch relay. The energized relay provides a current path to the boom actuator causing the actuator to extend and the boom section to lower. This maintains the boom height at the calibrated distance from the ground. Once the boom section is lowered to the calibrated distance, the elapsed time between the sensor signal generation and the received echo returns to the correct timeframe and the boom stops lowering.

The boom sensor target distance is initiated during initial sonic boom calibration and is typically set at twenty (20) inches. When in automatic mode, the booms will not move if the target distance change is three (3) inches or less (inner dead band). Once the target distance exceeds five (5) inches (outer dead band), the ECU will energize the appropriate power switch relay. The energized relay will lead to a change in boom actuator length and ultimately a change in boom height.

A HIGHER BOOM HEIGHT IS DETECTED

SO ACTUATOR EXTENDS TO LOWER BOOM SECTION

SLOPE

Figure 4

Workman 200 Spray System Page 3.1 -- 9 Sonic Boom System (Optional Kit)

Rev. B

LEFT BOOM

ACTUATOR

(STATIONARY)

RIGHT BOOM

ACTUATOR

(RETRACTING)

(NOT ENERGIZ ED)

(ENERGIZED)

(IN AUTO POSITION)

RIGHT BOOM

ACTUATOR SWITCH

Rev. B

LEFT BOOM

ACTUATOR SWITCH

Power Current

Control Current

Indicator Light Current

Sonic Boom System

Rise in Turf Encountered (Right Boom Shown)

Sonic Mode Switch in Automatic

Workman 200 Spray SystemPage 3.1 -- 10Sonic Boom System (Optional Kit)

Rise in Turf Encountered

During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo. As long as the sensor height remains the same as the calibrated height, the spray boom section will remain at a fixed distance from the ground for spraying accuracy.

When a spray boom section encounters a rise in the turf, the time necessary for the sensor to receive the signal echo is shorter than the calibrated timeframe. This change in time causes the ECU to energize the appropriate power switch relay and H--bridge relays. These energized relays provide a current path to the boom actuator causing the actuator to retract and the boom section to raise. This maintains the boom height at the calibrated distance from the ground. Once the boom section is raised to the calibrated distance, the elapsed time between the sensor signal generation and the received echo returns to the correct timeframe and the boom stops raising.

A LOWER BOOM HEIGHT IS DETECTED

SO ACTUATOR RETRACTS TO RAISE BOOM SECTION

RISE

Figure 5

Workman 200 Spray System Page 3.1 -- 11 Sonic Boom System (Optional Kit)

Rev. B

LEFT BOOM

ACTUATOR

(RETRACTING)

RIGHT BOOM

ACTUATOR

(STATIONARY)

(ENERGIZED)

(NOT ENERGIZ ED)

(IN AUTO POSITION)

RIGHT BOOM

ACTUATOR SWITCH

Rev. B

LEFT BOOM

ACTUATOR SWITCH

(PRESSED TO RAISE)

Power Current

Control Current

Indicator Light Current

Sonic Boom System

Boom Level Changed by Operator (Raise Left Boom Shown)

Sonic Mode Switch in Automatic

Workman 200 Spray SystemPage 3.1 -- 12Sonic Boom System (Optional Kit)

Boom Level Changed by Operator During Automatic Operation

During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo. As long as the sensor height remains the same as the calibrated height, the spray boom will remain at a fixed distance from the ground for spraying accuracy.

If the sprayer operator should press a boom actuator switch while in automatic operation, the ECU energizes the necessary power switch relay and H--bridge relays to raise or lower the appropriate boom. The energized relay(s) provides a current path to the requested boom actuator to raise or lower the boom. The boom actuator will stay energized as long as the operator keeps the boom actuator switch pressed. The sonic boom light will flash as long as the boom actuator switch is pressed.

If a boom is raised by the operator while the Sonic Boom System is in automatic operation, the boom will remain in the raised position until it is lowered halfway with the boom actuator switch to re--engage automatic sonic boom operation. If one boom is moved by the operator, the other boom continues to function automatically.

Workman 200 Spray System Page 3.1 -- 13 Sonic Boom System (Optional Kit)

Rev. B

LEFT BOOM

ACTUATOR

(STATIONARY)

RIGHT BOOM

ACTUATOR

(EXTENDING)

(NOT ENERGIZ ED)

(ENERGIZED)

(IN MANUAL POSITION)

Rev. B

RIGHT BOOM

ACTUATOR SWITCH

(PRESSED TO LOWER)

LEFT BOOM

ACTUATOR SWITCH

Power Current

Sonic Boom System

Manual Boom Operation (Lower Right Boom Shown)

Sonic Mode Switch in Manual

Control Current

Indicator Light Current

Workman 200 Spray SystemPage 3.1 -- 14Sonic Boom System (Optional Kit)

Manual Boom Operation

During sprayer operation with the sonic boom switch in the manual position, the spray booms will remain in position unless the operator presses a boom actuator switch. When the sonic boom switch is in the manual position, the sonic boom light should be illuminated. The operator will control the boom position with the boom actuator switches.

Raise Boom

When a boom actuator switch is pressed to raise a boom section, the electronic control unit (ECU) energizes the power switch relay and both H--bridge relays for the requested boom section. The energized relays provide a current path to the boom actuator causing the actuator to retract which will raise the boom section. The boom will continue to rise until the operator releases the boom actuator switch.

Lower Boom

When a boom actuator switch is pressed to lower a boom section, the electronic control unit (ECU) energizes the power switch relay for the requested boom section. The energized relay provides a current path to the boom actuator causing the actuator to extend which will lower the boom section. The boom will continue to lower until the operator releases the boom actuator switch.

Workman 200 Spray System Page 3.1 -- 15 Sonic Boom System (Optional Kit)

Rev. B

Troubleshooting

For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on the Sonic Boom System (see Sonic Boom System Operation in this chapter).

Sonic Boom Light

The Sonic Boom System is designed to automatically adjust the sprayer boom height if changes in the turf surface are detected. The sonic boom light should be illuminated whenever the vehicle ignition switch is ON and the sonic boom switch is in either the automatic or manual position.

The sonic boom light flashing quickly indicates that the Sonic Boom System is in the calibration mode. This mode allows the spray booms to be adjusted for the desired boom height. The calibration mode lasts for twenty (20) seconds after which the boom light should quit flashing.

NOTE: A sequence of switch movements is necessary to engage the calibration mode. Refer to the Sonic Boom Kit Installation Instructions for this sequence.

NOTE: When troubleshooting an electrical problem on your Sonic Boom System, refer to information regarding the sonic boom light in this section. Also, use the Diagnostic Display (see Special Tools in this chapter) to test electronic control unit (ECU) inputs and outputs.

The sonic boom light flashing slowly indicates that a system error has been encountered. If the boom light is flashing slowly, lower the affected boom(s) with the boom actuator switch(es) to clear the error. If the error continues, there may be an issue with the Sonic Boom System electronic control unit (ECU). If this occurs, see Diagnostic Display and Troubleshooting Chart in this section.

Sonic Boom Calibration

The Sonic Boom sensor calibration process is critical to the correct operation of the Sonic Boom System. The calibration process establishes the sensor target distance between the boom and the turf surface. Typically, this distance is approximately twenty (20) inches. Steps needed for proper calibration are identified in the Sonic Boom Kit Installation Instructions.

Figure 6

1. Spray control console 2. Sonic boom light

While calibrating the Sonic Boom sensors, it is best to perform the calibration process on turf. A shiny surface (e.g. cement shop floor) can skew sensor signals. Also, ensure the calibration area is free of buildings, trees, underground plumbing and other machines that could interfere with sensor signals.

Rev. B

Workman 200 Spray SystemPage 3.1 -- 16Sonic Boom System (Optional Kit)

Diagnostic Display

The Sonic Boom System is equipped with an electronic control unit (ECU) which controls machine sonic boom electrical functions. The ECU monitors various input switches (e.g. boom actuator switches, sonic boom sensors) and energizes outputs to actuate relays for appropriate machine functions.

For the ECU to control the machine as desired, each of the inputs (switches and sensors) and outputs (relays) must be connected and functioning properly.

The Diagnostic Display (see Special Tools in this chapter) is a tool to help the technician verify correct electrical functions of the machine.

IMPORTANT: The Diagnostic Display must not be left connected to the machine. It is not designed to withstand the environment of the machine’s every day use. When use of the Diagnostic Display is completed, disconnect it from the machine and reconnect loopback connector to harness connector. The machine will not operate without the loopback connector installed on the harness. Store the Diagnostic Display in a dry, secure, indoor location and not on machine.

Verify Diagnostic Display Input Functions

1. Park vehicle on a level surface, stop the engine and apply the parking brake.

CAUTION

When testing ECU inputs with the Diagnostic Display, boom actuators may be energized causing the spray booms to move. Be cautious of potential sprayer component movement while verifying inputs with the Diagnostic Display.

6. The Diagnostic Display will illuminate the LED associated with each of the inputs when that input switch is closed. Individually, change each of the switches from open to closed (e.g. toggle sonic mode switch), and note that the appropriate LED on the Diagnostic Display will illuminate when the corresponding switch is closed. Repeat on each switch that is possible to be changed by hand (see Inputs and LED Operation chart on following page).

7. If appropriate LED does not toggle on and off when switch state is changed, check all wiring and connections to that switch and/or test switch. Replace any defective switches and repair any damaged wiring.

8. After input functions testing is complete, disconnect the Diagnostic Display connector from the harness connector and plug loopback connector into wire harness.

2. Locate Sonic Boom wire harness communication port and loopback connector under the vehicle dash panel. Carefully unplug loopback connector from harness connector.

3. Connect the Diagnostic Display connector to the wire harness connector. Make sure correct overlay decal is positioned on the Diagnostic Display (Fig. 7).

4. Turn the vehicle ignition switch to the ON position, but do not start vehicle.

NOTE: The red text on the Diagnostic Display overlay decal refers to input switches and the green text refers to ECU outputs.

5. Make sure that the “INPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display, is illuminated. If “OUTPUTS DISPLAYED” LED is illuminated, press the toggle button on the Diagnostic Display to change to “INPUTS DISPLAYED” LED.

System

Electrical

Figure 7

Workman 200 Spray System Page 3.1 -- 17 Sonic Boom System (Optional Kit)

Rev. B

Diagnostic Display

Inputs

Diagnostic Display

LED Operation

AUTO MODE Sonic mode switch in auto position: LED ON

Sonic mode switch not in auto position: LED OFF

L RAISE Left boom actuator switch in raise position: LED ON

Left boom actuator switch not in raise position: LED OFF

LLOWER Left boom actuator switch in lower position: LED ON

Left boom actuator switch not in lower position: LED OFF

R RAISE Right boom actuator switch in raise position: LED ON

Right boom actuator switch not in raise position: LED OFF

RLOWER Right boom actuator switch in lower position: LED ON

Right boom actuator switch not in lower position: LED OFF

LNOSNSRDATA ECU has detected an invalid reading from left sensor: LED ON

Left sensor operating normally: LED OFF

L NOT TRACKING Left boom not tracking to target within 5 seconds: LED ON

Left sensor operating normally: LED OFF

RNOSNSRDATA ECU has detected an invalid reading from right sensor: LED ON

Right sensor operating normally: LED OFF

R NOT TRACKING Right boom not tracking to target within 5 seconds: LED ON

Right sensor operating normally: LED OFF

L -- SNSR FEEDBACK ECU receiving signal from left sensor: LED ON

ECU not receiving signal from left sensor: LED OFF

R -- SNSR FEEDBACK ECU receiving signal from right sensor: LED ON

ECU not receiving signal from right sensor: LED OFF

NOTE: When the vehicle ignition switch is in the OFF position, all Diagnostic Display LED’s should be OFF.

NOTE: Initial calibration of the Sonic Boom sensors is required for proper operation of ECU inputs. Refer to your Sonic Boom Kit Installation Instructions for information on initial sensor calibration.

NOTE: Right and left side Sonic Boom sensors are identical so they can be exchanged to assist in troubleshooting. If a problem follows the exchanged sensor,an electrical problem likely exists with the sensor. If the problem remains unchanged, something other than the sensor is the problem source (e.g. switch, circuit wiring).

Rev. B

Workman 200 Spray SystemPage 3.1 -- 18Sonic Boom System (Optional Kit)

Verify Diagnostic Display Output Functions

The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the electronic control unit (ECU). This is a quick way to determine which electrical component is malfunctioning.

NOTE: It may be necessary to toggle between “INPUTS DISPLAYED” and “OUTPUTS DISPLAYED”several times to perform the following step. To change from inputs to outputs, press toggle button once. This may be done as often as required. Do not press and hold

toggle button.

NOTE: An open output (e.g. an unplugged connector or

a broken wire) cannot be detected with the Diagnostic Display.

1. Park vehicle on a level surface, stop the engine and engage the parking brake.

2. Locate Sonic Boom System wire harness and loopback connector under the vehicle dash panel. Carefully unplug loopback connector from harness connector.

3. Connect the Diagnostic Display connector to the harness connector.Make sure correct overlay decal is positioned on the Diagnostic Display (see Special Tools in this chapter).

4. Turn the ignition switch to the ON position.

NOTE: The red text on the Diagnostic Display overlay decal refers to input switches and the green text refers to ECU outputs.

5. Make sure that the “OUTPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display,is illuminated. If “INPUTS DISPLAYED” LED is illuminated, press the toggle button on the Diagnostic Display to change the LED to “OUTPUTS DISPLAYED”.

6. Attempt to operate the desired function of the machine. The appropriate output LED’s should illuminate on the Diagnostic Display to indicate that the ECU is turning on that function. The outputs can be checked with the vehicle ignition switch in the ON position and the engine not running.

A. If the correct output LED’s do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur.

B. If the output LED’s are on as specified, but the booms do not function properly, suspect a failed electrical component, an open in the tested circuit or a non-electrical problem (e.g. binding of the boom hinge). Repair as necessary.

C. If each input switch is in the correct position and functioning correctly, but the output LED’s are not correctly illuminated, this indicates an ECU problem. If this occurs, contact your Toro Distributor for assistance.

7. After output functions testing is complete, disconnect the Diagnostic Display connector from the harness connector and plug loopback connector into wire harness.

Diagnostic Display

Outputs

Diagnostic Display

LED Operation

L BOOM -- RAISE Left boom is rising: LED ON

Left boom is stationary: LED OFF

R BOOM -- RAISE Right boom is rising: LED ON

Right boom is stationary: LED OFF

POWER ON/ERROR Power to ECU: LED ON

No power to ECU: LED OFF

System error: LED flashing slowly

L BOOM MOTOR ECU output exists to energize left power switch relay: LED ON

No ECU output to left power switch relay: LED OFF

R BOOM MOTOR ECU output exists to energize right power switch relay: LED ON

No ECU output to right power switch relay: LED OFF

Workman 200 Spray System Page 3.1 -- 19 Sonic Boom System (Optional Kit)

Rev. B

Troubleshooting Chart

The chart that follows contains suggestions that can be used to assist in diagnosing Sonic Boom System performance issues. These suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem.

Problem Possible Cause

Sonic boom light is not illuminated. Sonic mode switch is in the OFF position.

5 amp or 10 amp fuse in sonic boom fuse block is faulty.

Electrical power from vehicle is not available (all sonic boom functions are affected).

Sonic boom light or circuit wiring is faulty.

Sonic mode switch or circuit wiring is faulty.

LED on one of the sonic boom sensors is not illuminated.

LED on both of the sonic boom sensors is not illuminated.

Sonic boom sensor or circuit wiring is faulty.

Sonic mode switch is in the OFF position.

5 amp fuse in sonic boom fuse block is faulty.

One of the boom actuators will not retract.

Neither of the boom actuators will retract.

Sonic mode switch or circuit wiring is faulty.

30 amp auto resetting fuse for affected boom actuator is faulty.

Power switch relay or circuit wiring for affected boom actuator is faulty.

One or both of the H--bridge relays or circuit wiring for the affected boom actuator is faulty.

Boom actuator switch or circuit wiring for affected boom actuator is faulty.

Affected boom actuator or circuit wiring is faulty.

Loop back connector is unplugged from wire harness connector.

5 amp or 10 amp fuse in sonic boom fuse block is faulty.

Electrical power from vehicle is not available (all sonic boom functions are affected).

Both of the boom actuator 30 amp auto resetting fuses are faulty.

ECU or circuit wiring is faulty.

Rev. B

Workman 200 Spray SystemPage 3.1 -- 20Sonic Boom System (Optional Kit)

Problem Possible Cause

One of the boom actuators will not extend.

Neither of the boom actuators will extend.

One of the booms does not automatically follow ground irregularities. Boom can be controlled with boom actuator switch.

30 amp auto resetting fuse for affected boom actuator is faulty.

Power switch relay or circuit wiring for affected boom actuator is faulty.

Boom actuator switch or circuit wiring for affected boom actuator is faulty.

Affected boom actuator or circuit wiring is faulty.

Loop back connector is unplugged from wire harness connector.

5 amp or 10 amp fuse in sonic boom fuse block is faulty.

Electrical power from vehicle is not available (all sonic boom functions are affected).

30 amp auto resetting fuse is faulty in both boom actuators.

ECU or circuit wiring is faulty.

On affected boom, the sonic boom sensor cover is on sensor or is hanging in sensor path.

On affected boom, the sensor filter is dirty or damaged.

Calibration of the Sonic Boom sensors is incorrect.

Neither boom automatically follows ground irregularities. Booms can be controlled with boom actuator switches.

On affected boom, the sonic sensor angle needs adjustment.

Sonic sensor or circuit wiring for affected boom is faulty.

ECU or circuit wiring is faulty.

Sonic mode switch is not in the AUTO position.

Sonic boom sensor covers are on both sensors or are hanging in sensor path.

The filters on both sensors are dirty or damaged.

Calibration of the Sonic Boom sensors is incorrect.

The sonic sensor angle on both booms need adjustment.

Both sonic sensors or circuit wiring are faulty.

ECU or circuit wiring is faulty.

Workman 200 Spray System Page 3.1 -- 21 Sonic Boom System (Optional Kit)

Rev. B

Service and Repairs

Sonic Mode Switch

The sonic mode switch is used as an input for the ECU to activate the Sonic Boom System. This switch has three (3) positions: automatic, manual and off.The sonic mode switch is located on the console.

If the sonic mode switch is in the automatic position, the sonic sensors will be activated to allow automatic movement of the boom. The tips of the booms will remain at a constant distance from the ground. The boom switches can be used to raise/lower the booms when the sonic mode switch is in the automatic position.

If the sonic mode switch is in the manual position, the sonic sensors are disabled. The boom switches are used to raise/lower the booms w hen the sonic mode switch is in the manual position.

If the sonic mode switch is in the OFF position, the booms will remain in position. The boom actuators will not be energized regardless of sonic boom sensor activity or change in boom switch position.

Testing

1. Before disconnecting the sonic mode switch for testing, the switch and its circuit wiring should be tested as a ECU input with the Diagnostic Display (see Diagnostic Display in the Troubleshooting section of this chapter). If the Diagnostic Display verifies that the sonic mode switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the Display determines that the sonic mode switch and circuit wiring are not functioning correctly, proceed with test.

6. If the sonic mode switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematic and Wire Harness Drawings in this chapter).

7. After testing is completed, connect wire harness connector to the sonic mode switch.

Figure 8

1. Spray control console 2. Sonic mode switch

2. Park vehicle on a level surface, stop engine, engage parking brake and remove key from ignition switch.

3. Disassemble console to gain access to sonic mode switch.

4. Disconnect harness electrical connector from the sonic mode switch.

5. The switch terminals are marked as shown in Figure

9. The circuit logic of the sonic mode switch is shown in the chart to the right. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals. Replace switch if testing identifies a faulty switch.

BACK OF SWITCH

Figure 9

SWITCH

POSITION

AUTOMATIC 2+3

OFF NONE ALL

MANUAL 2+1

Rev. B

CLOSED

CIRCUITS

5+6

5+4

Workman 200 Spray SystemPage 3.1 -- 22Sonic Boom System (Optional Kit)

OPEN

CIRCUITS

2+1 5+4

2+3 5+6

Toro 41229, 41235 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Safety Instructions

Before Op erating

While Operating

Maintenance and Service

Product Records

Safety and Instruction Decals

Special Tools

Component Testing

Master Boom Switch

Rate Control and Boom Actuator Switches

Supervisor Key Switch

Boom Control and Monitor Power Switches

Traction Speed Sensor

Specifications

General Information

Precautions Concerning Chemicals Used in Spray System

Precautions for Removing or Adjusting Spray System Components

Spray System Flow Diagram

Spray System Operation

Troubleshooting

Service and Repairs

Suction Dampener

Pressure Dampener

Spray Pump

Spray Pump Service

Agitation Control Valve

Agitation Nozzles (Tank mounted)

Pressure Relief Valve (Tank Mounted)

Boom Bypass

Tank Suction

Tank Drain

Turret Bodies

Turret Body Service

General Information

Installation Instructions

Precautions Concerning Chemicals Used in Spray System

Precautions for Removing or Adjusting Spray System Components

Special Tools

Electrical Schematic

Sonic Boom System Operation

Sprayer Operation on Level Turf

Troubleshooting

Sonic Boom Light

Sonic Boom Calibration

Diagnostic Display

Troubleshooting Chart

Service and Repairs

Sonic Mode Switch