PART NO. 03124SL (Rev. C)
Service Manual
(Models 41229 and 41235)
WorkmanR 200 Spray System
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).
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE, AND ADJUSTMENT
INSTRUCTIONS. Keep the Operator’s Manual, Instal-
lation Instructions and Parts Catalog for your machine
with this Service Manual. Replacement Operator’s
Manuals and Parts Catalogs are available on the inter-
net at www.Toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - 2003, 2005, 2011, 2014
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Table Of Contents
Chapter 1 -- Safety and Product Records
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 3
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 3
Chapter 2 -- Electrical System
Electrical Schematic and Electrical Harness and Con-
nector Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 4
Chapter 3 -- Spray System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Spray System Flow Diagram . . . . . . . . . . . . . . . . . 3 -- 4
Spray System Operation . . . . . . . . . . . . . . . . . . . . 3 -- 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 6
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 8
Chapter 3.1 -- Sonic Boom System (Optional Kit)
General Information . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 3
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 4
Sonic Boom System Operation . . . . . . . . . . . . . 3.1 -- 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 16
Service and Repairs . . . . . . . . . . . . . . . . . . . . . 3.1 -- 22
Chapter 3.2 -- Ultra Sonic Boom System (Optional
Kit)
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
Workman 200 Spray System
Rev. C
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Chapter 1
Safety and Product Records
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2ꢀ
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ꢀ
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ꢀ
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3ꢀ
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 3ꢀ
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 3ꢀ
Workman 200 Spray System
Page 1 – 1
Safety and Product Recordsꢀ
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Safety Instructions
The Workman 200 Spray System is designed and
tested to offer safe service when operated and main-
tained properly. Although hazard control and accident
prevention are partially dependent upon the design and
configuration of the machine, these factors are also de-
pendent upon the awareness, concern, and proper
training of the personnel involved in the operation, trans-
port, maintenance, and storage of the machine. Improp-
er 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.
WARNING
To reduce the potential for injury or death, com-
ply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Be-
come 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.
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.
While Operating
1. Sit on the seat when starting and operating the ma-
chine.
5. Before getting off the seat:
A. Ensure that drive system is in the NEUTRAL
position.
2. Before starting the engine:
A. Engage the parking brake.
B. Set parking brake.
B. Make sure drive system is in the NEUTRAL posi-
tion and the pump switch is OFF.
C. Turn pump switch OFF.
D. Stop engine and remove key from ignition switch.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
E. Do not park on slopes unless wheels are chocked
or blocked.
6. Follow spray chemical manufacturer’s recommen-
dations for handling precautions, protective equipment,
and mixing proportions.
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.
Rev. B
Safety and Product Records
Page 1 -- 2
Workman 200 Spray System
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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.
7. Disconnect battery before servicing the machine.
Disconnect negative (–) battery cable first and positive
(+) cable last. If battery voltage is required for trouble-
shooting or test procedures, temporarily connect the
battery. Reconnect positive (+) cable first and negative
(–) cable last.
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.
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.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
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 non-
conformance with safety standards, and the warranty
may be voided.
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 de-
sired, 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.
Safety and Instruction Decalsꢀ
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 de-
cals from your Authorized Toro Distributor.
Product Recordsꢀ
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 Recordsꢀ
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Safety and Product Records
Page 1 – 4
Workman 200 Spray Systemꢀ
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Chapter 2
Electrical 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
Rev. B
Workman 200 Spray System
Page 2 -- 1
Electrical System
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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
Workman 200 Spray Systemꢀ
Page 2 – 2
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Special Toolsꢀ
Multimeterꢀ
The multimeter can test electrical components and cir-
cuits 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 cur-
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Workman 200 Spray System
Electrical Systemꢀ
Page 2 – 3
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Component Testingꢀ
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.
1
3. Reconnect the harness connectors to the switch af-
ter 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
Workman 200 Spray Systemꢀ
Page 2 – 4
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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 actua-
tors.
2
Testing
1
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 be-
tween terminals 5 and 6. In the neutral, center position,
there should be no continuity between any switch termi-
nals. In the DECREASE or boom lower position, conti-
nuity should exist between terminals 2 and 1 and also
between terminals 5 and 4.
Figure 4
1. Rate control switch
2. Boom actuator switch
3. Reconnect the harness connector to the switch after
testing. Install console panel to machine.
4
5
6
1
2
3
BACK OF SWITCH
Figure 5
Rev. B
Workman 200 Spray System
Page 2 -- 5
Electrical System
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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 sprayers with serial numbers above
270000000 is shown in Figure 8.
Testing
1. Remove spray control enclosure faceplate, locate
supervisorkeyswitchandremovewireharnessconnec-
tors from switch.
1
2. Test switch for continuity as follows:
Figure 6
A. For sprayers with serial numbers below
270000000 (Fig. 7), when the key is in the ON posi-
tion, continuity should exist between the two switch
terminals. In the OFF position, there should be no
continuity between the switch terminals.
1. Supervisor key switch
SERIAL NUMBER BELOW 270000000
OFF
B. For sprayers with serial numbers above
270000000 (Fig. 8), when the key is in the ON posi-
tion, continuity should exist between switch termi-
nals 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.
60o
ON
3. Reconnect the harness connectors to the switch af-
ter testing. Install console panel to machine.
BACK OF SWITCH
Figure 7
FRONT OF SWITCH
SERIAL NUMBER ABOVE 270000000
OFF (LOCKED)
o
45
ON (UNLOCKED)
FRONT OF SWITCH
BACK OF SWITCH
Figure 8
Rev. B
Electrical System
Page 2 -- 6
Workman 200 Spray System
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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).
2
Testing
1. Remove spray control enclosure faceplate, locate
boom control switch and unplug wire harness connector
from switch.
1
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.
Figure 8
1. Boom control switch
2. Monitor power switch
4. Reconnect the harness connector to the switch after
testing. Install console panel to machine.
7
4
5
6
8
1
2
3
BACK OF SWITCH
Figure 9
Workman 200 Spray System
Electrical Systemꢀ
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Hold and Boom Actuator (Serial Numbers Above 260000000) Relays
Workman sprayers with serial numbers below
260000000 use a single relay for the sprayer hold func-
tion. 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
locatedinthespray controlenclosure. Therelays canbe
identified by a tag at the relay wire harness connector.
SERIAL NUMBER BELOW 260000000
3
4
1
86
85
87A
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.
30
2
1
Testing
Figure 11
1. Remove spray control enclosure faceplate, locate
relay that is to be tested and unplug wire harness con-
nector from relay.
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open term.
2. Connect multimeter (ohms setting) leads to relay ter-
minals 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.
SERIAL NUMBER ABOVE 260000000
3
1
4
86
85
87A
87
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
4. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between termi-
nals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
30
2
1
5. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to machine wire har-
ness and install spray control enclosure faceplate.
Figure 12
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open term.
Rev. B
Electrical System
Page 2 -- 8
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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
transaxleturns, thesensor accurately senses themove-
ment 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.
2
1
Testing
6. Locate traction speed sensor on the transaxle as-
sembly. Disconnectthewireharnessconnector fromthe
traction speed sensor.
7. Remove cap screw and lock washer that secure
speed sensor to transaxle. Remove speed sensor from
transaxle.
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.
Figure 13
1. Transaxle assembly
2. Traction speed sensor
IMPORTANT: Incorrect jumper wire connections
during testing can damage the sensor.
1K ohm
resistor
9. Using a +12 VDC battery, a multimeter, a 1K ohm re-
sistor and appropriate jumper wires, connect the battery
and multimeter to the speed sensor using Figure 14 as
a guide.
--
12 VDC
+
10.Set multimeter to DC volts setting.
11.The multimeter should display verylow voltagewhen
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.
6
4
C B
A
12.After testing is complete, remove jumper wires, re-
sistor and multimeter leads from sensor connector.
3
5
13.Replace speed sensor if necessary.
1
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 har-
ness.
2
Figure 14
1. Speed sensor
2. Sensor tip
3. Sensor connector
4. Red striped wire
5. Gray striped wire
6. Black wire
Rev. B
Workman 200 Spray System
Page 2 -- 9
Electrical System
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Chapter 3
Spray System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Precautions Concerning Chemicals Used in
Regulating Valve Assembly (Serial Numbers
Above 310000000) . . . . . . . . . . . . . . . . . . . . . 27.1
Boom Valve Motor (Serial Numbers Below
Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Precautions for Removing or Adjusting Spray
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
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
(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
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
Rev. B
Workman 200 Spray System
Page 3 -- 1
Spray System
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Specificationsꢀ
Item
Description
Diaphragm Pump, 29 GPM
Spray Pump
Spray Pressure Relief Valve
Sprayer Tank
Poppet Style, 220 PSI Maximum
200 Gallon (757 Liter), Polyethylene
Suction Strainer
50 Mesh, Stainless Steel, Tank Mounted
(30 Mesh and 90 Mesh Optional)
Spray System
Workman 200 Spray Systemꢀ
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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:
4. Always wear protective clothing, chemical resistant
gloves, eye protection, and other personal protective
equipment as recommended by the chemical manufac-
turer.
1. Select the proper chemical for the job.
5. Properly dispose of chemical containers, unused
chemicals, and chemical solution.
2. Carefully read the directions printed on the chemical
manufacturer’s labels before handling chemicals. In-
structions on chemical manufacturer’s container labels
regarding mixing proportions should be read and strictly
followed.
3. Keep spray materialaway 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).
Precautions for Removing or Adjusting Spray System Components
1. Stop the vehicle and set the parking brake.
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).
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.
5. Make sure line pressure is relieved before loosening
any system component.
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 control 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
Rev. B
Workman 200 Spray System
Page 3 -- 3
Spray System
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Spray System Flow Diagram
SUCTION
PRESSURE
AGITATION
BOOM SUPPLY
FLOW DIRECTION
Workman 200 Spray System
Spray System Flow Diagram
Spray System
Workman 200 Spray System
Page 3 – 4
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Spray System Operationꢀ
The Workman 200 Spray System uses a positive dis-
placement 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 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 di-
rectly 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.
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.
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.
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.
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 5
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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.
Faulty diaphragm(s) in spray pump.
Fluid leaking from bottom of spray
pump.
Excessive suction hose vibration.
Suction screen in tank is plugged.
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 line is restricted.
Spray pressure is low.
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.
Diaphragm in turret body is leaking or damaged.
Nozzles on one spray boom leak
when boom is switched off.
Diaphragm in turret body is leaking or damaged.
Boom valve motor for affected boom not seating.
Vehicle clutch pedal is depressed.
Spray pump doesn’t rotate.
Key on spray pump shaft is sheared.
Auxiliary PTO not engaged or faulty.
Auxiliary PTO output shaft damaged.
PTO drive shaft damaged or missing.
Spray System
Page 3 -- 6
Workman 200 Spray System
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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.
Hoses on boom are pinched or kinked.
No spray output from one spray
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.
Workman 200 Spray System
Page 3 -- 7
Spray System
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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.
2
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components.
1
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).
3
Figure 2
1. Spray pump
2. Suction dampener
3. Suction hose
1
3
4
2
Figure 3
1. Spray pump
2. O–ring
3. Dampener housing
4. Diaphragm
Spray System
Workman 200 Spray System
Page 3 – 8
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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).
2
IMPORTANT: Any fluid in the pressure dampener
will include spray system chemicals so take neces-
sary precautions when working with the dampener.
Use appropriate protective equipment: protective
clothing, chemical resistant gloves, and eye protec-
tion.
1
If fluid is present when pressure in the dampener is
checked, the diaphragm in the pressure dampener is
damaged and should be replaced.
Figure 4
Dampener Service (Fig. 5)
1. Spray pump
2. Pressure dampener
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components.
4
5
1. Loosen and remove cap screws and nuts that secure
diaphragm between housings.
8
7
2. Remove diaphragm from dampener.
2
1
3. Replace diaphragm and reassemble dampener.
3
6
Figure 5
1. Spray pump
2. O–ring
3. Hex nut (12 used)
4. Rear housing
5. Diaphragm
6. Front housing
7. Cap screw (12 used)
8. Air valve
Workman 200 Spray System
Spray System
Page 3 – 9
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Spray Pump
11
10
9
8
Apply thread sealant
FRONT
RIGHT
7
Anti–seize
Lubricant
4
12
Loctite #242
13
16
6
14
5
3
2
1
28
17
27
16
15
13
26
25
24
18
Loctite #242
22
23
5
19
20
Apply thread sealant
21
Figure 6
1. Spray pump assembly
2. Elbow (pressure)
3. Gasket
4. Pressure tee fitting
5. O–ring
11. Pressure hose
20. Pump mount bracket
12. Flange head screw (4 used)
13. Pump drive shroud
14. Shroud bracket
15. Square key
21. Flange head screw (4 used)
22. Suction tee fitting
23. Suction dampener
24. Gasket
6. Pressure dampener
7. O–ring
16. Set screw
25. Hosebarb
17. PTO driveshaft
18. Flange nut (4 used)
19. Flange nut (4 used)
26. Nut
8. Hosebarb
27. Hose clamp
9. Nut
28. Suction hose
10. Hose clamp
Spray System
Workman 200 Spray System
Page 3 – 10
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Removal (Fig. 6)
3. Install elbow (pressure), pressure tee fitting, and
pressure dampener to pump outlet. Orientate elbow to-
ward right side of machine (Fig. 7).
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components.
4. Remove set screws (item 16) from PTO driveshaft.
Clean threads of set screws and set screw threads in dri-
veshaft.
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
5. Apply anti–seize lubricant to pump shaft. Position
square key in pump shaft and slide PTO driveshaft fully
onto pump shaft.
2. Loosen hose clamp that secures suction hose (item
28) to hosebarb (item 25). Pull suction hose from hose-
barb.
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.
3. Loosen hose clamp that secures pressure hose
(item 11) to hosebarb (item 8). Pull pressure hose from
hosebarb.
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.
4. Remove PTO driveshaft (item 17) from output shaft
of transaxle PTO assembly.
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.
5. Remove four (4) flange head screws and flange nuts
that secure pump assembly to pump mount bracket.
6. Remove pump assembly (with PTO driveshaft and
drive shrouds attached) from machine.
9. Attach PTO driveshaft to output shaft of transaxle
PTO assembly.
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.
10.Install pressure and suction hoses to correct barb fit-
tings. Secure hoses with hose clamps.
1
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 compo-
nents from pump using Figure 6 as a guide. Discard any
removed o–rings and gaskets.
Installation (Fig. 6)
2
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 fit-
ting, elbow (pressure), and suction tee fitting. Position
new o–rings and gaskets on suction and pressure fit-
tings that were removed during disassembly.
Figure 7
1. Elbow (pressure)
2. Suction hose
2. Install suction tee fitting and suction dampener to
pump inlet. Orientate tee toward right side of machine
(Fig. 7).
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 11
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Spray Pump Serviceꢀ
26
60 ft–lb
(81 N–m)
1
2
25
3
28
2
25
55 ft–lb
(75 N–m)
4
9
4
3
5
60 ft–lb
(81 N–m)
16
6
7
8
7
5
18
6
8
24
9
11
10
13
12
14
12
14
13
20
21
23
15
22
21
32 ft–lb
(43 N–m)
10
20
18
19
25 ft–lb
(34 N–m)
27
17
Figure 8
1. Valve chamber
11. Hex bolt
20. Connecting rod
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
12. Ball bearing (crankshaft)
13. Dust plate
21. Ball bearing (connecting rod)
22. Grease fitting
14. Pump casing
23. Crankshaft
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
24. Hex nut (5 used)
25. Valve (outlet position)
26. Hex bolt (2 used)
27. Washer (2 used)
28. Poly o–ring
19. Hex nut
Spray System
Workman 200 Spray Systemꢀ
Page 3 – 12
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Disassembly (Fig. 8)
D. Position dust plate and felt seal on both ends of
crankshaft.
IMPORTANT: Make sure to remove and neutralize
chemicals from pump before disassembly. Wear
protective clothing, chemical resistant gloves, and
eye protection during pump repair.
IMPORTANT: If connecting rod position is incor-
rect, 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).
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.
2. Place second pump casing onto assembly. Pump
casing surfaces should mate together.
1. Remove two (2) hex bolts that retain valve chamber
to pump. Separate valve chamber from pump.
3. Install three (3) shorter (30 mm) bolts and two (2) lon-
ger (55 mm) bolts with washers into pump casing as-
sembly (Fig. 10). Thread hex nuts onto bolts but do not
fully tighten. Check that crankshaft turns freely.
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.
4. Remove hex bolt, washer, nylon washer, diaphragm,
and diaphragm back disc from each connecting rod.
Discard diaphragms.
2
1
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 con-
dition of bearings on crankshaft. If bearings require re-
placement, remove and disassemble crankshaft:
Figure 9
1. Closest connecting rod (to right side)
2. Rear connecting rod (to left side)
A. Remove crankshaft assembly from pump casing.
B. Slide felt seal and dust plate from both ends of
crankshaft.
1
C. Loosen hex bolt and hex nut that secure connect-
ing rods to crankshaft. Slide connecting rods from
crankshaft. Press ball bearings from crankshaft.
1
Assembly (Fig. 8)
1. If disassembled, reassemble crankshaft.
1
2
A. Hand pack new bearings with #2 general purpose
lithium base grease.
2
B. Pressing on bearing inner race, install two con-
necting rod and two crankshaft ball bearings onto
crankshaft.
Figure 10
1. Hex bolt (30 mm long)
2. Hex bolt (55 mm long)
C. Slide connecting rods onto connecting rod bear-
ings. 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
Spray Systemꢀ
Page 3 – 13
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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).
2
1
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.
Figure 11
1. Diaphragm
2. Connecting rod
1
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).
3
2
2
Figure 12
1. Inlet (suction)
2. Inlet valve
3. Outlet valve
Spray System
Workman 200 Spray Systemꢀ
Page 3 – 14
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This page is intentionally blank.ꢀ
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 15
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Agitation Control Valve
8
A
FRONT
RIGHT
1
4
4
2
7
6
3
5
A
8
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
Figure 13
1. Agitation control valve
2. Fork
3. Hosebarb/hose (to agitation nozzles)
4. O–ring
5. O–ring
7. Connector
8. Pump suction hose
6. Hosebarb/hose (from spray control)
Spray System
Workman 200 Spray System
Page 3 – 16
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Removal (Fig. 13)
4
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
3
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
1
2
2. Label disconnected hoses for proper installation af-
ter repairs are completed.
3. Remove agitation control valve using Figures 13 and
14 as guides.
Figure 14
1. Agitation control valve
2. Control bypass hose
3. Suction hose (from tank)
4. Suction hose (to pump)
4. Disassemble agitation valve as required (Fig 15).
Installation (Fig. 13)
9
10
11
NOTE: Coat all o–rings with vegetable oil before instal-
7
lation to reduce the chance of damage during assembly.
4
8
12
13
3
1. Assemble agitation control valve (Fig 15). Align ar-
row on valve handle with large hole in valve ball during
assembly (Fig. 16).
15
14
3
4
6
2
2. Install agitation valve using Figures 13 and 14 as
guides.
5
2
1
3. Check spray system for leaks.
7
5
16
Figure 15
1. Valve housing
2. Ball seat
9. Screw
10. Button
11. Valve handle
12. Disc
13. O–ring
14. Spindle
15. Valve ball
16. Lock nut (4 used)
3. O–ring
4. O–ring
5. Washer (8 used)
6. Cap screw (4 used)
7. End cover
8. Screw (4 used)
2
1
Figure 16
1. Valve handle arrow
2. Valve ball large hole
Workman 200 Spray System
Spray Systemꢀ
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Agitation Nozzles (Tank mounted)
FRONT
RIGHT
6
7
8
C
4
15
17
9
11
2
C
A
10
12
9
12
16
B
11
7
4
13
14
8
6
18
16
4
1
11
6
19
20
B
23
2
4
A
5
22
8
3
10
7
11
21
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
Figure 17
1. Agitation supply
2. Tee fitting
3. Hosebarb/hose
4. O–ring
9. Hosebarb
10. Agitation nozzle
11. Nut
12. Fork (12 used)
13. Hosebarb/hose
14. Hosebarb/hose
15. Hosebarb/hose
16. Agitation nozzle
17. Hosebarb/hose
18. Tee fitting
19. Nipple
20. Adapter
5. Connector
6. Bulkhead nut
7. Gasket
21. O–ring
22. Elbow
23. Hosebarb/hose
8. Bulkhead fitting
Spray System
Workman 200 Spray System
Page 3 – 18
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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.
NOTE: Coat all o–rings with vegetable oil before instal-
lation 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.
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
2. Check spray system for leaks.
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.
Workman 200 Spray System
Spray Systemꢀ
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Pressure Relief Valve (Tank Mounted)
FRONT
RIGHT
5
6
A
8
7
4
3
A
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
1
2
Figure 18
1. Hosebarb/hose
2. Ringnut
3. Pressure relief valve
4. Gasket
7. Fork
5. Hosebarb/hose
6. O–ring
8. Hosebarb/hose (from spray pump)
Spray System
Workman 200 Spray System
Page 3 – 20
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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.
2
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
2. Drain spray tank (see Operator’s Manual).
3. Label disconnected hoses for proper installation af-
ter repairs are completed.
1
3
4. Remove pressure relief valve from spray tank using
Figure 18 and 19 as guides. Discard all removed o–rings
and gaskets.
Figure 19
1. Hose to pressure relief
2. Hose from spray pump
3. Control supply hose
5. Disassemble pressure relief valve using Figure 20
as a guide.
4
Assembly (Fig. 18)
3
2
NOTE: Coat all o–rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
1
1. Assemble and install pressure relief valve using Fig-
ure 18, 19 and 20 as guides. Replace all removed o–
rings and gaskets.
5
2. Check spray system for leaks.
Figure 20
1. Nut
2. Seat
3. Spring
4. Cone
5. Relief valve housing
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 21
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Spray Control (Serial Numbers Below 290999999)
17
19
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
18
20
39
FRONT
RIGHT
16
15
21
14
71 in--lb
(8 N--m)
11
22
8
7
7
2
23
7
1
12
10
25
24
10
9
71 in--lb
(8 N--m)
6
5
4
3
13
41
5
40
26
3
1
29
7
7
31
30
29
29
29
7
28
30
32
29
10
12
35
32
34
27
32
32
32
7
36
34
38
32
37
12
33
35
Figure 21
15. Rate control motor
16. Screw (4 used)
17. Screw
1. Nut
29. Fork
2. Threaded rod
3. Washer
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)
4. Bushing
18. O--ring
5. O--ring
19. Lock washer
20. Handgrip
21. Flowmeter assembly
22. Flowmeter housing
6. Cap
7. O--ring
8. Tee piece
9. Hose: control supply (1”)
10. Hose clamp
11. Fork
23. Hose: control bypass (1”)
24. Hosebarb
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
25. O--ring
12. Screw
26. End cap
27. Hose: boom bypass (1”)
28. Hosebarb
13. Control valve bracket
14. Rate control valve housing
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 hold-
er located in the motor harness.
Rev. B
Spray System
Page 3 -- 22
Workman 200 Spray System
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IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
4
3
1
5
Removal (Fig. 21)
2
1. Park machine on a level surface, stop engine, en-
gage 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.
6
3. Unplug electrical connectors from rate control motor,
flowmeter, and three (3) boom valve motors from ma-
chine electrical harness.
Figure 22
1. Rate control motor
2. Flowmeter
4. Center boom valve motor
5. RH boom valve motor
6. Valve mounting bar
4. Remove pressure gauge tube from coupler on back
of flowmeter housing (Fig. 23).
3. LH boom valve motor
5. Remove three (3) flange head screws that secure
spray control assembly to valve mounting bar. Remove
spray control assembly from machine.
2
3
6. Remove spray control components as required us-
ing Figure 21 as a guide. Discard all removed o–rings
and gaskets.
Assembly (Fig. 21)
1
NOTE: Coat all o–rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
1. Install spray control components using Figure 21 as
a guide. Replace all removed o–rings and gaskets.
Figure 23
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).
1. Flowmeter
3. Coupler
2. Pressure gauge tube
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 as-
sembly. 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.
Workman 200 Spray System
Spray Systemꢀ
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Spray Control (Serial Numbers Above 310000000)
10
FRONT
RIGHT
9
11
5
12
8
2
6
1
7
5
6
13
13
14
15
4
17
16
8
3
18
19
12
20
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
Figure 23.1
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
8. Clamp (2 used)
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
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
Rev. B
Spray System
Page 3 -- 23.1
Workman 200 Spray System
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Disassembly (Fig. 23.1)
3. Using labels placed during disassembly, install
hoses to correct locations on spray control assembly.
Secure hoses with hose clamps.
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.
4. Install pressure gauge tube (item 10) to coupler on
pressure gauge port on right side of boom valve man-
ifold assembly.
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
5. Using labels placed during disassembly, secure wire
harness connectors to regulating valve, flowmeter and
three (3) boom valve motors.
2. Label all spray control assembly hoses for proper
installation after repairs are completed. Loosen hose
clamps and disconnect hoses from spray control.
6. Operate spray system and check for leaks. Repair all
leaks before returning the sprayer to service.
3. Label all wire harness leads for assembly purposes.
Disconnect wire harness connectors from regulating
valve, flowmeter and three (3) boom valve motors.
3
1
2
4. Remove pressure gauge tube (item 10) from coupler
on pressure gauge port on right side of boom valve man-
ifold assembly.
5. Support spray control assembly to prevent it from fal-
ling.
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 ma-
chine.
Figure 23.2
1. Boom valve manifold
2. Flowmeter
3. Regulating valve
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.
NOTE ARROW
DIRECTION
TO BOOM
VALVE
MANIFOLD
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 dur-
ing assembly.
1. Assemble spray control using Figure 23.1 as a
guide. Replace all removed gaskets. Make sure that ar-
row on flowmeter body points toward boom valve man-
ifold assembly (Fig. 23.3).
FROM
REGULATING
VALVE
2. Position spray control assembly to valve mounting
bar and secure with eight (8) flange head screws, flat
washers and flange nuts.
Figure 23.3
Rev. B
Workman 200 Spray System
Page 3 -- 23.2
Spray System
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Flowmeter (Serial Numbers Below 290999999)
24
23
21
18
22
20
FRONT
14
RIGHT
11
8
19
7
6
7
2
17
7
12
10
1
16
15
13
71 in--lb
(8 N--m)
10
5
4
3
28
9
71 in--lb
(8 N--m)
7
5
25
3
27
1
26
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
Figure 24
1. Nut
11. Fork
20. O--ring
2. Threaded rod
3. Washer
12. Screw
21. Flowmeter rotor shaft
22. Flowmeter rotor
23. Flow sensor
13. Control valve bracket
14. Rate control motor/housing
15. O--ring
4. Bushing
5. O--ring
24. Nut
25. End cap
26. LH boom control motor
27. Center boom control motor
28. RH boom control motor
6. Cover
16. Hosebarb
7. O--ring
17. Hose: control bypass (1”)
18. Coupler (pressure gauge)
19. Flowmeter housing
8. Tee piece
9. Hose: control supply (1”)
10. Hose clamp
Rev. B
Spray System
Page 3 -- 24
Workman 200 Spray System
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Removal and Inspection (Fig. 24)
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
1
2
1. Park machine on a level surface, stop engine, en-
gage 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.
Figure 25
1. Rotor shaft
2. Rotor
4. Clean rotor, rotor shaft, and flowmeter sensor if re-
quired (see Operator’s Manual).
4
1
3
5
5. With the flow sensor harness connected to the ma-
chine 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.
2
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 mag-
net poles pass the sensor, replace the flow sensor.
Figure 26
1. Rate control motor
2. Flowmeter
4. Center boom valve motor
5. RH boom valve motor
3. LH boom valve motor
7. If necessary, remove flowmeter housing using Fig-
ures 24 and 26 as guides (also see Spray Control) in this
section). Discard all removed o–rings and gaskets.
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
Spray Systemꢀ
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Flowmeter (Serial Numbers Above 310000000)
NOTE ARROW
DIRECTION
NOTCH
7
9
NOTCH
8
5
4
5
1
2
3
6
THREAD
SEALANT
Figure 26.1
1. Flowmeter body
2. Rotor/magnet assembly
3. Upstream hub with bearing
4. Downstream hub
5. Retaining ring (2 used)
6. Turbine stud with bearing
7. Sensor assembly
8. Cable clamp
9. Screw
Rev. B
Spray System
Page 3 -- 25.1
Workman 200 Spray System
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Removal and Inspection (Fig. 26.1)
3
1
2
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
1. Remove spray control assembly from machine and
separate flowmeter from spray control (see Spray Con-
trol Assembly (Serial Numbers Above 310000000) Re-
moval in this section).
2. Disassemble flowmeter as required using Figures
26.1 and 26.3 as guides.
Figure 26.2
1. Boom valve manifold
2. Flowmeter
3. Regulating valve
3. Clean rotor (item 2), both hubs (items 3 and 4) and
flowmeter body to remove any metal filings, spray
chemicals or other materials.
Assembly (Fig. 26.1)
6
1. Assemble flowmeter using Figures 26.1 and 26.3 as
guides. Check the following items during flowmeter as-
sembly.
1
A. If turbine stud (item 6) was removed from up-
stream hub, apply thread sealant to threads of stud
before installation.
5
2
2
3
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.
4
Figure 26.3
C. When installing hubs (items 3 and 4) into hous-
ing, make sure to align locating notch on each hub
with boss in housing bore.
1. Flowmeter body
2. Retaining ring
3. Upstream hub
4. Rotor
5. Downstream hub
6. Sensor
D. If sensor (item 7) was removed from flowmeter
body, thread sensor into housing so that it lightly bot-
toms 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.
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).
Rev. B
Workman 200 Spray System
Page 3 -- 25.2
Spray System
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Rate Control Motor (Serial Numbers Below 290999999)
1
2
3
1
4
5
6
7
8
11
12
9
13
14
10
Figure 27
6. Rate control motor assembly
1. Phillips head screw (5 used)
2. Lock washer
11. O--ring
12. Cone
13. Control valve
14. Seal
7. Gasket
3. Hand grip
8. Phillips head screw (4 used)
9. Rate valve spindle section
10. Rate control valve housing
4. O--ring
5. Phillips head screw (4 used)
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.
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 mo-
tor fully in a clockwise direction.
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.
B. Unplug rate control motor electrical connector
from machine electrical harness.
Disassembly and Inspection (Fig. 27)
C. Loosen four (4) phillips head screws (item 5)
evenly to allow removal of the rate control motor.
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
D. The inside of motor housing should be free of ex-
cessive moisture, corrosion, and dirt.
Rev. B
Spray System
Page 3 -- 26
Workman 200 Spray System
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2. Remove four (4) phillips head screws (item 8) that
secure spindle section to housing. Remove spindle sec-
tion.
4
1
3
5
3. Locate, remove, and discard o–ring (item 11) and
seal (item 14).
2
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 re-
moving 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.
Figure 28
1. Rate control motor
2. Flowmeter
3. LH boom valve motor
4. Center boom valve motor
5. RH boom valve motor
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.
1. If removed, install rate control valve housing to ma-
chine (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. Se-
cure 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 hous-
ing. 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
Spray Systemꢀ
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Regulating Valve Assembly (Serial Numbers Above 310000000)
10
7
1
3
12
4
11
7
5
10
9
12
8
6
13
14
2
9
11
Figure 28.1
1. Regulating valve motor
2. Hose barb
3. Flange
6. Elbow fitting
7. Mounting bracket (2 used)
8. Fork
9. Washer (4 used)
10. Cap screw (4 used)
11. Lock nut (4 used)
12. O--ring (2 used)
13. O--ring
4. Adaptor
14. O--ring
5. Flynut
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.
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.
NOTE: The regulating valve affects flow to all spray
booms. Therefore, a problem with the regulating valve
will affect all booms and nozzles.
3. To remove valve motor cover from regulating valve
motor (Fig. 28.3):
Removal and Inspection (Fig. 28.1)
A. Loosen three (3) screws that secure valve motor
cover to valve motor assembly.
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
B. Carefully lift and rotate cover from valve motor.
C. Unplug wire connections and remove cover.
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).
D. Make sure that screws that secure valve motor
are tight.
Rev. B
Spray System
Page 3 -- 27.1
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Assembly (Fig. 28.1)
3
1
2
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 color 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.
Figure 28.2
NOTE: Coat all O--rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
1. Boom valve manifold
2. Flowmeter
3. Regulating valve
2. Assemble regulating valve assembly using Figure
28.1 as a guide.
5
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).
3
Piston Valve Service (Fig. 28.4)
1. Remove hosebarb from bottom of valve motor to al-
low access to piston valve.
3
4
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 dis-
assembly. 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.
1
2
Figure 28.3
1. Valve motor assembly
2. Valve motor cover
3. Wire connector
4. Socket screw (4 used)
5. Phillips screw (2 used)
3. Use 3mm allen wrench to loosen and remove piston
valve assembly from valve motor. Locate and retrieve
spring from above piston valve.
5
4. Inspectseals 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 dam-
aged, replace piston valve assembly. The piston valve
is not designed to be disassembled.
4
3
5. Apply silicone grease to seals on piston valve as-
sembly.
6. Position spring into valve motor housing. Use 3mm
allen wrench to secure piston valve assembly to valve
motor.
2
1
7. Secure hosebarb to bottom of valve motor.
Figure 28.4
1. Valve motor assembly
2. Piston valve assembly
3. Valve seal
4. Spring
5. Valve motor cover
Rev. B
Workman 200 Spray System
Page 3 -- 27.2
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Boom Valve Motor (Serial Numbers Below 290999999)
9
8
1
10
4
11
12
5
13
14
7
28
15
6
29
2
16
17
19
21
23
18
20
3
4
30
31
22
32
24
26
25
33
27
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
12. Spring seat
13. O--ring
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
14. Spindle housing
15. Phillips head screw (4 used)
16. O--ring
6. Lock washer
7. Hand grip
17. O--ring
18. Flat washer
19. Seat outer o--ring
20. Seat
8. Roller
9. Roller pin
10. Spindle
21. Seat inner o--ring
22. Seat base
11. Spring
The Workman 200 Sprayer (serial numbers below
290999999) uses three boom valve motor assemblies
to control the spray booms. Each boom valve motor as-
sembly 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).
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.
Disassembly and Inspection (Fig. 29)
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 sec-
tion.
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant 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).
Rev. B
Spray System
Page 3 -- 28
Workman 200 Spray System
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4. Remove rear housing cover from boom valve motor
to inspect motor components.
4
1
3
5
A. Cam should be tight on shaft. Cam surface
should be free of wear and/or scoring.
2
B. The inside of motor housing should be free of ex-
cessive 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.
Figure 30
1. Rate control motor
2. Flowmeter
3. LH boom valve motor
4. Center boom valve motor
5. RH boom valve motor
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.
1
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.
3
6. If leakage occurs from balancing valve knob at bot-
tom of boom valve manifold (Fig. 32):
2
Figure 31
A. Carefully remove roll pin that secures balancing
valve to knob.
1. Spindle roller
2. Cone
3. Seat
B. Remove knob from manifold. Remove and dis-
card o–ring.
C. Inspect seating surfaces of manifold and balanc-
ing valve. Clean or replace components as needed.
1
Assembly (Fig. 29)
4
NOTE: Coat all o–rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
3
1. Replace all removed o–rings.
2. If boom valve manifold was disassembled (Fig. 32):
2
A. Install o–ring, balancing valve, and knob to man-
ifold.
Figure 32
1. Boom valve manifold
2. Balancing valve
3. Balancing valve knob
4. Roll pin
B. Secure balancing valve to knob by carefully
installing roll pin.
Workman 200 Spray System
Spray Systemꢀ
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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).
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.
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).
7. Assemble spray control assembly. Install spray con-
trol to machine (see Spray Control in this section).
8. Operate spray system and check for leaks.
5. Replace rear housing to boom valve motor.
Spray System
Workman 200 Spray Systemꢀ
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This page is intentionally blank.ꢀ
Workman 200 Spray System
Spray Systemꢀ
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Boom Valve Manifold Assembly (Serial Numbers Above 310000000)
3
1
17
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
7
9
1
1
12
16
10
13
12
5
12
7
11
6
12
14
13
8
18
2
11
16
15
4
18
19
Figure 32.1
1. Boom valve motor (3 used)
2. Hose barb (3 used)
3. Pressure gauge port
4. Flange
8. Balancing valve assembly
9. Flange
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
10. Fork (3 used)
11. Fork (6 used)
12. O--ring (4 used)
13. O--ring (4 used)
5. Flynut
6. Elbow fitting
7. Mounting bracket (2 used)
The sprayer system for serial numbers above
310000000 uses three (3) boom valve motor assem-
blies to control the spray booms. Each boom valve mo-
tor assembly includes a motor section and a balancing
valve assembly.
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 re-
moved O--rings and gaskets.
The boom control switches on the operator spray con-
sole are used to energize the boom valve motors and
opentheboomvalves. Theopenboomvalvesallowsys-
tem flow to reach the appropriate boom section (right,
center or left).
NOTE: There are limited replacement parts available
for boom valve motor assembly. Check your parts cata-
log for parts that are available.
Disassembly (Fig. 32.1)
3. To remove cover from boom valve (Fig. 32.3):
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
A. Loosen three (3) screws that secure valve motor
cover to valve motor assembly.
B. Carefully lift and rotate cover from valve motor.
Rev. B
Spray System
Page 3 -- 31.1
Workman 200 Spray System
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C. Unplug wire connections and remove cover.
3
1
2
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 color is the same as the motor wire
color when connecting wires.
B. Carefully rotate cover onto valve motor taking
care to not damage wires.
Figure 32.2
1. Boom valve manifold
2. Flowmeter
3. Regulating valve
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.
5
3
2. Assemble boom valve manifold assembly using Fig-
ure 32.1 as a guide.
3. Attach boom valve manifold assembly to spray con-
trol and then install spray control assembly to machine
(see Spray Control Assembly (Serial Numbers Above
310000000) Installation in this section).
3
Piston Valve Service (Fig. 32.4)
4
1
1. Remove hosebarb from bottom of valve motor to al-
low access to piston valve.
2
Figure 32.3
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 dis-
assembly. 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.
1. Valve motor assembly
2. Valve motor cover
3. Wire connector
4. Socket screw (4 used)
5. Phillips screw (2 used)
5
3. Use 3mm allen wrench to loosen and remove piston
valve assembly from valve motor. Locate and retrieve
spring from above piston valve.
4
3
4. Inspectseals 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 dam-
aged, replace piston valve assembly. The piston valve
is not designed to be disassembled.
5. Apply silicone grease to seals on piston valve as-
sembly.
1
2
6. Position spring into valve motor housing. Use 3mm
allen wrench to secure piston valve assembly to valve
motor.
Figure 32.4
1. Valve motor assembly
2. Piston valve assembly
3. Valve seal
4. Spring
5. Valve motor cover
7. Secure hosebarb to bottom of valve motor.
Rev. B
Workman 200 Spray System
Page 3 -- 31.2
Spray System
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Boom Bypass
1
8
5
FRONT
RIGHT
2
3
A
4
6
A
5
7
NOTE: ARROW SHOWS FLUID
FLOW DIRECTION
Figure 33
1. Boom bypass elbow
2. O–ring
3. Bulkhead fitting
4. Gasket
5. Fork
6. Bulkhead nut
7. Hosebarb/hose
8. Hosebarb/hose
Spray System
Workman 200 Spray System
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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.
2
1
1. Park machine on a level surface, stop engine, en-
gage 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)
Figure 34
1. Boom bypass elbow
2. Tank suction tube
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.
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 33
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Tank Suction
1
2
18
17
FRONT
3
RIGHT
4
5
6
8
16
7
9
10
11
13
12
14
15
NOTE: ARROW SHOWS FLUID
FLOW DIRECTION
Figure 35
1. Suction hosebarb
2. O–ring
7. Expansion pin
13. Suction hose
14. Suction tube
15. Suction tube foot
16. Spray tank
17. Hose clamp
18. Suction hose (1 1/2”)
8. Bulkhead gasket
9. Bulkhead nut
10. O–ring
3. Screen vane
4. Suction screen
5. Fork
11. Hosebarb
6. Filter housing
12. Hose clamp
Spray System
Workman 200 Spray System
Page 3 – 34
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NOTE: If suction tube in tank develops an air leak, spray
performance will diminish when tank level reaches the
leak.
3
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.
2
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
1
2. Remove suction strainer from spray tank (see Oper-
ator’s Manual).
Figure 36
1. Suction strainer
2. Tank drain
3. Tank lid
3. Raise tank lid and remove strainer basket to gain ac-
cess 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.
1
Assembly (Fig. 35)
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
2. Check spray tank for leaks.
Figure 37
1. Tank suction tube
2. Tank drain
Workman 200 Spray System
Spray Systemꢀ
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Tank Drain
FRONT
11
RIGHT
1
2
3
4
5
6
7
8
9
10
Figure 38
1. Drain handle
2. Nut
5. Gasket
6. Ringnut
7. Chain
9. Hose clamp
10. Drain hose
11. Spray tank
3. O–ring
4. Bulkhead
8. Drain assembly
Spray System
Workman 200 Spray System
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Disassembly (Fig. 38)
3
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, en-
gage parking brake, and remove key from the ignition
switch.
1
2. Drain spray tank (see Operator’s Manual).
3. Raise tank lid and remove strainer basket to gain ac-
cess to chain (item 7) that connects drain handle (item
1) to plunger in drain assembly (item 8). Disconnect
chain from drain handle.
2
Figure 39
1. Tank drain
2. Suction strainer
3. Tank lid
4. If necessary, remove drain handle and bulkhead us-
ing Figure 38 as a guide.
5. If necessary, remove drain assembly from tank:
2
A. Loosen hose clamp and slide drain hose from
drain assembly hosebarb.
4
1
B. Remove fork from drain assembly to allow hose-
barb to be removed from drain assembly.
5
3
7
C. Remove bulkhead nut that secures drain assem-
bly to spray tank.
6
D. Lift drain assembly from bottom of tank.
9
6. Disassemble drain assembly using Figure 40 as a
guide.
8
11
7. Discard all removed o–rings and gaskets.
12
10
Assembly (Fig. 38)
NOTE: Coat all o–rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
13
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 to-
ward the rear of the spray tank. Make sure that clear-
ance exists between drain assembly and sprayer frame.
Figure 40
1. Adapter
2. Plunger holder
3. Spring
8. Drain bulkhead
9. Fork
10. Gasket
4. Drain plunger
5. O–ring
6. Drain seat
7. O–ring
11. Bulkhead nut
12. O–ring
13. Hosebarb
3. Check spray tank for leaks.
Workman 200 Spray System
Spray System
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Turret Bodies
6
7
3
8
3
5
4
2
9
3
CENTER
BOOM
SUPPLY
LEFT
RIGHT
BOOM
SUPPLY
BOOM
SUPPLY
1
5
4
4
4
1
4
5
4
4
4
5
Figure 41
4. Turret body (w/double hose barb)
5. Turret body (w/single hose barb)
6. Single hose barb (3 used)
o
1. Turret body (w/90 elbow)
7. Double hose barb (7 used)
8. Turret body clamp
o
2. 90 elbow (1 used)
o
3. Screw
9. Hose barb (for 90 elbow)
Removal (Fig. 41)
Installation (Fig. 41)
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
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.
1. Park machine on a level surface, stop engine, en-
gage parking brake, and remove key from the ignition
switch.
2. Loosen hose clamp(s) and remove supply hose(s)
from turret body.
2. Install supply hose(s) to turret body. Tighten hose
clamp(s).
3. Remove screw that secures turret body clamp to
spray boom. Separate clamp halves and remove turret
body from machine.
Spray System
Workman 200 Spray System
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Turret Body Service
Disassembly (Fig. 42)
1
1. Pull e–clip from body and slide plug with o–ring from
body.
7
18
17
5
2
2. Disassemble turret body using Figure 42 as a guide.
3
6
4
3. Discard all removed seals, gaskets, o–rings, and di-
aphragms.
8
9
10
Assembly (Fig. 42)
NOTE: Coat all o–rings with vegetable oil before instal-
lation to reduce the chance of damage during assembly.
6
16
13
14
11
1. Replace all removed seals, gaskets, o–rings, and di-
aphragms.
15
12
2. Assemble turret body using Figure 42 as a guide.
Figure 42
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).
1. Upper clamp
2. O–ring
3. Pivot pin
4. Body
5. E–clip
10. Plug
11. Nozzle
12. Nozzle cap
13. O–ring
14. Seal
15. Screw
16. End cap
17. Diaphragm
18. Hose barb
B. Make sure to align notch on plug (item 10) with
groove in body (item 4) as plug is installed.
6. Gasket (3 used)
7. Dust cap (2 used)
8. Turret
C. Install e–clip (item 5) into body to secure assem-
bly.
9. O–ring
1
3
2
2
Figure 43
1. Body
2. Detent post
3. Detent groove
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 39
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Boom Frame Breakaway Pivot Assembly (Serial Numbers Below 260000000)
6
5
7
4
3
8
9
2
1
10
10
16
12
15
11
6
14
11
18
13
17
19
20
12
Figure 44
1. Hinge
8. Carriage screw
9. Flat washer
15. Cap screw
2. Breakaway pivot
3. Spring
16. Boom support
10. Cotter pin
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)
4. Washer
11. Clevis pin
12. Clevis pin
5. Roll pin
6. Hex nut
13. Main boom frame
14. Breakaway pivot assembly
7. Support bracket
Rev. A
Spray System
Page 3 -- 40
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Disassembly (Fig. 44)
2
1. Park machine on a level surface, lower booms, stop
engine, engage parking brake, and remove key from the
ignition switch.
3
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.
1
4
CAUTIONꢀ
Figure 45
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.
1. Breakaway pivot
2. Support bracket
3. Boom support
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.
1
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
2. Lubricate grease fitting on breakaway pivot after as-
sembly is complete (see Operator’s Manual).
Figure 46
1. Roll pin
2. Spring
Workman 200 Spray System
Spray Systemꢀ
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Boom Hinge (Serial Numbers Above 260000000)
16
8
19
15
9
18
17
FRONT
RIGHT
10
20
14
3
1
4
12
2
13
7
11
10
9
5
8
6
Figure 47
1. Hinge (2 used per boom)
8. Lock nut
15. Flange nut
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)
9. Cap screw
16. Boom frame
10. Flat washer
11. Pivot bracket
12. Bushing (2 used per pivot bracket)
13. Flange head screw
14. Pivot pin
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)
6. Tee fitting
7. Flange hd screw (4 used per hinge)
Disassembly (Fig. 47)
4. Loosen two (2) cap screws (item 9) and lock nuts
(item 8) to allow breakaway springs (item 18) to fully ex-
tend.
IMPORTANT: Make sure to remove and neutralize
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves, and eye protection during repair.
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 (Ma-
chines with Serial Numbers Above 260000000) in this
section).
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.
6. Clean all removed components. If pivot bracket was
removed, inspect bushings and pivot pin for damage or
wear.
3. Support spray boom to prevent it from falling.
Rev. A
Spray System
Page 3 -- 42
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Assembly (Fig. 47)
2
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).
UP
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.
Figure 48
1. Rubber boot
2. Rib
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 wash-
ers (item 10) and hinges. Place tube (item 17), break-
away 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.
1.560”
(39.6 mm)
5. Tighten lock nuts so there is 1.560” (39.6 mm) be-
tween the face of the spring retainer and the hinge cast-
ing (Fig. 49).
6. Connect supply hose to tee fitting on spray boom and
secure with hose clamp.
7. Lubricate grease fittings on boom hinge (see Opera-
tor’s Manual).
Figure 49
Workman 200 Spray System
Spray Systemꢀ
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Boom Actuator (Optional) (Serial Numbers Below 260000000)
5
FRONT
RIGHT
5
1
2
3
4
1
3
2
Figure 50
3. Boom actuator
4. Wire harness
1. Cotter pin
2. Clevis pin
5. Adjustable clevis
Removal (Fig. 50)
Installation (Fig. 50)
1. Park machine on a level surface, lower booms, stop
engine, engage parking brake, and remove key from the
ignition switch.
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.
2. Label actuator electrical leads to ease reassembly.
Unplug boom actuator connector wires from machine
harness.
3. Plug actuator connector wires into machine harness.
Make sure that operator switches engage correct actua-
tor.
3. Support boom to prevent it from falling. Remove cot-
ter pins and clevis pins that attach boom actuator to cen-
ter and side boom.
A. Left side actuator connector has orange and blue
wires.
4. Pull boom actuator from machine.
B. Right side actuator connector has yellow and
green wires.
Rev. A
Spray System
Page 3 -- 44
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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 cle-
vis.
2. Fully raise side boom with the boom actuator. The
boom actuator should fully extend and ratchet.
4
2
3
3. With the boom actuator at full extension, the break-
away pivot gusset should just touch the center boom
frame slot (Fig. 52).
1
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 cle-
vis adjustment.
Figure 51
1. Boom actuator
2. Adjustable clevis
3. Jam nut
4. End nut
1
3
2
Figure 52
1. Breakaway pivot gusset
2. Boom frame slot
3. Boom actuator
Workman 200 Spray System
Spray Systemꢀ
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Boom Actuator Service (Serial Numbers Below 260000000)
20
18
70 in--lb
(7.9 N--m)
15
16
14
12
11
19
9
10
20 in--lb
(2.3 N--m)
7
6
4
1
17
70 in--lb
(7.9 N--m)
13
8
3
5
3
2
Figure 53
1. Screw
2. Rear housing
3. Washer
4. Woodruff key
5. Clutch
6. Thin washer
7. Intermediate gear
8. Thick washer
9. Hex nut (2 used)
10. Motor gear
15. Motor assembly
16. Ball screw and brake assembly
17. Washer head screw (4 used)
18. Cover tube
11. Housing gasket
12. Front housing
13. Cover tube gasket
14. Motor seal
19. O--ring
20. O--ring
Rev. A
Spray System
Page 3 -- 46
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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.
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).
2. Slide thin washer, intermediate gear, and thick wash-
er from front housing support pin.
3. Install new o–rings into rear of cover tube. Slide cov-
er tube gasket and cover tube over ball screw.
3. In order, remove washer, clutch, woodruff key, and
second washer from ball screw shaft.
4. Place washer on ball screw shaft. Position woodruff
key and then slide clutch and second washer onto shaft.
4. Pull cover tube from front housing. Remove cover
tube gasket.
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.
5. Loosen and remove two (2) hex nuts that secure mo-
tor to front housing. Slide motor, motor gear, and motor
seal from front housing.
6. Position housing gasket to front housing. Slide rear
housing over gears.
6. Remove ball screw and brake assembly from front
housing.
7. Secure rear housing:
7. Clean actuator components. Replace worn or dam-
aged parts.
A. Thread one (1) screw (item 1) through rear hous-
ing and into front housing.
8. Discard and replace all removed gaskets and o–
rings.
B. Install four (4) washer head screws through cover
tube.
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
Spray Systemꢀ
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Boom Actuator (Serial Numbers Above 260000000)
1
2
12
11
9
10
8
7
6
4
3
5
Figure 54
1. Boom actuator (2 used)
2. Carriage screw (4 used)
3. Boom frame
5. Lock nut (4 used)
9. Clevis strap (2 used)
6. Flange nut (2 used)
7. Flange head screw (2 used)
8. Pivot pin (2 used)
10. Boom pivot bracket
11. Clevis pin (2 used)
12. Cotter pin (2 used)
4. Washer plate
Rev. A
Spray System
Page 3 -- 48
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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.
1. Position boom actuator to boom frame and boom
pivot bracket.
2. Secure actuator to boom pivot bracket with clevis pin
and cotter pin.
2. Disconnect boom actuator from machine wire har-
ness.
3. Secure actuator to clevis strap on boom frame with
pivot pin.
3. Remove pivot pin (item 8) that secures actuator to
clevis strap (item 9) on boom frame.
4. Connect boom actuator to machine wire harness.
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.
Workman 200 Spray System
Spray Systemꢀ
Page 3 – 49 Rev. A
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Boom Actuator Service (Serial Numbers Above 260000000)
IMPORTANT: Do not dismantle, repair or modify the
boom actuator. Internal components are not avail-
able for the actuator. If an actuator is damaged or
worn, replace actuator.
Actuator Air Bleeding
If actuator freeplay is excessive, air bleeding of the ac-
tuator should be performed using the following proce-
dure:
1. Thoroughly clean the exterior of the actuator to pre-
vent contaminates from entering the actuator.
CAUTION
During and after operation, the actuator may be
very hot. To avoid possible burns, allow the ac-
tuator to cool before working on it.
2. Make sure that the actuator cylinder is fully retracted.
IMPORTANT: To prevent actuator damage, use vise
with protective jaws when clamping actuator.
Actuator Circuit Protection
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.
Each boom actuator is protected internally by a thermal
circuit breaker. In case of actuator overheating, the ther-
mal breaker will trip, causing the actuator to cease func-
tioning. Once the actuator cools to appropriate
operating temperature, the actuator thermal breaker will
reset to allow actuator operation to resume.
CAUTION
A separate 30 amp thermal breaker also protects each
boom actuator circuit. These thermal breakers are lo-
cated at the machine fuse panel and will prevent circuit
operation if overloaded. The thermal breakers reset au-
tomatically.
The actuator reservoir is pressurized. If the res-
ervoir 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.
Actuator Freeplay Inspection
5. Using a light through the plug hole, confirm that the
reservoir oil is clear. If the oil appears milky, air is en-
trained 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.
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.
6. When oil appears clear, use a 12 volt DC power sup-
ply to power the actuator and extend the cylinder com-
pletely.
Measure actuator freeplay using the following proce-
dure:
1. Movethevehicletoanopenareaandlower thespray
booms to the spray position.
IMPORTANT: To ensure proper reservoir pressure,
make sure that cylinder is extended before instal-
ling reservoir plug.
2. Lift up on the boom at the last triangular gusset with
a 25 pound (11.4 kg) force. Support boom in that posi-
tion.
7. Install the reservoir plug and torque from 45 to 60 in--
lb (5.1 to 6.8 N--m).
3. Using a non--permanent felt tipped marker, mark the
cylinder rod at the outside of the cylinder seal.
8. If reservoir oil was milky, use power supply to con-
tract and extend the actuator cylinder 3 times. Repeat
steps 2 through 7 until oil is clear.
4. Release the spray boom and allow it to return to the
spray (fully lowered) position.
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 ma-
chine.
5. Determine the actuator freeplay by measuring the
distance fromthe mark on thecylinder rodto thecylinder
seal. The freeplay should be less than 0.100” (2.5 mm).
If excessive freeplay is found, bleed air from actuator.
Rev. A
Spray System
Page 3 -- 50
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Actuator Oil Level
RESERVOIR
PLUG
UP
Under normal conditions, actuator oil level should re-
main constant. If any oil is spilled from the reservoir dur-
ing air bleeding, the oil level in the actuator should be
checked and adjusted.
RESERVOIR
CYLINDER
1. Thoroughly clean the exterior of the actuator to pre-
vent contaminates from entering the actuator.
VISE
CLAMPING
AREA
2. Make sure that the actuator cylinder is fully retracted.
IMPORTANT: To prevent actuator damage, use vise
with protective jaws when clamping actuator.
ELECTRIC
MOTOR
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.
DOWN
Figure 55
CAUTION
The actuator reservoir is pressurized. If the res-
ervoir plug is removed too quickly, oil under
pressure can be ejected from the actuator.
0.98
(25 m
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.
Figure 56
7. When oil level is correct, use a 12 volt DC power sup-
ply to power the actuator and extend the cylinder com-
pletely.
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
Spray Systemꢀ
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Spray System
Workman 200 Spray Systemꢀ
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Chapter 3.1
Sonic Boom System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 2
Precautions Concerning Chemicals Used in
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
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
Workman 200 Spray System
Page 3.1 -- 1
Sonic Boom System (Optional Kit)
Rev. C
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General Information
Installation Instructions
The Sonic Boom Kit Installation Instructions provides in-
formation regarding the installation, operation and gen-
eral maintenance for your Sonic Boom System. Refer to
that publication for additional information when servic-
ing 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:
4. Always wear protective clothing, chemical resistant
gloves, eye protection and other personal protective
equipment as recommended by the chemical manufac-
turer.
1. Select the proper chemical for the job.
5. Properly dispose of chemical containers, unused
chemicals and chemical solution.
2. Carefully read the directions printed on the chemical
manufacturer’s labels before handling chemicals. In-
structions on chemical manufacturer’s container labels
regarding mixing proportions should be read and strictly
followed.
3. Keepspray materialaway 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).
Precautions for Removing or Adjusting Spray System Components
1. Park vehicle on a level surface and apply the parking
brake.
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).
2. Shut off the vehicle’s engine and remove the key
from the ignition switch.
5. Make sure spray system pressure is relieved before
loosening any system component.
3. Disengage all power and wait until all moving parts
have stopped.
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 2
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Special Tools
Diagnostic Display
The Diagnostic Display (Fig. 1) can be connected to the
Sonic Boom wire harness communication connector to
verify correctelectricalfunctions ofthe Sonic BoomSys-
tem. Electronic control unit (ECU) inputs and outputs for
the Sonic Boom System can be checked using the Diag-
nostic 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 com-
pleted, disconnect it from the machine and recon-
nect loopback connector to wire harness
communication connector. Machine will not oper-
ate without loopback connector installed on wire
harness. Store Diagnostic Display in a dry, secure,
indoor location and not on machine.
Figure 1
Figure 2
Rev. B
Workman 200 Spray System
Page 3.1 -- 3
Sonic Boom System (Optional Kit)
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Electrical Schematic
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 4
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This page is intentionally blank.
Rev. B
Workman 200 Spray System
Page 3.1 -- 5
Sonic Boom System (Optional Kit)
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Sonic Boom System Operation
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 6
Workman 200 Spray System
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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 sig-
nals 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 sec-
tions 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
Rev. B
Workman 200 Spray System
Page 3.1 -- 7
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Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 8
Workman 200 Spray System
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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 sig-
nals 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.
The boomsensor targetdistance 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 ex-
ceeds five (5) inches (outer dead band), the ECU will en-
ergize the appropriate power switch relay. The
energized relay will lead to a change in boom actuator
length and ultimately a change in boom height.
When a spray boom section encounters a downward
slope in the turf, the time necessary for the sensor to re-
ceive the signal echo is longer than the calibrated time-
frame. This change in time causes the ECU to energize
the appropriate power switch relay. The energized relay
provides acurrentpathtothe boomactuator causingthe
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.
A HIGHER BOOM HEIGHT IS DETECTED
SO ACTUATOR EXTENDS TO LOWER BOOM SECTION
SLOPE
Figure 4
Rev. B
Workman 200 Spray System
Page 3.1 -- 9
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Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 10
Workman 200 Spray System
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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 sig-
nals 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 re-
mains the same as the calibrated height, the spray
boom section will remain at a fixed distance from the
ground for spraying accuracy.
The boomsensor targetdistance 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 ex-
ceeds five (5) inches (outer dead band), the ECU will en-
ergize the appropriate power switch relay. The
energized relay will lead to a change in boom actuator
length and ultimately a change in boom height.
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 ap-
propriate 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
Rev. B
Workman 200 Spray System
Page 3.1 -- 11
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Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 12
Workman 200 Spray System
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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 sig-
nals 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 re-
mains the same as the calibrated height, the spray
boom will remain at a fixed distance from the ground for
spraying accuracy.
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.
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.
Rev. B
Workman 200 Spray System
Page 3.1 -- 13
Sonic Boom System (Optional Kit)
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Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 14
Workman 200 Spray System
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Manual Boom Operation
During sprayer operation with the sonic boom switch in
themanualposition, the spraybooms willremain inposi-
tion 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 ac-
tuator switches.
Lower Boom
When a boom actuator switch is pressed to lower a
boom section, the electronic control unit (ECU) ener-
gizes 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.
Raise Boom
Whenaboom actuator switch is pressed toraise aboom
section, the electronic control unit (ECU) energizes the
power switch relay and both H--bridge relays for the re-
quested 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.
Rev. B
Workman 200 Spray System
Page 3.1 -- 15
Sonic Boom System (Optional Kit)
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Troubleshooting
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and com-
ponents used on the Sonic Boom System (see Sonic
Boom System Operation in this chapter).
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 Diag-
nostic Display (see Special Tools in this chapter) to test
electronic control unit (ECU) inputs and outputs.
Sonic Boom Light
The Sonic Boom System is designed to automatically
adjust the sprayer boom height if changes in the turf sur-
face 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 de-
sired boom height. The calibration mode lasts for twenty
(20) seconds after which the boom light should quit
flashing.
2
1
NOTE: A sequence of switch movements is necessary
to engage the calibration mode. Refer to the Sonic
Boom Kit Installation Instructions for this sequence.
Figure 6
Thesonic boomlightflashingslowly indicates that asys-
tem 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.
1. Spray control console
2. Sonic boom light
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 dis-
tance 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.
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, un-
derground plumbing and other machines that could in-
terfere with sensor signals.
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 16
Workman 200 Spray System
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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 boomsen-
sors) and energizes outputs to actuate relays for ap-
propriate machine functions.
CAUTION
When testing ECU inputs with the Diagnostic
Display, boom actuators may be energized caus-
ing the spray booms to move. Be cautious of po-
tential sprayer component movement while veri-
fying inputs with the Diagnostic Display.
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.
6. The Diagnostic Display will illuminate the LED
associatedwitheachoftheinputs whenthatinputswitch
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. Re-
peat on each switch that is possible to be changed by
hand (see Inputs and LED Operation chart on following
page).
The Diagnostic Display (see Special Tools in this chap-
ter) is a toolto helpthe technicianverify correctelectrical
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 com-
pleted, disconnect it from the machine and recon-
nect loopback connector to harness connector. The
machine will not operate without the loopback con-
nector installed on the harness. Store the Diagnos-
tic Display in a dry, secure, indoor location and not
on machine.
7. If appropriate LED does not toggle on and off when
switch state is changed, check all wiring and connec-
tions to that switch and/or test switch. Replace any de-
fective switches and repair any damaged wiring.
8. After input functions testing is complete, disconnect
the Diagnostic Display connector from the harness con-
nector and plug loopback connector into wire harness.
Verify Diagnostic Display Input Functions
1. Park vehicle on a level surface, stop the engine and
apply the parking brake.
2. Locate Sonic Boom wire harness communication
port and loopback connector under the vehicle dash
panel. Carefully unplug loopback connector from har-
ness connector.
3. Connect the Diagnostic Display connector to the
wire harness connector. Make sure correct overlay de-
cal 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 illumi-
nated. If “OUTPUTS DISPLAYED” LED is illuminated,
press the toggle button on the Diagnostic Display to
change to “INPUTS DISPLAYED” LED.
Figure 7
Rev. B
Workman 200 Spray System
Page 3.1 -- 17
Sonic Boom System (Optional Kit)
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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
L LOWER
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
R LOWER
Right boom actuator switch in lower position: LED ON
Right boom actuator switch not in lower position: LED OFF
L NO SNSR DATA
L NOT TRACKING
R NO SNSR DATA
R NOT TRACKING
L -- SNSR FEEDBACK
R -- SNSR FEEDBACK
ECU has detected an invalid reading from left sensor: LED ON
Left sensor operating normally: LED OFF
Left boom not tracking to target within 5 seconds: LED ON
Left sensor operating normally: LED OFF
ECU has detected an invalid reading from right sensor: LED ON
Right sensor operating normally: LED OFF
Right boom not tracking to target within 5 seconds: LED ON
Right sensor operating normally: LED OFF
ECU receiving signal from left sensor: LED ON
ECU not receiving signal from left sensor: LED OFF
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: Right and left side Sonic Boom sensors are
identical so they can be exchanged to assist in trouble-
shooting. 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).
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 infor-
mation on initial sensor calibration.
Sonic Boom System (Optional Kit)
Page 3.1 -- 18 Rev. B
Workman 200 Spray System
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Verify Diagnostic Display Output Functions
NOTE: It may be necessary to toggle between “IN-
PUTS DISPLAYED” and “OUTPUTS DISPLAYED” sev-
eral 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.
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 de-
termine which electrical component is malfunctioning.
NOTE: An open output(e.g. an unplugged connector or
a broken wire) cannot be detected with the Diagnostic
Display.
6. Attempt to operate the desired function of the ma-
chine. 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 andthe
engine not running.
1. Park vehicle on a level surface, stop the engine and
engage the parking brake.
2. Locate Sonic Boom System wire harness and loop-
back connector under the vehicle dash panel. Carefully
unplug loopback connector from harness connector.
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.
3. ConnecttheDiagnosticDisplay connectortothehar-
ness connector. Make sure correct overlay decal is posi-
tioned on the Diagnostic Display (see Special Tools in
this chapter).
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.
4. Turn the ignition switch to the ON position.
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 assis-
tance.
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 illumi-
nated. If “INPUTS DISPLAYED” LED is illuminated,
press the toggle button on the Diagnostic Display to
change the LED to “OUTPUTS DISPLAYED”.
7. After output functions testing is complete, discon-
nect the Diagnostic Display connector from the harness
connector and plug loopback connector into wire har-
ness.
Diagnostic Display
Outputs
Diagnostic Display
LED Operation
L BOOM -- RAISE
R BOOM -- RAISE
POWER ON/ERROR
Left boom is rising: LED ON
Left boom is stationary: LED OFF
Right boom is rising: LED ON
Right boom is stationary: LED OFF
Power to ECU: LED ON
No power to ECU: LED OFF
System error: LED flashing slowly
L BOOM MOTOR
R BOOM MOTOR
ECU output exists to energize left power switch relay: LED ON
No ECU output to left power switch relay: LED OFF
ECU output exists to energize right power switch relay: LED ON
No ECU output to right power switch relay: LED OFF
Rev. B
Workman 200 Spray System
Page 3.1 -- 19
Sonic Boom System (Optional Kit)
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Troubleshooting Chart
The chart that follows contains suggestions that can be
used to assist in diagnosing Sonic Boom System perfor-
mance issues. These suggestions are not all--inclusive.
Also, consider that there may be more than one cause
for a machine problem.
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 Diag-
nostic Display (see Special Tools in this chapter) to test
electronic control unit (ECU) inputs and outputs.
Problem
Possible Cause
Sonic mode switch is in the OFF position.
Sonic boom light is not illuminated.
5 amp or 10 amp fuse in sonic boom fuse block is faulty.
Electrical power from vehicle is not available (all sonic boom func-
tions are affected).
Sonic boom light or circuit wiring is faulty.
Sonic mode switch or circuit wiring is faulty.
Sonic boom sensor or circuit wiring is faulty.
LED on one of the sonic boom sen-
sors is not illuminated.
LED on both of the sonic boom sen-
sors is not illuminated.
Sonic mode switch is in the OFF position.
5 amp fuse in sonic boom fuse block is faulty.
Sonic mode switch or circuit wiring is faulty.
One of the boom actuators will not
retract.
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.
Neither of the boom actuators will
retract.
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 func-
tions are affected).
Both of the boom actuator 30 amp auto resetting fuses are faulty.
ECU or circuit wiring is faulty.
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 20
Workman 200 Spray System
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Problem
Possible Cause
One of the boom actuators will not
extend.
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.
Neither of the boom actuators will
extend.
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 func-
tions are affected).
30 amp auto resetting fuse is faulty in both boom actuators.
ECU or circuit wiring is faulty.
One of the booms does not automat-
ically follow ground irregularities.
Boom can be controlled with boom
actuator switch.
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.
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.
Neither boom automatically follows
ground irregularities. Booms can be
controlled with boom actuator
switches.
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.
Rev. B
Workman 200 Spray System
Page 3.1 -- 21
Sonic Boom System (Optional Kit)
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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.
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.
If the sonic mode switch is in the automatic position, the
sonic sensors will be activated to allow automatic move-
ment of the boom. The tips of the booms will remain at
a constant distance from the ground. The boom
switches canbeusedtoraise/lower thebooms whenthe
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 when 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 activ-
ity or change in boom switch position.
2
1
Testing
1. Before disconnecting the sonic mode switch for test-
ing, 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 fur-
ther switch testing is necessary. If, however, the Display
determines that the sonic mode switch and circuit wiring
are not functioning correctly, proceed with test.
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.
BACK OF SWITCH
Figure 9
4. Disconnect harness electrical connector from the
sonic mode switch.
SWITCH
CLOSED
OPEN
POSITION
CIRCUITS
CIRCUITS
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.
AUTOMATIC
2 + 3
5 + 6
2 + 1
5 + 4
OFF
NONE
ALL
MANUAL
2 + 1
5 + 4
2 + 3
5 + 6
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 22
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Relays
The Sonic Boom System uses six (6) identical relays to
control the boom actuators and ultimately the boom
height. Three (3) of the relays control the right actuator
and the other three (3) relays control the left actuator.
The electronic control unit (ECU) controls the operation
of the relays. The relays are located on a mounting plate
under the vehicle dash panel (Fig. 10) and can be identi-
fied by a label on the wire harness connector.
7. Disconnect voltage and multimeter test leads from
the relay terminals. Replace relay if necessary.
8. Secure relay to mount plate and connect wire har-
ness connector to relay.
3
For each actuator, a power switch relay and two (2) H--
bridge relays are used. The power switch relay is ener-
gized by the ECU whenever the actuator is to be
energized to change boom height (either lowered or
raised). Both H--bridge relays are energized by the ECU
when a boom is to be raised. The energized bridge re-
lays provide current flow to the actuator so the actuator
retracts. The H--bridge relays are not energized when a
boomis tobelowered. Thenon--energizedbridgerelays
provide current flow to the actuator so the actuator ex-
tends.
7
6
1
4
2
5
Testing
1. Park vehicle on a level surface, stop engine, engage
parking brake and remove key from ignition switch.
Figure 10
1. Mount plate
5. Cap screw (4 used)
6. Lock washer (4 used)
7. Nut (4 used)
2. Locate relay to be tested and disconnect wire har-
ness connector from relay. Remove relay from mount
plate for testing.
2. Electronic control unit
3. Sonic boom fuse block
4. Relay (6 used)
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
4
3
1
86
85
87A
87
3. Using a multimeter, verify that coil resistance be-
tween terminals 85 and 86 is from 71 to 88 ohms.
30
4. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay terminals 30 and 87
should have continuity as +12 VDC is applied toterminal
85. The relay terminals 30 and 87 should not have conti-
nuity as +12 VDC is removed from terminal 85.
2
1
Figure 11
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open term.
5. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
6. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87A. With terminal 86 grounded, apply
+12 VDC to terminal 85. The relay terminals 30 and 87A
should not have continuity as +12 VDC is applied to ter-
minal 85. The relay terminals 30 and 87A should have
continuity as +12 VDC is removed from terminal 85.
Rev. B
Workman 200 Spray System
Page 3.1 -- 23
Sonic Boom System (Optional Kit)
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Electronic Control Unit (ECU)
The Sonic Boom System uses an electronic control unit
(ECU) to control electrical system operation. The ECU
is attached to a mounting plate under the vehicle dash
panel (Fig. 12).
3
Power is provided to the ECU when the vehicle ignition
switch is ON. A 5 amp fuse provides circuit protection for
this logic power to the ECU. The fuse is located in the
Sonic Boom System fuse block.
1
The ECU monitors the states of the following compo-
nents as inputs: thesonic modeswitch, thetwo (2) boom
actuator switches and the two (2) boom sonic sensors.
4
2
The ECU controls electrical output to the sonic boom
light and the six (6) relays that are part of the Sonic
Boom System. Circuit protection for the ECU outputs is
provided by a 10 amp fuse located in the Sonic Boom
System fuse block.
Figure 12
1. Mount plate
2. Electronic control unit
3. Sonic boom fuse block
4. Relay (6 used)
Because of the solid state circuitry built into the ECU,
there is no method to test it directly. The ECU may be
damaged if an attempt is made to test it with an electrical
test device (e.g. digital multimeter or test light).
IMPORTANT: Before performing welding on the ma-
chine, disconnect both cables from the battery and
disconnect wire harness connector from the ECU.
These steps will prevent damage to the machine
electrical system.
Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 24
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Sonic Sensor
Two (2) identical sonic sensors are used in the Sonic
Boom System. The sensors are mounted to the spray
booms (Fig. 13). During sprayer operation with the sonic
mode switch in the automatic position, the sonic sensors
will provide inputs for the electronic control unit (ECU)
to keep the booms at a constant distance from the
ground.
4
5
3
2
6
7
During sprayer operation, the sonic boom sensor con-
tinually sends an impulse signal and then receives an
echo as the signal bounces off the turf. The ECU estab-
lishes the sensor distance from the ground based on the
time between the sensor signal generation and the re-
ceived echo. The ECU then determines if the boom
height is different than the calibrated height and, if nec-
essary, energizes the appropriate boom actuator to
change the boom height.
1
13
12
8
11
9
10
Figure 13
1. Sonic sensor
8. Spray boom (RH shown)
9. Lock washer (2 used)
10. Nut (2 used)
2. Sensor bracket
3. Screw (2 used)
4. Protection tube
5. U--bolt (4 used)
6. Lock nut (8 used)
7. Sensor cover
Sensors and protection tubes should be rotated above
parallel with the ground for proper sonic sensor opera-
tion. Refer to theSonic BoomKit InstallationInstructions
for sonic sensor setup information.
11. Foam sensor filter
12. Sensor shield
13. Patch
The sonic sensor includes a LED that should be illumi-
nated during sprayer operation regardless of whether
the sonic mode switch is in manual or automatic mode.
The intensity of the LED can be used to assure that the
sensor is properly adjusted on the spray boom.
The sonic sensors and their circuit wiring can be tested
as ECU inputs with the Diagnostic Display (see Diag-
nostic Display in the Troubleshooting section of this
chapter). Because ofthe solid state circuitry built into the
sensors, there is no method to test them directly. The
sensors may be damaged if an attempt is made to test
them with an electrical test device (e.g. digital multime-
ter or test light)
IMPORTANT: Do not spray water at or on the sen-
sors. Water sprayed under even household pres-
sure can damage the sensor. Always install sensor
cover (item 7) on sensor before washing the spray-
er. Also, install cover when sprayer is not in use.
As required, use a damp cloth to clean the sensors.
Make sure that the sensor covers (item 7) are clean and
dry before installing them on sensors.
The patch (item 13) that is adhered to the sensor is de-
signed to allow moisture to escape from inside the sen-
sor housing. The patch should be replaced if it is
deteriorated or has loosened from the sensor.
Inspect the foam sensor filter (item 11) for damage or ex-
cessive debris buildup. Replace filter if necessary.
Rev. B
Workman 200 Spray System
Page 3.1 -- 25
Sonic Boom System (Optional Kit)
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Rev. B
Sonic Boom System (Optional Kit)
Page 3.1 -- 26
Workman 200 Spray System
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Chapter 3.2
Ultra Sonic Boom System
(Optional Kit)
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 2
Precautions Concerning Chemicals Used in
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 17
Sonic Boom Light . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ultra Sonic Boom Calibration . . . . . . . . . . . . . . . . 17
Diagnostic Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . 24
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 26
Sonic Boom Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 26
Sonic Boom Switch . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Toro Electronic Controller (TEC) . . . . . . . . . . . . . 31
Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Precautions for Removing or Adjusting Spray
System Components . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 4
ULTRA SONIC BOOM SYSTEM OPERATION . . . . 6
Sprayer Operation on Level Turf . . . . . . . . . . . . . . 6
Downward Slope in Turf Encountered . . . . . . . . . . 8
Rise in Turf Encountered . . . . . . . . . . . . . . . . . . . . 10
Boom Level Changed by Operator During
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . 12
Manual Boom Operation . . . . . . . . . . . . . . . . . . . . 14
Workman 200
Page 3.2 -- 1
Ultra Sonic Boom System (Rev. C)
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General Information
Installation Instructions
The Ultra Sonic Boom Kit Installation Instructions pro-
vides information regarding the installation, operation
and general maintenance for your Ultra Sonic Boom
System. Refer to that publication for additional informa-
tion 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:
4. Always wear protective clothing, chemical resistant
gloves, eye protection and other personal protective
equipment as recommended by the chemical manufac-
turer.
1. Select the proper chemical for the job.
5. Properly dispose of chemical containers, unused
chemicals and chemical solution.
2. Carefully read the directions printed on the chemical
manufacturer’s labels before handling chemicals. In-
structions 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
(refer to container labels and Material Safety Data
Sheets).
Precautions for Removing or Adjusting Spray System Components
1. Park vehicle on a level surface and apply the parking
brake.
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).
2. Shut off the vehicle’s engine and remove the key
from the ignition switch.
5. Make sure spray system pressure is relieved before
loosening any system component.
3. Disengage all power and wait until all moving parts
have stopped.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 2
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Special Tools
Diagnostic Display
The Diagnostic Display (Fig. 1) can be connected to the
Ultra Sonic Boom wire harness communication connec-
tor to verify correct electrical functions of the Ultra Sonic
Boom System. Toro electronic controller (TEC) inputs
and outputs for the Ultra Sonic Boom System can be
checked using the Diagnostic Display.
Toro Part Number for Diagnostic Display: 85--4750
Toro Part Number for Overlay (English): 119--9431
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 com-
pleted, disconnect it from the machine and recon-
nect loopback connector to wire harness
communication connector. Machine will not oper-
ate without loopback connector installed on wire
harness. Store Diagnostic Display in a dry, secure,
indoor location and not on machine.
Figure 1
119--9431
Figure 2
Workman 200
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Electrical Schematic
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 4
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Ultra Sonic Boom System Operation
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 6
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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 echoes as the
signals bounce off the turf. The Toro electronic controller
(TEC) 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.
NOTE: During normal Ultra Sonic Boom system opera-
tion, there may be some slight movement of the booms.
On level turf, the boom sensors continually send signals
and receive echoes that determine that the boom sec-
tions are at the calibrated height. Thus, there is no need
to change boom height and the boom sections will re-
main at the correct, level position.
CONSISTENT BOOM HEIGHT
SO BOOM ACTUATOR MOVEMENT
IS NOT NECESSARY
LEVEL GROUND
Figure 3
Workman 200
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Ultra Sonic Boom System (Rev. C)
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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 echoes as the
signals bounce off the turf. The Toro electronic controller
(TEC) 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.
The boom sensor target distance is initiated during initial
sonic boom calibration and is typically set at twenty (20)
inches. If the boom target distance changes when in au-
tomatic mode, the TEC will energize the appropriate
electrical relays. The energized relays will lead to a
change in boom actuator length and ultimately a change
in boom height.
When a spray boom section encounters a downward
slope in the turf, the time necessary for the sensor to re-
ceive the signal echo is longer than the calibrated time-
frame. This change in time causes the TEC to energize
the appropriate electrical relays causing the controlled
boom actuator to extend and the boom section to lower.
Once the boom section is lowered to the calibrated dis-
tance, the elapsed time between the sensor signal gen-
eration and the received echo returns to the correct
timeframe, relays are de--energized and the boom stops
lowering. This maintains the boom height at the cali-
brated distance from the ground.
A HIGHER BOOM HEIGHT IS DETECTED SO THE
BOOM ACTUATOR EXTENDS TO LOWER BOOM SECTION
SLOPE
Figure 4
Workman 200
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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 echoes as the
signals bounce off the turf. The Toro electronic controller
(TEC) 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 re-
mains the same as the calibrated height, the spray
boom section will remain at a fixed distance from the
ground for spraying accuracy.
The boom sensor target distance is initiated during initial
sonic boom calibration and is typically set at twenty (20)
inches. If the boom target distance changes when in au-
tomatic mode, the TEC will energize the appropriate
electrical relays. The energized relays will lead to a
change in boom actuator length and ultimately a change
in boom height.
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 TEC to energize the appropri-
ate electrical relays causing the controlled boom actuat-
or to retract and the boom section to raise. 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, re-
lays are de--energized and the boom stops raising. This
maintains the boom height at the calibrated distance
from the ground.
A LOWER BOOM HEIGHT IS DETECTED SO THE
BOOM ACTUATOR RETRACTS TO RAISE BOOM SECTION
RISE
Figure 5
Workman 200
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Boom Level Changed by Operator During Automatic Operation
During sprayer operation with the sonic boom switch in
the automatic position (sonic boom switch light is illumi-
nated), the boom mounted sonic boom sensors continu-
ally send impulse signals and then receive echoes as
the signals bounce off the turf. The Toro electronic con-
troller (TEC) 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 a boom is raised by the operator while the Ultra Sonic
Boom System is in automatic operation, that boom will
remain in the raised position until the boom lift switch is
pressed to lower and released which will re--engage au-
tomatic sonic boom operation on that boom section.
If a boom is lowered by the operator while the Ultra Sonic
Boom System is in automatic operation, that boom will
lower until the boom lift switch is released. The automat-
ic sonic boom operation will be re--engaged as soon as
the lift switch is released from lower.
NOTE: To re--engage automatic sonic boom operation,
the boom lift switch must be pressed to lower and re-
leased. Pressing the boom lift switch to raise will not re--
engage automatic operation.
If the sprayer operator should press a boom lift switch
while in automatic operation, the TEC energizes the ap-
propriate boom lift control electrical relays. The ener-
gized relays cause the boom actuator to raise or lower
the boom section. The relays will stay energized as long
as the operator keeps the boom lift switch pressed. The
sonic boom light will flash while the boom lift switch is be-
ing depressed. If one boom is moved by the operator,
the other boom continues to function automatically.
OPERATOR PRESSES LEFT BOOM LIFT SWITCH SO THE LEFT
BOOM ACTUATOR RETRACTS TO RAISE BOOM SECTION
Figure 6
Workman 200
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Ultra Sonic Boom System (Rev. C)
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Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 14
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Manual Boom Operation
During sprayer operation with the sonic boom switch in
the manual position, the spray booms will remain in posi-
tion unless the operator presses a boom lift switch. The
sonic boom light should not be illuminated when in the
manual position. The operator will control the boom
position with the boom lift switches.
Raise Boom
When a boom lift switch is pressed to raise a boom sec-
tion, the Toro electronic controller (TEC) energizes the
appropriate electrical relays causing the controlled
boom actuator to retract and the boom section to raise.
The boom will continue to rise until the operator releases
the boom lift switch.
Lower Boom
When a boom lift switch is pressed to lower a boom sec-
tion, the Toro electronic controller (TEC) energizes the
appropriate electrical relays causing the controlled
boom actuator to extend and the boom section to lower.
The boom will continue to lower until the operator re-
leases the boom actuator switch.
Workman 200
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Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 16
Workman 200
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Troubleshooting
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and com-
ponents used on the Ultra Sonic Boom System (see Ul-
tra Sonic Boom System Operation in this chapter).
NOTE: When troubleshooting an electrical problem on
your Ultra Sonic Boom System, refer to information re-
garding the sonic boom light and diagnostic lamp in this
section. Also, use the Diagnostic Display (see Special
Tools in this chapter) to test Toro electronic controller
(TEC) inputs and outputs.
Sonic Boom Light
The sonic boom light is included in the sonic boom
switch on the spray control panel (Fig. 7). This light
should be illuminated whenever the vehicle ignition
switch is ON and the sonic boom switch is in the auto-
matic position.
1
The sonic boom light flashing quickly indicates that the
Ultra Sonic Boom System is in the calibration mode.
This mode allows the spray booms to be adjusted for the
desired boom height and continues for approximately
twenty (20) seconds. The sonic boom light will then flash
slowly for approximately two (2) minutes to finalize the
calibration settings.
2
Figure 7
NOTE: A sequence of switch movements is necessary
to engage the calibration mode. Refer to the Sonic
Boom Kit Installation Instructions for this sequence.
1. Spray control panel
2. Sonic boom switch
The sonic boom light flashes slowly when the sonic
boom switch is in the automatic position and a boom lift
switch is pressed to manually change the boom height.
The flashing light will return to being constantly ON and
automatic operation will be re--engaged once the boom
switch is manually pressed to the lower position.
A slowly flashing sonic boom light may also indicate that
a system fault has been encountered. In the event that
there is a fault in the Ultra Sonic Boom System (e.g.
there is no signal coming from a boom sensor), the af-
fected boom will raise briefly and then stop. The sonic
boom light will begin to flash slowly and the diagnostic
lamp on the console will also flash. If this occurs, refer
to Diagnostic Lamp, Diagnostic Display and Trouble-
shooting Chart in this section.
Ultra Sonic Boom Calibration
The sensor calibration process is critical to the correct
operation of the Ultra Sonic Boom System. The calibra-
tion process establishes the sensor target distance be-
tween the boom and the turf surface. Typically, this
distance is approximately twenty (20) inches. Steps
needed for proper calibration are identified in the Ultra
Sonic Boom Kit Installation Instructions.
While calibrating the Ultra Sonic Boom sensors, it is best
to perform the calibration process on turf. A shiny sur-
face (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.
Workman 200
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Ultra Sonic Boom System (Rev. C)
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Diagnostic Lamp
The Ultra Sonic Boom System includes a diagnostic
lamp that displays the status of the sonic boom system.
The diagnostic lamp is located on the spray control pan-
el (Fig. 8).
1
When the ignition switch is moved to the ON position
and the Ultra Sonic Boom System electrical system is
functioning properly, the diagnostic lamp will be illumi-
nated for approximately three (3) seconds and then will
turn off. The diagnostic lamp should remain off during
normal sonic boom operation.
2
If the sonic boom system TEC controller detects an elec-
trical system malfunction (fault) during operation (e.g.
there is no signal coming from a boom sensor), the af-
fected boom will raise briefly and then stop. The sonic
boom light (in sonic boom switch) will begin to flash
slowly and the diagnostic lamp will flash rapidly. The
diagnostic lamp will stop flashing and will automatically
reset when the ignition switch is turned to the OFF posi-
tion. The fault, however, will be retained in controller
memory and can be retrieved at a future time (see Re-
trieving Fault Codes below).
Figure 8
1. Spray control panel
2. Diagnostic lamp
If the diagnostic lamp does not illuminate when the igni-
tion switch is turned to the ON position, possible causes
are:
D The loopback connector (6 pin connector) is not
connected to the machine wire harness (Fig. 9). The
loopback connector is near the TEC controller on the
mounting plate under the dash panel.
1
3
4
2
D The diagnostic lamp (or circuit wiring) is faulty.
D TEC controller fuse(s) are faulty.
D The TEC controller is faulty.
Figure 9
1. TEC controller location
2. Loopback connector
3. Diagnostic tether cap
4. Diagnostic shunt wires
Check electrical connections, controller fuses and the
diagnostic lamp to determine malfunction. Make sure
that the loopback connector is secured to the wire har-
ness connector during machine operation.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 18
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Retrieving Fault Codes
Fault codes displayed by the diagnostic lamp are two (2)
digit numbers with no digit larger than five (5). Fault
codes are listed in the chart below. There will be a one
(1) second pause between the first and second digit of
a code. Up to three (3) fault codes retained in controller
memory will be displayed by the diagnostic lamp in order
from the most recent fault to the oldest fault. If there are
multiple faults in controller memory, there will be a three
(3) second pause between codes. The fault codes will
continually repeat after a five (5) second pause until the
ignition key is turned OFF.
All Ultra Sonic Boom System fault codes are retained in
the TEC controller memory. The three (3) most recent
fault codes that have occurred within the last forty (40)
hours of operation can be retrieved using the diagnostic
lamp. To retrieve these fault codes from the controller
memory, perform the following steps:
1. Make sure that ignition switch is OFF.
2. Locate diagnostic tether cap that connects the two
(2) diagnostic shunt wires located near the TEC control-
ler on the mounting plate under the dash panel (Fig. 9).
If there are no faults that have occurred within the last
forty (40) hours of operation, the diagnostic lamp will
flash continuously after performing the above steps.
3. Remove diagnostic tether cap from diagnostic shunt
wires and connect the two (2) shunt wires together.
If a fault code is not retrieved from the controller memory
within forty (40) hours of machine operating time, the
fault cannot be retrieved from controller memory using
this procedure. If necessary, contact your Toro distribu-
tor to retrieve older fault codes.
4. Turn ignition switch to the ON position.
5. Monitor the diagnostic lamp for fault code(s).
After necessary service has been performed, discon-
nect diagnostic shunt wires and insert shunt leads into
diagnostic tether cap. Lower operator seat.
Fault Code (Lamp Flashes)
Fault Description
1 -- 2
1 -- 3
Left sonic boom sensor fault occurred
Right sonic boom sensor fault occurred
1 -- 6
2 -- 1
2 -- 2
2 -- 3
2 -- 4
3 -- 4
4 -- 1
4 -- 2
4 -- 5
TEC inputs are out of range (sonic boom operation will stop)
The extreme right 7.5 Amp fuse in boom supply fuse block is faulty
The middle right 7.5 Amp fuse in boom supply fuse block is faulty
The middle left 7.5 Amp fuse in boom supply fuse block is faulty
Main electrical power to sonic boom system was interrupted
Left boom raise function (output) is grounded or faulty
Right boom raise function (output) is grounded or faulty
Right boom lower function (output) is grounded or faulty
Left boom lower function (output) is grounded or faulty
Clearing Fault Codes
2. At the same time, press the left boom switch to lower
and the right boom switch to raise.
After fault codes have been retrieved, clearing of those
faults can be completed using the following switch se-
quence:
3. Monitor the diagnostic lamp for continuous flashing
indicating that all faults have been cleared from the con-
troller memory.
1. Place sprayer in fault retrieval mode (see above).
The diagnostic lamp should be displaying the fault
codes.
Workman 200
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Diagnostic Display
The Ultra Sonic Boom System is equipped with the Toro
electronic controller (TEC) which controls machine son-
ic boom electrical functions. The TEC monitors various
input switches (e.g. sonic boom switch, boom lift
switches, sonic boom sensors) and energizes outputs
(e.g. boom actuators, diagnostic lamp) for appropriate
machine functions.
For the TEC to control the machine as desired, each of
the inputs (switches and sensors) and outputs (e.g.
boom actuators) must be connected and functioning
properly.
1
The Diagnostic Display (see Special Tools in this chap-
ter) is a tool to help the technician verify correct electrical
functions of the machine.
3
2
Figure 10
1. TEC controller location
2. Loopback connector
3. Diagnostic tether cap
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 com-
pleted, disconnect it from the machine and recon-
nect loopback connector to harness connector. The
machine will not operate without the loopback con-
nector installed on the harness. Store the Diagnos-
tic Display in a dry, secure, indoor location and not
on machine.
Verify Diagnostic Display Input Functions
1. Park machine on a level surface, stop the engine and
apply the parking brake.
2. Locate Ultra Sonic Boom wire harness communica-
tion port and loopback connector (6 pin connector) loc-
ated near the TEC controller on the mounting plate
under the dash panel (Fig. 10). Carefully unplug loop-
back connector from harness connector.
3. Connect the Diagnostic Display connector to the
wire harness communication port connector. Make sure
correct overlay decal is positioned on the Diagnostic
Display (Fig. 11).
4. Turn the machine ignition switch to the ON position,
but do not start engine.
119--9431
NOTE: The red text on the Diagnostic Display overlay
decal refers to input switches and the green text refers
to TEC outputs.
Figure 11
5. Make sure that the “INPUTS DISPLAYED” LED, on
lower right column of the Diagnostic Display, is illumi-
nated. If “OUTPUTS DISPLAYED” LED is illuminated,
press the toggle button on the Diagnostic Display to
change to “INPUTS DISPLAYED” LED.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 20
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7. If appropriate LED does not toggle on and off when
switch state is changed, perform test of switch and/or
check all wiring and connections to that switch. Replace
any defective switches and repair any damaged wiring.
CAUTION
When testing TEC inputs with the Diagnostic Dis-
play, boom actuators may be energized causing
the spray booms to move. Be cautious of poten-
tial sprayer component movement while verify-
ing inputs with the Diagnostic Display.
8. After input functions testing is complete, disconnect
the Diagnostic Display connector from the harness con-
nector. Plug loopback connector into wire harness.
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 boom switch), and note
that the appropriate LED on the Diagnostic Display will
illuminate when the corresponding switch is closed. Re-
peat on each switch that is possible to be changed by
hand (see Inputs and LED Operation chart below).
Diagnostic Display
Inputs
Diagnostic Display
LED Operation
AUTO MODE
Sonic boom switch in auto position: LED ON
Sonic boom switch not in auto position: LED OFF
RIGHT RAISE
Right boom lift switch in raise position: LED ON
Right boom lift switch not in raise position: LED OFF
RIGHT LOWER
LEFT RAISE
Right boom lift switch in lower position: LED ON
Right boom lift switch not in lower position: LED OFF
Left boom lift switch in raise position: LED ON
Left boom lift switch not in raise position: LED OFF
LEFT LOWER
Left boom lift switch in lower position: LED ON
Left boom lift switch not in lower position: LED OFF
RETRIEVE FAULTS
LEFT SENSOR FAULT
RIGHT SENSOR FAULT
KEY RUN
Diagnostic shunt wires are connected for fault retrieval: LED ON
Diagnostic shunt wires are not connected: LED OFF
The TEC has detected an invalid reading from left sensor: LED ON
Left sensor operating normally: LED OFF
The TEC has detected an invalid reading from right sensor: LED ON
Right sensor operating normally: LED OFF
Ignition key is in ON position: LED ON
Ignition key is in OFF position: LED OFF
NOTE: When the vehicle ignition switch is in the OFF
position, all Diagnostic Display LED’s should be OFF.
NOTE: Right and left side Ultra Sonic Boom sensors
are identical so they can be exchanged to assist in trou-
bleshooting. 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).
NOTE: Initial calibration of the Ultra Sonic Boom sen-
sors is required for proper operation of TEC inputs. Re-
fer to your Sonic Boom Kit Installation Instructions for
information on initial sensor calibration.
Workman 200
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Verify Diagnostic Display Output Functions
6. Attempt to operate the desired function of the ma-
chine. The appropriate output LED’s should illuminate
on the Diagnostic Display to indicate that the TEC is
turning on that function (see Outputs and LED Opera-
tion chart on next page). The outputs can be checked
with the ignition switch in the ON position and the engine
not running.
The Diagnostic Display also has the ability to detect
which output boom actuators or lights (sonic boom or
diagnostic) are energized by the Toro electronic control-
ler (TEC). This is a quick way to determine which electri-
cal component is malfunctioning.
NOTE: An open output (e.g. an unplugged connector or
a broken wire) cannot be detected with the Diagnostic
Display.
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.
1. Park machine on a level surface, stop the engine and
engage the parking brake.
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.
2. Locate Ultra Sonic Boom wire harness communica-
tion port and loopback connector (6 pin connector) loc-
ated near the TEC controller on the mounting plate
under the dash panel (Fig. 12). Carefully unplug loop-
back connector from harness connector.
C. If each input switch is in the correct position and
functioning correctly, but the output LED’s are not
correctly illuminated, this may indicate a TEC prob-
lem. If this occurs, contact your Toro Distributor for
assistance.
3. Connect the Diagnostic Display connector to the har-
ness communication port connector. Make sure correct
overlay decal is positioned on the Diagnostic Display
(see Special Tools in this chapter).
7. After output functions testing is complete, discon-
nect the Diagnostic Display connector from the harness
connector and plug loopback connector into wire har-
ness.
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 TEC outputs.
5. Make sure that the “OUTPUTS DISPLAYED” LED,
on lower right column of the Diagnostic Display, is illumi-
nated. If “INPUTS DISPLAYED” LED is illuminated,
press the toggle button on the Diagnostic Display to
change the LED to “OUTPUTS DISPLAYED”.
NOTE: It may be necessary to toggle between “IN-
PUTS DISPLAYED” and “OUTPUTS DISPLAYED” sev-
eral 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.
1
3
2
Figure 12
1. TEC controller location
2. Loopback connector
3. Diagnostic tether cap
CAUTION
When testing TEC inputs with the Diagnostic Dis-
play, boom actuators may be energized causing
the spray booms to move. Be cautious of poten-
tial sprayer component movement while verify-
ing inputs with the Diagnostic Display.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 22
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Diagnostic Display
Outputs
Diagnostic Display
LED Operation
DIAG LAMP
SONIC SENSOR
RIGHT RAISE
RIGHT LOWER
INDICATOR LAMP
LEFT RAISE
Diagnostic lamp is ON or FLASHING: LED ON or FLASHING
Diagnostic lamp is not ON or FLASHING: LED OFF
TEC output exists to sonic sensors: LED ON
No TEC output to sonic sensors: LED OFF
TEC output exists to energize relays to raise right boom: LED ON
No TEC output to energize relays to raise right boom: LED OFF
TEC output exists to energize relays to lower right boom: LED ON
No TEC output to energize relays to lower right boom: LED OFF
Sonic boom switch is in automatic position: LED ON
Sonic boom switch is in manual position: LED OFF
TEC output exists to energize relays to raise left boom: LED ON
No TEC output to energize relays to raise left boom: LED OFF
LEFT LOWER
TEC output exists to energize relays to lower left boom: LED ON
No TEC output to energize relays to lower left boom: LED OFF
Workman 200
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Troubleshooting Chart
The chart that follows contains suggestions that can be
used to assist in diagnosing Ultra Sonic Boom System
performance issues. These suggestions are not all--in-
clusive. Also, consider that there may be more than one
cause for a machine problem.
NOTE: When troubleshooting an electrical problem on
your Ultra Sonic Boom System, refer to information re-
garding the sonic boom light in this section. Also, use the
Diagnostic Display (see Special Tools in this chapter) to
test Toro electronic controller (TEC) inputs and outputs.
Problem
Possible Cause
Sonic boom switch is in the MANUAL position.
Light in sonic boom switch is not illu-
minated.
2 Amp fuse in sonic boom fuse block is faulty (all sonic boom func-
tions are affected).
Upper, middle right fuse (7.5 Amp) in sonic boom fuse block is
faulty.
Loopback connector is unplugged from wire harness connector (all
sonic boom functions are affected).
Electrical power from vehicle is not available (all sonic boom func-
tions are affected).
Sonic boom switch or circuit wiring is faulty.
One of the boom actuators will not
extend or retract.
Boom lift switch or circuit wiring for affected boom actuator is faulty.
A problem exists with the affected boom actuator.
Neither of the boom actuators will
extend or retract.
Loopback connector is unplugged from wire harness connector (all
sonic boom functions are affected).
Fuse(s) in sonic boom fuse block is faulty.
Electrical power from vehicle is not available (all sonic boom func-
tions are affected).
A problem exists with both boom actuators.
The Toro electronic controller (TEC) or circuit wiring is faulty.
Sonic boom sensor or circuit wiring is faulty.
The LED’s on one of the sonic boom
sensors are not illuminated.
The LED’s on both of the sonic
boom sensors are not illuminated.
Sonic boom switch is in the MANUAL position.
Upper, middle left fuse (7.5 Amp) in sonic boom fuse block is faulty
(diagnostic lamp also affected).
Sonic boom switch or circuit wiring is faulty.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 24
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Problem
Possible Cause
One of the booms does not automat-
ically follow ground irregularities.
Boom can be controlled with boom
lift switch.
On affected boom, the sonic boom sensor cover is on sensor.
On affected boom, calibration of the sonic boom sensors is incor-
rect.
The sonic boom sensor is incorrectly installed.
Sonic boom sensor or circuit wiring for affected boom is faulty.
The Toro electronic controller (TEC) or circuit wiring is faulty.
Sonic boom switch is not in the AUTOMATIC position.
Neither boom automatically follows
ground irregularities. Booms can be
controlled with boom lift switches.
Sonic boom sensor covers are on both sensors.
Calibration of the sonic boom sensors is incorrect.
Both sonic boom sensors or circuit wiring are faulty.
The Toro electronic controller (TEC) or circuit wiring is faulty.
Workman 200
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Service and Repairs
Sonic Boom Fuses
Fuses for the Ultra Sonic Boom system are included in
the fuse blocks attached to the mounting plate under the
dash panel (Fig. 13).
1
Fuse Identification and Function
The upper row of fuses protect circuits as follows:
1. The upper, extreme left 2 Amp fuse protects power
supply for TEC logic.
2. The upper, middle left 7.5 Amp fuse is not used.
3. The upper, middle right 7.5 Amp fuse protects TEC
output circuits (sonic boom switch light and boom actu-
ator power supply).
4. The upper, extreme right 7.5 Amp fuse protects TEC
output circuits (diagnostic light and sonic sensor power
supply).
2
Figure 13
1. Dash panel
2. Fuse blocks
The lower row of fuses protect circuits as follows:
1. The lower, extreme left fuse position is not used.
2. The lower, middle left fuse position is not used.
2
3
1
4
3. The lower, middle right 30 Amp fuse (auto resetting)
protects the left boom actuator circuit.
4. The extreme right 30 Amp fuse (auto resetting) pro-
tects the right boom actuator circuit.
Fuse Testing
Remove fuses from the fuse block for testing. Fuse
should have continuity between fuse terminals.
7
6
NOTE: The auto resetting fuses should only be re-
5
moved if they are faulty.
Figure 14
1. Upper, extreme left fuse
2. Upper middle left fuse
3. Upper, middle right fuse
4. Upper right fuse
5. Auto resetting fuse
6. Auto resetting fuse
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 26
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Sonic Boom Switch
The sonic boom switch is used as an input for the Toro
electronic controller (TEC) to activate the Ultra Sonic
Boom System. This switch has two (2) positions: auto-
matic and manual. The sonic boom switch is located on
the spray control panel (Fig. 15).
1
If the sonic boom switch is in the automatic position, the
sonic sensors will be activated to allow automatic move-
ment of the booms. The tips of the booms will remain at
a constant distance from the ground. The boom lift
switches can be used to raise/lower the booms when the
sonic boom switch is in the automatic position. The light
in the switch should be illuminated when the switch is in
the automatic position.
2
Figure 15
If the sonic boom switch is in the manual position, the
sonic sensors are disabled. The boom lift switches are
used to raise/lower the booms when the sonic boom
switch is in the manual position.
1. Spray control panel
2. Sonic boom switch
7
4
5
2
6
Testing
NOTE: Before disconnecting sonic boom switch for
testing, the switch and its circuit wiring should be tested
as a TEC input with the Diagnostic Display (see Diag-
nostic Display in the Troubleshooting section of this
chapter). If the Diagnostic Display verifies that the sonic
boom switch and circuit wiring are functioning correctly,
no further switch testing is necessary. If, however, the
Display determines that the sonic boom switch and cir-
cuit wiring are not functioning correctly, proceed with
switch test.
8
1
3
BACK OF SWITCH
Figure 16
SWITCH
POSITION
CLOSED
CIRCUITS
OPEN
CIRCUITS
1. Park vehicle on a level surface, stop engine, engage
parking brake and remove key from ignition switch.
MANUAL
2 + 3
5 + 6
2 + 1
5 + 4
AUTOMATIC
2 + 1
5 + 4
2 + 3
5 + 6
2. Locate sonic boom switch, remove console panel
and unplug wire harness connector from switch.
3. The switch terminals are shown in Figure 16. The cir-
cuit logic of the sonic boom 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 termi-
nals. Replace switch if testing identifies a faulty switch.
4. To test switch light, apply 12 VDC to terminal 8 (+)
and ground terminal 7 (--). The light should illuminate.
5. If the sonic boom switch tests correctly and circuit
problem still exists, check sonic boom system wire har-
ness.
6. After testing is completed, connect wire harness
connector to the sonic boom switch. Install console pan-
el to machine.
Workman 200
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Sonic Sensors
Two (2) identical sonic sensors are used in the Ultra
Sonic Boom System. The sensors are mounted to the
spray booms (Figs. 17, 18 and 19). During sprayer op-
eration with the sonic boom switch in the automatic posi-
tion, the sonic sensors will provide inputs for the Toro
electronic controller (TEC) to keep the booms at a
constant distance from the ground.
4
2
14 to 16 ft--lb
(19 to 21 N--m)
During sprayer operation, the sonic boom sensor con-
tinually sends an impulse signal and then receives an
echo as the signal bounces off the turf. The TEC estab-
lishes the sensor distance from the ground based on the
time between the sensor signal generation and the re-
ceived echo. The TEC then determines if the boom
height is different than the calibrated height and, if nec-
essary, energizes the appropriate boom actuator(s) to
change the boom height.
3
5
6
1
Sensors should be secured to the spray booms correctly
for proper sonic sensor operation. Refer to the Ultra
Sonic Boom Kit Installation Instructions for sonic sensor
installation and setup information.
Figure 17
1. Sonic sensor
2. Lower housing
3. Nut (2 used)
4. Cover
5. Programming plug
6. Cap
The sonic sensors and their circuit wiring can be tested
as TEC inputs with the Diagnostic Display (see Diagnos-
tic Display in the Troubleshooting section of this chap-
ter). Because of the solid state circuitry built into the
sensors, there is no method to test them directly. The
sensors may be damaged if an attempt is made to test
them with an electrical test device (e.g. digital multime-
ter or test light)
1
2
IMPORTANT: Do not spray water at or on the sen-
sors. Water sprayed even under household pres-
sure can damage the sensor. Always install sensor
cap on sensor before washing the sprayer. Also,
install cap when sprayer is not in use.
Figure 18
1. Sensor with cover
2. Sensor without cover
As required, use a damp cloth to clean the sensors.
Make sure that the sensor covers and caps are clean
and dry before installing them on sensors. When the
sprayer is not being used, it is recommended to have the
caps installed on the sensors for sensor protection.
1
2
Each of the sonic sensor assemblies includes a pro-
gramming plug for sensor accuracy. If a programming
plug is removed from the sensor, make sure that the ar-
row below the sideways T on the plug is aligned with the
notch on the top edge of the sensor (Fig. 20).
3
NOTE: The two (2) sonic sensors are identical. To as-
sist in troubleshooting, sensors can be exchanged. If the
problem follows the exchanged sensor, an electrical
problem likely exists with the sensor. If the problem re-
mains unchanged, something other than the sensor is
the problem source.
Figure 19
1. Sonic sensor
2. Lower housing
3. Nut (2 used)
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 28
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Sonic Sensor LED Window
The sonic sensor includes a LED window that identifies
sensor status during sprayer operation during operation
of the Ultra Sonic Boom system (Fig. 21). To view the
LED window, carefully remove cover from sonic sensor.
The LED window includes four (4) LED’s.
2
3
During normal operation, the green LED and both yellow
LED’s should be illuminated. The red LED will be off.
4
If there is some interference with normal sensor opera-
tion, the red LED will be flashing. The green LED will be
off. The yellow LED’s may flash, be illuminated or be off.
1
5
If the sensor programming plug is removed or is faulty,
the red LED will be illuminated. The green LED will be
off. The yellow LED’s may flash, be illuminated or be off.
Figure 20
1. Sonic sensor
2. Programming plug
3. Letter T
4. Plug arrow
5. Sensor notch
The status of the LED’s on the sensors can be used to
identify a faulty or unplugged programming plug. The
LED’s also can be used to identify the presence of inter-
ference that can affect Ultra Sonic Boom system opera-
tion. If the LED’s do not illuminate correctly, a problem
may exist with circuit wiring to the sensor or with the sen-
sor itself.
1
2
4
3
Figure 21
1. Yellow LED
2. Green LED
3. Red LED
4. Yellow LED
Workman 200
Page 3.2 -- 29
Ultra Sonic Boom System (Rev. C)
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Relays
The Ultra Sonic Boom System uses four (4) identical re-
lays to control the boom actuators and ultimately the
boom height. Two (2) of the relays control the right boom
actuator and the other two (2) relays control the left
boom actuator. The Toro electronic controller (TEC)
controls the operation of the relays. The appropriate
relay is energized by the TEC to allow current flow to the
boom actuators in the proper direction so that the actu-
ator extends (boom raise) or retracts (boom lower).
8. Disconnect voltage and multimeter test leads from
the relay terminals. Replace relay if necessary.
9. Secure relay to mount plate and connect wire har-
ness connector to relay. Secure mount plate to machine
frame.
4
2
3
The relays are located on a mount plate under the ve-
hicle dash panel (Fig. 22) and can be identified by a label
on the wire harness connector.
5
6
Testing
1. Park vehicle on a level surface, stop engine, engage
parking brake and remove key from ignition switch.
2. Remove mount plate from under dash panel to allow
easier relay access.
1
3. Locate relay to be tested and disconnect wire har-
ness connector from relay. Remove relay from mount
plate for testing.
Figure 22
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
1. Mount plate
4. Cap screw (4 used)
5. Lock washer (4 used)
6. Nut (4 used)
2. U--bolt clamp (2 used)
3. Relay (4 used)
4
3
1
4. Using a multimeter, verify that coil resistance be-
tween terminals 85 and 86 is from 71 to 88 ohms.
86
85
87A
87
5. Connect multimeter (ohms setting) leads to relay ter-
minals 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.
30
2
1
6. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
Figure 23
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open term.
7. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between termi-
nals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 30
Workman 200
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Toro Electronic Controller (TEC)
The Ultra Sonic Boom System uses the Toro Electronic
Controller (TEC) to control electrical system operation.
The TEC is attached to a mounting plate under the dash
panel (Fig. 24).
1
Power is provided to the TEC when the vehicle ignition
switch is ON. A 2 Amp fuse provides circuit protection for
this logic power to the TEC. The fuse is located in the Ul-
tra Sonic Boom System fuse block under the dash pan-
el.
2
The TEC monitors the states of the following compo-
nents as inputs: the sonic boom switch, the two (2) boom
lift switches, the two (2) sonic boom sensors and the
diagnostic shunt wires.
The TEC controls electrical output to the sonic boom
light, the diagnostic lamp, the four (4) relays used to con-
trol the sonic boom system and the two (2) sonic boom
sensors. Circuit protection for the TEC outputs is pro-
vided by three (3) 7.5 Amp fuses located in the Ultra
Sonic Boom System fuse block.
Figure 24
1. Dash panel
2. TEC controller
Testing of the TEC inputs and outputs can be completed
with the use of the Diagnostic Display (see the Special
Tools and Troubleshooting sections of this chapter).
4
2
Because of the solid state circuitry built into the TEC,
there is no method to test it directly. The TEC may be
damaged if an attempt is made to test it with an electrical
test device (e.g. digital multimeter or test light).
IMPORTANT: Before performing welding on the ma-
chine, disconnect both cables from the battery and
disconnect wire harness connector from the TEC.
These steps will prevent damage to the machine
electrical system.
1
5
3
Figure 25
1. Mount plate
4. Nut (4 used)
5. Cap screw (4 used)
2. U--bolt clamp (2 used)
3. TEC controller
Workman 200
Page 3.2 -- 31
Ultra Sonic Boom System (Rev. C)
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This page is intentionally blank.
Ultra Sonic Boom System (Rev. C)
Page 3.2 -- 32
Workman 200
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Chapter 4
Electrical Diagrams
Table of Contents
ELECTRICAL SCHEMATICS
Serial Numbers Below 260000000 . . . . . . . . . . . . . 3
Serial Numbers Above 260000000 . . . . . . . . . . . . . 4
WIRE HARNESS DRAWINGS
Spray System Wire Harness (Serial Numbers
Below 260000000) . . . . . . . . . . . . . . . . . . . . . . . . . 6
Spray System Wire Harness (Serial Numbers
From 260000001 to 280000200) . . . . . . . . . . . . . 8
Spray System Wire Harness (Serial Numbers
From 280000201 to 290999999) . . . . . . . . . . . . 10
Spray System Wire Harness (Serial Numbers
Above 310000000) . . . . . . . . . . . . . . . . . . . . . . . . 12
Spray Console Wire Harness (Serial Numbers
Below 260000000) . . . . . . . . . . . . . . . . . . . . . . . . 14
Spray Console Wire Harness (Serial Numbers
From 260000001 to 260999999) . . . . . . . . . . . . 16
Spray Console Wire Harness (Serial Numbers
From 270000001 to 290999999) . . . . . . . . . . . . 18
Spray Console Wire Harness (Serial Numbers
Above 310000000) . . . . . . . . . . . . . . . . . . . . . . . . 20
Sprayer Power Harness (Serial Numbers
Below 260000000) . . . . . . . . . . . . . . . . . . . . . . . . 22
Sprayer Power Harness (Serial Numbers
Above 260000000) . . . . . . . . . . . . . . . . . . . . . . . . 23
Rev. B
Workman 200 Spray System
Page 4 -- 1
Electrical Diagrams
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This page is intentionally blank.ꢀ
Electrical Diagrams
Page 4 – 2
Workman 200 Spray Systemꢀ
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R/BK
R/W
R
R
BOOM LIFT
RH SWITCH
(OPTIONAL)
BOOM LIFT
LH SWITCH
(OPTIONAL)
BOOM FOAM
LH SWITCH
(OPTIONAL)
BOOM FOAM
RH SWITCH
(OPTIONAL)
R/BK
MASTER BOOM
SPRAY VALVE
SPRAY VALVE
MONITOR POWER
R
SPRAY VALVE
SYSTEM PRESSURE
SWITCH
R
FUSE BLOCK 4 WAY
R
R
R
LS BOOM SWITCH
CTR. BOOM SWITCH
SWITCH
1
R
RT BOOM SWITCH
SWITCH
R
1
3
4
6
1
3
1
3
1
1
1
3
4
6
1
3
4
6
1
1
1
3
5
7
2FOAM
2
5
2
2
2
2
2
2
5
2
5
2
2
3
4
6
3
3
4
6
3
4
6
3
4
6
PK
PK
4BOOM LIFT
4
6
4
6
4
6
BU
PK
PK
GN/BK
GN/W
5
5
5
5
5
5
7
5
7
SPRAY SYSTEM
6
8
BK
8
7
8
8
R
PK
8
7
8
7
8
7
BK
R
BN
BU/BK
R/W
BN
W/BK
R
PK
R/BK
OR
BN
BN/W
BN
BU/GN
W/BK
BK
Y
BU/W
R/WH
R/WH
R/BK
GN/W
BK
GN
BK
BK
BU/R
BK
BK
BK
Y/BU
(+) (–)
BK
BK
HOLD
RELAY
BN
86
85
30
87
87a
VIO/R
VIO/W
A
B
C
GN/W
R/BK
BU/W
1
2
5
3
4
6
MONITOR
VIO/R
VIO/W
A
B
C
D
E
F
(OPTIONAL FOOT
MASTER BOOM
SWITCH)
G
H
J
K
PK/W
PK/BK
PK/BU
BN/W
BU/BK
R/W
GN/BK
BU/GN
BK
W/BK
BU/R
GN/W
BU/W
R/BK
BK
BK
BK
Y/BU
BU/BK
BK
PK/BK
GY/BK
PK/W
GY
OR
1
PK/BU
GY/OR
R/W
GN/BK
Y
GN
2
BN/W
BU/R
BU
2
BK
BK
1
BOOM
1
2
BOOM
LS LIFT
RS LIFT
FOAM
(OPTIONAL)
(OPTIONAL)
LH FOAM
SOLENOID
(OPTIONAL)
RIGHT SPRAY
VALVE
RH FOAM
SOLENOID
(OPTIONAL)
RATE CONTROL
VALVE
SUPERVISOR
SWITCH
LEFT SPRAY
VALVE
CENTER SPRAY
VALVE
MASTER
FOAM
SOLENOID
(OPTIONAL)
COMPRESSOR
(OPTIONAL)
FLOW
METER
SPEED
SENSOR
Workman 200 Spray System
Electrical Schematic
(Serial Numbers Below 260000000)
Page 4 – 3
Rev. A
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Workman 200 Spray System
Electrical Schematic
(Serial Numbers Above 260000000)
Page 4 – 4
Rev. A
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This page is intentionally blank.
Page 4 -- 5
Rev. B
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Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers Below 260000000)
Page 4 -- 6
Rev. B
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BLACK
BLACK
WHITE/BLACK
WHITE/BLACK
BLACK
BLACK
BLUE/GREEN
YELLOW/BLUE
Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers Below 260000000)
Page 4 -- 7
Rev. B
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Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers From 260000001 to 280000200)
Page 4 -- 8
Rev. B
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BLACK
BLACK
WHITE/BLACK
WHITE/BLACK
BLACK
BLACK
BLUE/GREEN
YELLOW/BLUE
Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers From 260000001 to 280000200)
Page 4 -- 9
Rev. B
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Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers From 280000201 to 290999999)
Page 4 -- 10
Rev. B
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Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers From 280000201 to 290999999)
Page 4 -- 11
Rev. B
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Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers Above 310000000)
Page 4 -- 12
Rev. B
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Workman 200 Spray System
Spray System Wire Harness
(Serial Numbers Above 310000000)
Page 4 -- 13
Rev. B
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Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers Below 260000000)
Page 4 -- 14
Rev. B
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BLACK
RED
WHITE/BLACK
RED/WHITE
RED/WHITE
BLUE/GREEN
RED
RED
RED
RED
BLACK
VIOLET/RED
VIOLET/WHITE
BLUE/RED
GRAY/ORANGE
BLUE/RED
GRAY/BLACK
GRAY
BROWN
BLACK
PINK/BLUE
BLACK
PINK/BLACK
PINK/WHITE
RED/WHITE
RED/BLACK
BLACK
BROWN
PINK
BLACK
RED
Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers Below 260000000)
Page 4 -- 15
Rev. B
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Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers From 260000001 to 260999999)
Page 4 -- 16
Rev. B
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BLACK
BLACK
YELLOW
YELLOW
PINK
PINK
RED
PINK
RED
WHITE/BLACK
BLUE/GREEN
BLACK
BLUE/RED
BLUE/RED
VIOLET/WHITE
BLUE
VIOLET
BROWN
VIOLET/RED
BLACK
GRAY
BLACK
ORANGE
YELLOW
GREEN
YELLOW
BLACK
BLACK
GREEN
BLUE
BLACK
RED
BLACK
ORANGE
RED
YELLOW
RED
RED
PINK
BLACK
PINK/BLACK
BROWN
Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers From 260000001 to 260999999)
Page 4 -- 17
Rev. B
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Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers From 270000001 to 290999999)
Page 4 -- 18
Rev. B
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BLACK
BLACK
YELLOW
YELLOW
PINK
PINK
PINK
BLUE/GREEN
RED
RED
WHITE/BLACK
BLACK
BLUE/RED
BLUE/RED
BLUE
VIOLET/WHITE
BROWN
VIOLET
GRAY
VIOLET/RED
BLACK
BLACK
ORANGE
YELLOW
GREEN
YELLOW
BLACK
BLACK
ORANGE
RED
RED
PINK
BLACK
PINK/BLACK
BROWN
Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers From 270000001 to 290999999)
Page 4 -- 19
Rev. B
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Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers Above 310000000)
Page 4 -- 20
Rev. B
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BLACK
BLACK
YELLOW
YELLOW
PINK
RED
PINK
RED
WHITE/BLACK
BLUE/GREEN
BLACK
BLUE/RED
BLUE/RED
VIOLET/WHITE
BLACK
CLEAR
SHIELD
BROWN
VIOLET/RED
BLACK
ORANGE
YELLOW
GREEN
BLACK
YELLOW
BLACK
BLACK
ORANGE
RED
GREEN
BLUE
RED
RED
YELLOW
PINK
BLACK
PINK/BLACK
BROWN
Workman 200 Spray System
Spray Console Wire Harness
(Serial Numbers Above 310000000)
Page 4 -- 21
Rev. B
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BLACK
PINK/BLUE
PINK/BLACK
PINK/WHITE
RED
RED/WHITE
RED/BLACK
Workman 200 Spray System
Sprayer Power Harness
(Serial Numbers Below 260000000)
Page 4 -- 22
Rev. B
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RED
ORANGE
ORANGE
YELLOW
GREEN
BLACK
PINK
YELLOW
Workman 200 Spray System
Sprayer Power Harness
(Serial Numbers Above 260000000)
Page 4 -- 23
Rev. B
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