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03124SL - Toro Media

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7. 1 2 P Safety and Instruction Decals 1 3 5 Product Records 1 3 5 2 Chapter 2 Electrical System 55 Electrical Schematic and Electrical Harness and Con o 3 Doctor DRAWINGS 2 2 Special Tools 2 9 Component Testing 2 4 ES 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 E Electrical Schematic 3 1 4 Sonic Boom System Operation 3 1 6 mo Troubleshooting 3 1 16 2 S Service and Repairs 3 1 22 9 d Chapter 3 2 Ultra Sonic Boom System Optional BiU 5 General Information 3 2 2 e Special Tools 3 2 3 Electrical Schematic 3 2 4 5 9 Sonic Boom System Operation 3 2 6 Troubleshooting 3 2 17 Service and Repairs
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9. hah NO 1431 Work LINN 1OMINOO OINOYLOATS 8 40d IMS HOLVNLOV WOOd LHOIY 9 12018 3SN4 FIOIHSA NIV 05 35 SINOS MOO1d STOIHSA 01 Q3193NNOO 75 me n8 8 Qnem n V 1m OSN3S DINOS 394105 N3MOd Q3HOLIMS OL 193410 os 8 09 Y AYM 92018 3SN4 vel 9Md MOVE dOO1 1908 WWOO 94113538 VOR 9 OLNY ND OLNY SA HOLIMS 300N SINOS Workman 200 Spray System B 1 12 Rev Page 3 it IK iona ic Boom System Opt Son 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 the sprayer operat
10. MOT NYO L 88 UU St Al f waz NOIVDIOV 222 woos SNILOVH I3H YOLVNLOV LHOIH ONO or Ni TOMO 391 ure me za 3GON 304 SI LAANI ea sa 8 HOLIMS 131 INOO8 LHOIY 14915 eke un Wey lt 1431 lt 44M 1331 lt 9 sx Javas THOS TH TASS 1 90 exe 1 s i 1007 Ae 91907 v ymd 1 6 und aid fe z ymd L SOJVOIGNI 300 pnuow TA HOLIMS 1008 INOS m mom o H3MOd 3 T1OIH3A OL 3OVJH3LNI JaMod ATL JOMOd 9018 ISNA SNILISS3N OLNV Y T ONILLJS3M VO 9018 ISNA Workman 200 10 2 Page 3 v C ic Boom System Re Ultra Son Rise in Tur
11. 8 v a YOLVNLOV LHSIY Old TOMINOO OINO1O3 13 a 2 1331 HOLIMS YAMOd Pa ANM 99018 3504 1 8 ver SNII3S3N OInv 9 SNII3S3H OLAV VOE Y Lld 390148 H P NE d 1431 5 2v8 d001 OLNV SA woivniov 1304 NNOO HO1IMS SINOS YOLVNLOV wood 1331 60d Page3 1 4 Rev B Workman 200 Spray System Sonic Boom System Optional Kit This page is intentionally blank Workman 200 Spray System Page 3 1 5 Rev B Sonic Boom System Optional Kit Sonic Boom System Operation jueun 1967 jo1eoipu OUD jueJn ui u9iIMS 2105 9 waysAS woog HOLIMS YHOLWNLOV 1331 Ny v 4 HOLIMS HOLWNLOV WOO8 1H9IH 8 FN T TW Le 90d 32018 3513 319IH3A aaziou3Na LON 1 018 HOLIMS WOSNSS INOS 32018 H3MOd 0 319IH3 NIV 2 Av OL Q3193NNOO x a i M E um 9 LON 8 8ld AV S SAL 300
12. CENTER RIGHT BOOM BOOM OPTIONAL OPTIONAL OPTIONAL REGULATOR SPRAY VALVES Page 4 4 Rev A SPEED SENSOR GEARTOOTH CONTROL ECU VALVE Workman 200 Spray System Electrical Schematic Serial Numbers Above 260000000 This page is intentionally blank 4 5 Rev B P13 BOOM LIFT RH P6 LH FOAM MARKER VALVE 1 mm Em OA H P5 RH FOAM MARKER VALVE SPRAY VALVE LH P16 FUSE SPRAY VALVE LH all P15 FUSE SPRAY VALVE CTR a INT CONN CONTROL 2 P12 P8 spray vatve cre P14 INTERCONNECT CONTROL HARN P7 Hi SPRAY VALVE RH H MINI FUSE SPRAY VALVE RH LE X FLOW METER EE n P3 FOAM COMPRESSOR P17 FUSE RATE VALVE Ph MASTER FOAM SOL VALVE RATE CONTROL ag Workman 200 Spray System Spray System Wire Harness Serial Numbers Below 260000000 4 6 Rev B CONTROL HARNESS CONTROL HARNESS
13. ANNOYS M 9 YAMOd 12 sie 7 cata OL 1ubnj sik fou Pee OIA enoa ork a asta HIT ubi NS 1 HOLIMS 14 ng y 5 n8 SAL 30010 p NO 79 i a te 15 SU UU s vez 24g 1331 6 O 08 mae P SE S pnus AZL 1 A d p 1 noos S3MO1 1H9IH 14 1 SAL 30010 Sec 01001 uns erem me L x s n NOLVOIONI 7 e HOLMS si pom AN WOOS DINOS a eoe V e ISNA d jeme d ONILLASSAY 089 T ONILAS3Y VO e 3504 Workman 200 Page 3 2 6 Ultra Sonic Boom System Rev C Sprayer Operation on Level Turf
14. LT LT ON OFF ON LT W BK BN BN BN R if BK 1 O BK BU BK P24 BU W o8 OR 1 1 6 BK P25 eor BU T ei pore maur Lt 1 1 RELAY RELAY iod BU esr P19 P18 PK Tr y L Bk Bk Foor switcH P26 Optional Foot Switch Kit BK T BK M BK BK BK J02 ae J 1 BU R BU R HOLD RELAY V R SPST SUPERVISOR SWITCH ics 12 RUN HOLD SIG BROWN WR V W 5 BN W OPTION CONTROL RED WW LgN sS YYYi 88 _ SPEED POWER ORANGE 0 BT Wi a BK SPEED SIGNAL YELLOW 0 Y P17 SPEED GROUND GREEN GN FLOW POWER BLUE F BU FLOW SIGNAL VIOLET FLOW GROUND GRAY BATTERY GROUND WHITE J BK BATTERY POWER BLACK R R LEFT BOOM SIGNAL RED BU W 4 CENTER BOOM SIGNAL GREEN B O BK RIGHT BOOM SIGNAL BLACK EE GN W 4 SPRAY MONITOR BN W GY BU BK O W GN BK Exodi ay P BU W O BK GN W Y BU Y BU A v E EDS BK BK BK 5 e TA EN 4 9 5 5 18 19 GN BK BU BK DIODE TVS 24 DIODE TVS 24 1 Pi Pi P pial P12 IY ae 2 ee no A fYYY W BK O 2 Flowmeter 2 2 2 ACTUATOR 20A ACTUATOR 20A ie PISTE MASTER FOAM FOAM COMPRESSOR LEFT RIGHT SOLENOID OPTIONAL
15. MOT 5140 YOSN3S 205095 9 voz so1vniov 2005931 9 90 NNY S SONY NL90NNY SONY Z NI SONNY 1 NI 1467 jueuno juaAn uonisog YOUMS woog woog 427 peJejunoou3 edojs ul9js S woog oiuos enn HOLIMS 141 Woods 1331 NYO 9g woog N SAL 30010 KE MOT NYO OND TOMO 391 ure x 3GON 304 SI LNANI HOLIMS 131 INOO8 LHOIY su 319IH3A OL 3OVJH3INI 14915 eke JaMod ATL lt un uem lt rend sox Avs 83MO1 LHOIY lt 44M 1007 Ast 91907 v ymd ve lt und aid z ymd iii ob OIA pnuow bob fen na
16. lt 83MO1 1431 nue 1331 ES Javas ABDI 107 Ae 91907 v ymd eu und aid z ymd SOJVOIGNI 0 aassaud HOLIMS 141 WOO8 uang 1467 enuen Ul woog 910 uwous woog 1 16071 woog enuen ul9 s S woog oiuos enn H3MOd 3 T1OIH3A OL 3OVJH3LNI JaMod ATL JOMOd 300 HOLMS WOOS DINOS SNILISS3N OLNV 0 ONILLJS3M VO 9018 ISNA Workman 200 14 2 Page 3 v C ic Boom System Re Ultra Son 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 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 lo
17. ANLOSLONd a YOLVNINYAL WHO 02 NYO 6005931 YOLVNINNSL WHO 001 Ni sow uia NYO oss HOLIMS 141 20 woos 1441 eiie z gt 5 n ano LN TOMO 91 NC NS HIT HST vez uo1vniov guy m AGOW 303 x SI IndNI HOLIMS 14 1H9IH y 4 gx ccs ANNOYS ng Mre s ee 3 10IH3A gt K i J OL 3OVJU31NI Jomo vay AZ vez uo1vniov S3MO1 1331 131 1391 OIA ATL 33M01 buo LHS 1907 und C NL ng oss MOIVOIONI NX 7 Josuog iub ores sul amd 300W uis WOO8 5 32018 3505 TA
18. Figure 17 1 Agitation supply 9 Hosebarb 17 Hosebarb hose 2 Tee fitting 10 Agitation nozzle 18 Tee fitting 3 Hosebarb hose 11 Nut 19 Nipple 4 O ring 12 Fork 12 used 20 Adapter 5 Connector 13 Hosebarb hose 21 O ring 6 Bulkhead nut 14 Hosebarb hose 22 Elbow 7 Gasket 15 Hosebarb hose 23 Hosebarb hose 8 Bulkhead fitting 16 Agitation nozzle Spray System Page 3 18 Workman 200 Spray System Disassembly Fig 17 IMPORTANT Make sure to remove and neutralize chemicals from tank and other components before disassembly Wear protective clothing chemical re sistant gloves and eye protection during repair 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Drain spray tank see Operator s Manual 3 Label hoses for proper installation after repairs are completed 4 Remove agitation nozzles as required using Figure 17 as a guide Discard all removed o rings and gaskets Assembly Fig 17 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 2 Check spray system for leaks Workman 200 Spray System Page 3 19 Spray System Pressure Relief Valve Tank Mounted NOTE ARROWS SHOW FLUID FLOW DIRECTION Figure 18 1 Hosebarb hose 4 Gasket 7
19. 1 Flowmeter 2 Pressure gauge tube Workman 200 Spray System Page 3 23 Figure 22 Figure 23 4 Center boom valve motor 5 RH boom valve motor 6 Valve mounting bar 3 Coupler Spray System Spray Control Serial Numbers Above 310000000 NOTE ARROWS SHOW FLUID FLOW DIRECTION NOOORONZ Flange nut 2 used Flange nut 8 used Flange head screw 2 used Valve mount Flange head screw 8 used Gasket 2 used Flowmeter Spray System Figure 23 1 Clamp 2 used Boom valve manifold Pressure gauge tube Coupler pressure gauge Hose clamp 3 used Hose clamp 3 used Hose boom bypass 3 231 Rev Hose RH boom supply Hose center boom supply Hose LH boom supply Regulating valve assembly Hose control bypass Hose control supply Workman 200 Spray System Disassembly Fig 23 1 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 2 Label all spray control assembly hoses for proper installation after repairs are completed Loosen hose clamps and disconnect hoses from spray control 3 Label all wire harness leads for assembly purposes
20. Workman 200 Spray System 4 1 Rev B Chapter 4 Electrical Diagrams Electrical Diagrams Ld 2 This page is intentionally blank Electrical Diagrams Page 4 2 Workman 200 Spray System R BK U GN RW R R BOOM LIFT PEDE BOOM FOAM BOOM FOAM LH SWITCH LH SWITCH RH SWITCH SPRAY VALVE SPRAY VALVE SPRAY VALVE R R MASTER BOOM R SYSTEM PRESSURE MONITOR POWER LSBOOM SWITCH CTR BOOM SWITCH T RT BOOM SWITCH SWITCH R SWITCH R SWITCH OPTIONAL OPTIONAD OPTIONAL OPTIONAL 1 1 1 ARFOAM s a d ino te gt m gt 2 oa MY dq NE 34 dure ee 4 X 7 o p ___ 9 44 5 gt BU 5 124 ENS 1 1 D 1 D b 7 6 SYSTEM 6 6 of 6 6 6 i 6 6 2 6 Z T
21. 3 2 26 Chapter 4 Electrical Diagrams oo Electrical Schematics 4 3 ii S Wire Harness Drawings 4 6 Workman 200 Spray System Rev C This page is intentionally blank Workman 200 Spray System Chapter 1 TORO Safety and Product Records JH ra Table of Contents 55 5 SAFETY INSTRUCTIONS 2 E Before Operating 2 While Operating 2 Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 3 PRODUCT RECORDS 3 Workman 200 Spray System Page 1 1 Safety and Product Records Safety Instructions The Workman 200 Spray System is designed and tested to offer safe service when operated and 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 Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come f
22. 94113533 Vor OLNY ND OLNY SA WANWN HOLIMS 300N 21105 Workman 200 Spray System B 1 10 Rev Page 3 I Kit iona ic Boom System Opt Son 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 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 bo
23. 3 40 Rev A Workman 200 Spray System Disassembly Fig 44 1 Park machine on a level surface lower booms stop engine engage parking brake and remove key from the ignition switch 2 Support boom to prevent it from falling Remove cap screw and hex nut that secure boom support to break away assembly 3 Remove hex nut flat washer and carriage screw that secure support bracket to breakaway pivot Slide support bracket from breakaway assembly 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 4 Compress spring in breakaway assembly slightly Drive roll pin from hinge Fig 46 Remove flat washer and spring from assembly 5 Complete disassembly as required using Figures 44 and 45 as guides Assembly Fig 44 1 Assemble breakaway pivot using Figures 44 and 45 as guides 2 Lubricate grease fitting on breakaway pivot after as sembly is complete see Operator s Manual Figure 45 1 Breakaway pivot 3 Boom support 2 Support bracket 4 Boom extension pipe Figure 46 1 Roll pin 2 Spring Workman 200 Spray System Page 3 41 Spray System Boom Hinge Serial Numbers Above 260000000 Figure 47 1 Hinge 2 used per boom 8 Lock nut 15 Flange nut 2 Rubber boot 2 used per hinge 9 Cap screw 16 Boom frame 3 Backing plate 4 used per hinge 10 Flat washer 17 Tube
24. 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 2 5 Boom System Workman 200 Page 3 2 25 Ultra Sonic Boom System Rev C 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 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 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 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 NOTE The auto resetting fuses should only be r
25. 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 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 3 Remove screw that secures turret body clamp to spray boom Separate clamp halves and remove turret body from machine Spray System 4 Turret body w double hose barb 5 Turret body w single hose barb 6 Single hose barb 3 used Page 3 38 7 Double hose barb 7 used 8 Turret body clamp 9 Hose barb for 90 elbow Installation Fig 41 NOTE The type of hose barb on turret body deter mines turret location on spray boom Refer to Figure 41 for turret position on booms 1 Position turret body clamp halves to spray boom and turret body Slide clamp halves together Position turret so that spray nozzle and nozzle fan slot are parallel to ground Tighten clamp screw to secure turret body 2 Install supply hose s to turret body Tighten hose clamp s Workman 200 Spray System Turret Body Service Disassembly Fig 42 1 Pull e clip from body and slide plug with o ring from body 2 Disassemble turret body using Figure 42 as a guide 3 Discard all removed seals gaskets o rings di aphragms Assembly Fig 42 NOT
26. TORO Electrical System Table of Contents ELECTRICAL SCHEMATIC and ELECTRICAL HARNESS and CONNECTOR DRAWINGS 2 SPECIAL TOOLS cip 3 Si COMPONENT TESTING 4 Master Boom 4 8 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 Workman 200 Spray System 2 1 Rev B Electrical System 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 2 2 Workman 200 Spray System Special Tools Multimeter 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 6 4 Figure 1 Workman 200 Spray System Page 2 3 Electrical System
27. Figure 27 1 Phillips head screw 5 used 6 Rate control motor assembly 11 O ring 2 Lock washer 7 Gasket 12 Cone 3 Hand grip 8 Phillips head screw 4 used 13 Control valve 4 O ring 9 Rate valve spindle section 14 Seal 5 Phillips head screw 4 used 10 Rate control valve housing The rate control motor allows the operator to vary the spray application rate The pressure increase decrease switch on the spray console energizes the rate control motor which adjusts the valve opening and allows some flow to bypass the spray booms NOTE The rate control motor affects flow to all spray booms Therefore a problem with the rate control motor will affect all booms and nozzles Disassembly and Inspection Fig 27 IMPORTANT Make sure to remove and neutralize chemicals from spray components before disas sembly Wear protective clothing chemical resist ant gloves and eye protection during repair Spray System 3 26 Rev 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 B Unplug rate control motor electrical connector from machine electrical harness C Loosen four 4 phillips head screws item 5 evenly to allow removal of the rate control motor D The inside of motor housin
28. PRAY GREEN BLACK VALVE FUSE 3AMP RATE CONTROL BROWN WHITE BLUE RED PIT RH SP VALVE B PIO RAY E BROWN WHITE RATE CONTROL FLOW VALVE GRAY VIOLET BLUE P02 C B METER CONTROL HARNESS INTERCONNECT PI4 zz d 1 gt SPO SP02 SP03 SP04 2 2 jm gt A B A B A PI PI8 PI3 LEFT TVS RIGHT ACTUATOR DIODE ACTUATOR GREEN m YELLOW gt YELLOW BLUE BLUE GREEN m WHITE BLACK o P19 TVS DIODE Workman 200 Spray System Spray System Wire Harness Serial Numbers From 280000201 to 290999999 P03 FOAM COMPRESSOR Page 4 11 Rev B 12345 Workman 200 Spray System Spray System Wire Harness Serial Numbers Above 310000000 Page 4 12 Rev B CONTROL HARNESS INTERCONNECT P18 TVS DIODE s P12 LEFT ACTUATOR BR pn RIGHT ACTUATOR P19 TVS DIODE ay P09 RH SPRAY VALVE P16 SPRAY VALVE FUSE SAMP P15 SPRAY VALVE FUSE 5AMP SPRAY VALVE FUSE SAMP p17 RATE VALVE FUSE 5AMP CTR SPRAY VALVE P07 LH SPRAY
29. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Workman 200 Spray System Models 41229 and 41235 REFER TO THE OPERATOR S MANUAL FOR 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 The Toro Company reserves the right to change product specifications or this publication without notice PART NO 03124SL Rev C Service Manual Models 41229 and 41235 Workman 200 Spray System 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 NOTE ANOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2003 2005 2011 2014 This page is intentionally blank Workman 200 Spray System Table Of Contents Chapter 1 Safety and Product Records Safety
30. Nees 300 HOLMS WOOd DINOS 9018 ISNA SNILLJS3N OLNV VOC ONILIASSY OLNY VO Workman 200 8 2 Page 3 v C ic Boom System Re Ultra Son 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 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 HI
31. 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 C Tighten screws to secure cover to valve motor NOTE Coatall O rings with vegetable oil before instal lation to reduce the chance of damage during assembly 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 Piston Valve Service Fig 32 4 1 Remove hosebarb from bottom of valve motor to al low access to piston valve 2 Make sure that valve is closed If valve is not closed spring above piston valve will be under compression and may damage valve motor or piston valve during 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 3 Use 3mm allen wrench to loosen and remove piston valve assembly from valve motor Locate and retrieve spring from above piston valve 4 Inspectseals on piston valve assembly O ring in top groove of piston valve assembly is available separately If lower two 2 seals in
32. VALVE P20 FLOW METER P10 ME CONTROL VALVE SPRAY VALVE FU SAMP POI PI CONTROL HARNESS NTERCONNECT Al A2 A4 5 B 82 B4 85 CI C2 C3 C4 C BLUE WHITE BLUE BLACK r BLUE BLACK 2y 9 POT LH SPRAY VALVE SPRAY VALVE FU SAMP PIS ORANGE BLACK ORANGE WHITE SPRAY VALVE F SAMP 16 ORANGE WHITE 2 3 P08 CTR SPRAY VALVE LL E lt 58 I Ze as Z Z a co RATE VALVE FUSE ug g 5AMP Tag 5 T 5 3 z m oO 2 3 2 3 2 3 09 PIO P20 RH SPRAY RATE CONTROL FLOW METER VALVE VALVE CONTROL HARNESS INTERCONNECT pia A D 1893 m m zoe B FOAM C COMPRESSOR D a 5 5 m gt 5 01 SP02 SP03 SP04 ow ua 2 2 EE ju jt gt gt B A B B A B 12 18 19 LEFT TVS RIGHT TVS ACTUATOR DIODE ACTUATOR DIODE Workman 200 Spray System Spray System Wire Harness Serial Numbers Above 310000000
33. 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 The Diagnostic Display see Special Tools in this chap ter is atool to help the technician verify correct electrical functions of the machine Figure 10 1 TEC controller location 3 Diagnostic tether cap IMPORTANT The Diagnostic Display must not be 2 Loopback connector 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 ELECTRIC machine will not operate without the loopback con E SONIC BOOM nector installed on the harness Store the Diagnos OUTPUT INPUT INPUT OUTPUT tic Display in a dry secure indoor location and not UNUSED AUTO UNUSED UNUSED on machine pac RIGHT UNUSED UNUSED Verify Diagnostic Display Input Functions SONIC RIGHT LEFTSENSOR UNUSED SENSOR LOWER FAULT 1 Park machine on alevel surface stop the engine and UNUSED LEFT RIGHT SENSOR UNUSED apply the parking brake RAISE FAULT RIGHT LEFT 2 Locate Ultra Sonic Boom wire harness communica RAISE LOWER RIGHT RETRIEVE UNUSED UNUSED tion port and loopback connector 6 pin connector
34. flowmeter body to remove any metal filings spray chemicals or other materials Assembly Fig 26 1 1 Assemble flowmeter using Figures 26 1 and 26 3 as guides Check the following items during flowmeter as sembly A If turbine stud item 6 was removed from up stream hub apply thread sealant to threads of stud before installation B Checkthatrotor spins freely with very little drag If necessary loosen the turbine stud 1 16 of aturn and check rotor drag Continue the process of loosening stud until rotor spins freely 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 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 Figure 26 2 1 Boom valve manifold 3 Regulating valve 2 Flowmeter Figure 26 3 1 Flowmeter body 4 Rotor 2 Retaining ring 5 Downstream hub 3 Upstream hub 6 Sensor Workman 200 Spray System Page 3 25 2 Rev B Spray System Rate Control Motor Serial Numbers Below 290999999
35. ie Jj x u BLACK 5 g I mz AI RED 22 uz 55 5 lt oo ao o m m en gt Pg RH FOAM MARKER SWITCH PIS MONITOR INPUT SPRAY MONITOR POWER HARNESS Workman 200 Spray System Spray Console Wire Harness Serial Numbers Below 260000000 Page 4 15 Rev B J02 P22 POWER HARNESS P23 P20 RIGHT P19 P16 P10 OPTIONAL MONITOR FOOT 03 POW ER SW ITCH RH BOOM SWITCH ACTUATOR P09 RH BOOM SWITCH P01 LEFT RELAY RH FOAM LIFT LH BOOM ACTUATOR MARKER SWITCH RELAY Sw ITCH SWITCH 1298 P12 SPRAY PRO MONITOR POL ae iii Ps p ACTUATOR LIFT Sw ITCH io De PRESSURE p45 P02 SW ITCH MONITOR HARNESS ACTUATOR 08 CTR BOOM INPUT CONNECTOR 5 2 RELAY SW ITCH SWITCH Workman 200 Spray System Spray Console Wire Harness Serial Numbers From 260000001 to 260999999 Page 4 16 Rev B MONITOR POWER SWITCH SUPVSR SWITCH LOCK RATE HOLD RELAY 16 OPTIONAL FOOT SWITCH
36. loc LOWER FAULTS UNUSED UNUSED 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 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 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 INDICATOR UNUSED LAMP LEFT UNUSED RAISE LEFT UNUSED LOWER UNUSED UNUSED 119 9431 UNUSED UNUSED KEY UNUSED RUN INPUTS DISPLAYED OUTPUTS DISPLAYED TORO Workman 200 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 6 The Diagnostic Display will illuminate the LED associated with each of the inputs when that input switch is closed Individually change ea
37. seat and o ring locations as spindle is removed C Inspect the cone located at the bottom of the spindle The cone should be free of nicks or worn spots A damaged cone will allow flow to the boom bypass rather than to the spray boom D The seat o rings allow the spindle to shut off flow to the spray boom If boom nozzles leak when the boom is shut off the seat and seat o rings should be inspected carefully 6 If leakage occurs from balancing valve knob at bot tom of boom valve manifold Fig 32 A Carefully remove roll pin that secures balancing Figure 31 valve to knob 1 Spindle roller 3 Seat 2 Cone 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 Assembly Fig 29 NOTE Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Replace all removed o rings oe 2 If boom valve manifold was disassembled Fig 32 A Install o ring balancing valve and knob to man ifold Figure 32 B Secure balancing valve to knob by carefully 1 Boom valve manifold 3 Balancing valve knob 2 Balancing valve 4 Roll pin installing roll pin Workman 200 Spray System Page 3 29 Spray System 3 Assemble spindle section by reversing disassembly process Align green indicator tab on spindle to slot in spindle housing Install screw into bottom of spindl
38. 07 07 TANT BK PK E he NN BN BU BK BN W BK BN PK R BK BN GN W 5 BU W BK R BK R WH R WH m BU R BK GN W BK BK BK Y BU BK BK HOLD nm RELAY bag BOY gs EN NE NE 87 30 VIO R T B nig OW n br BU W MC s ts MONITOR E OPTIONAL FOOT MASTER BOOM SWITCH PKW PK BK _ BN BU BK R W GN BK N BU GN wek GN W BU R BU W R BK BK BK Y BU PK BK PK BU GY GY OR BU BK RW GN BK BNW BU R OR BU Y GN BK BK BK BK a CH 1 2 CLAU g A BOOM Boom X ELSE 1 2 LS LIFT RS LIFT FOAM MEM SPEED FLOW VALVE VALVE SWITCH OPTIONAL OPTIONAL SOLENOID L SENSOR METER OPTIONAL Workman 200 Spray System Electrical Schematic Serial Numbers Below 260000000 Page 4 3 Rev A 1 10
39. 2 used per boom 4 Flange nut 4 used per hinge 11 Pivot bracket 18 Spring retainer 2 used per boom 5 Boom RH shown 12 Bushing 2 used per pivot bracket 19 Breakaway spring 2 used per boom 6 Tee fitting 13 Flange head screw 20 Grease fitting 2 used per hinge 7 Flange hd screw 4 used per hinge 14 Pivot pin Disassembly Fig 47 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 Park machine on alevel surface lower spray booms stop engine engage parking brake and remove key from the ignition switch 2 Loosen hose clamp and remove supply hose from tee fitting item 6 on spray boom 3 Support spray boom to prevent it from falling Spray System 3 42 Rev A 4 Loosen two 2 cap screws item 9 and lock nuts item 8 to allow breakaway springs item 18 to fully ex tend 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 6 Clean all removed components If pivot bracket was removed inspect bushings and pivot pin for damage or wear Workman 200 Spray System Assembly Fig 47 1 If pivot bracket item 11 was removed from machine
40. 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 5 Disconnect voltage and multimeter leads from the relay terminals Reconnect relay to machine wire har ness and install spray control enclosure faceplate Electrical System Page2 8 Rev B SERIAL NUMBER BELOW 260000000 Figure 11 3 Normally closed term 4 Normally open term 1 Coil terminal 2 Common terminal SERIAL NUMBER ABOVE 260000000 85 87a 87 Figure 12 3 Normally closed term 4 Normally open term 1 Coil terminal 2 Common terminal Workman 200 Spray System Traction Speed Sensor The traction speed sensor is attached to the upper transaxle cover Fig 13 It uses a magnetically based Hall Effect integrated circuit As the differential in the transaxle turns the sensor accurately senses the move 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 Testing 6 Locate traction speed sensor on the transaxle as sembly Disconnect the wire harness connector from traction speed sensor 7 Remove cap screw and lock washer that secure speed sensor to transaxle Remove speed sensor from transaxle 8 Co
41. A SOLENOID Z tr POS BLACK BLACK RH FOAM BLUE GREEN MARKER VALVE P06 LH FOAM YELLOW BLUE 2 MARKER VALVE SPO 02 03 04 z ul na 2 a gt gt tr m tr A B A B PI PI8 19 LEFT TVS RIGHT TVS ACTUATOR DIODE ACTUATOR DIODE Workman 200 Spray System Spray System Wire Harness Serial Numbers From 260000001 to 280000200 4 9 Rev B p11 CONTROL HARNESS INTERCONNECT FOAM COMPRESSER CONTROL HARNESS INTERCONNECT Workman 200 Spray System Spray System Wire Harness Serial Numbers From 280000201 to 290999999 Page 4 10 Rev B P13 RIGHT ACTUATOR P19 TVS DIODE B A I4 P08 CTR SPRAY VALVE xx TVS DIODE P07 LH SPRAY VALV P02 FLOW METER P P17 3AMP P16 P15 3AMP P10 RATE CONTROL VALVE LH SP VALVE 3AMP RAY CONTROL HARNESS INT ERCONNECT PII Al A2 A3 A4 AS B2 83 84 B5 C2 C3 C4 65 BLUE BLACK BLUE WHITE POT lang LH SP VALVE BLUE BLACK RAY CTR VALVE 3AMP 15 PRAY ORANGE WHITE ORANGE BLACK P08 ORANGE WHITE RH SPRAY VALVE FUSE 3AMP GREEN BLACK GREEN WHITE PI6 CTR S VALVE B A 09
42. Automatic Operation Manual Boom Operation Workman 200 Page 3 2 1 Chapter 3 2 Ultra Sonic Boom System Optional Kit 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 27 Sonic Sensors 28 30 Toro Electronic Controller Ultra Sonic Boom System Rev C 2 5 Boom System 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 1 Select the proper chemical for the job 2 Carefully read the directions printed on the chemical manufacturer s labels before handling chemicals In structions on chemic
43. Disconnect chain from drain handle 4 If necessary remove drain handle and bulkhead us ing Figure 38 as a guide 5 If necessary remove drain assembly from tank A Loosen hose clamp and slide drain hose from drain assembly hosebarb B Remove fork from drain assembly to allow hose barb to be removed from drain assembly C Remove bulkhead nut that secures drain assem bly to spray tank D Lift drain assembly from bottom of tank 6 Disassemble drain assembly using Figure 40 as a guide 7 Discard all removed o rings and gaskets Assembly Fig 38 NOTE Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Assemble drain tube using Figures 38 and 40 as guides Replace all removed o rings and gaskets 2 Hosebarb of drain assembly should be orientated to ward the rear of the spray tank Make sure that clear ance exists between drain assembly and sprayer frame 3 Check spray tank for leaks Workman 200 Spray System Page 3 37 1 2 Suction strainer Tank drain Adapter Plunger holder Spring Drain plunger O ring Drain seat O ring Figure 39 3 Figure 40 8 9 10 11 12 13 Tank lid Drain bulkhead Fork Gasket Bulkhead nut O ring Hosebarb Spray System Turret Bodies S _ UPPLY Figure 41 1 Turret body w 90 elbow 2 90 elbow 1 used 3 Screw Removal Fig 41
44. 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 Page 3 2 7 Ultra Sonic Boom System Rev C 2 5 Boom System SNIGNALXA YOLVNLOV 1331 voz so1vniov 3JALLO31O03d SOIVNINS31 WHO 821 MOT NYO HOVE cOOT 140d NOLO e INWOOD MOT NYO MOLVNINYAL WHO 821
45. L NO SNSR DATA ECU has detected an invalid reading from left sensor LED ON Left sensor operating normally LED OFF R NO SNSR DATA ECU has detected an invalid reading from right sensor LED ON a ee R NOT TRACKING Right boom not tracking to target within 5 seconds LED ON L TRACKING Left boom not tracking to target within 5 seconds LED ON Left sensor operating normally LED OFF L SNSR FEEDBACK ECU receiving signal from left sensor LED ON R SNSR FEEDBACK ECU receiving signal from right sensor LED ON BEEN Pc NOTE When the vehicle ignition switch is in the OFF position all Diagnostic Display LED s should be OFF NOTE Initial calibration of the Sonic Boom sensors is required for proper operation of ECU inputs Refer to your Sonic Boom Kit Installation Instructions for infor mation on initial sensor calibration Sonic Boom System Optional Kit 3 1 18 Rev B 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 sensoris the problem source e g switch circuit wiring Workman 200 Spray System Verify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the electr
46. Level Changed by Operator During Automatic Operation 12 Manual Boom Operation 14 Workman 200 Spray System 31 1 Rev C Chapter 3 1 Sonic Boom System TROUBLESHOOTING 16 Sonic Boom Light 16 Sonic Boom Calibration 16 Diagnostic Display 17 Troubleshooting Chart 20 SERVICE AND REPAIRS 22 Sonic Mode Switch 22 iiis uc tha bn eR 23 Electronic Control Unit ECU 24 Sonic Sensor 25 Sonic Boom System Optional Kit System 2 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 1 Select the proper chemical for the job 2 Carefully read the directions printed on the chemical manufacturer s labels before handling chemicals In structions on chemical manufacturer s container labels rega
47. Many pump components can be easily re versed During disassembly make note of component position e g crankshaft valve chamber to assure cor rect assembly 1 Remove two 2 hex bolts that retain valve chamber to pump Separate valve chamber from pump 2 Remove inlet and outlet valves and o rings from each diaphragm cover Note orientation of valves Dis card valves and o rings Clean valve and o ring seats in the valve chambers and diaphragm covers 3 Remove hex bolts that secure diaphragm covers to pump Remove diaphragm covers 4 Remove hex bolt washer nylon washer diaphragm and diaphragm back disc from each connecting rod Discard diaphragms 5 Remove five 5 hex bolts and nuts that secure pump casing halves together Note location of two 2 longer hex bolts with washers Carefully separate pump casing halves 6 Clean grease from bottom of housing and check con dition of bearings on crankshaft If bearings require re placement remove and disassemble crankshaft A Remove crankshaft assembly from pump casing B Slide felt seal and dust plate from both ends of crankshaft C Loosen hex bolt and hex nut that secure connect ing rods to crankshaft Slide connecting rods from crankshaft Press ball bearings from crankshaft Assembly Fig 8 1 If disassembled reassemble crankshaft A Hand pack new bearings with 2 general purpose lithium base grease B Pressing on bearing inner race install two
48. Page 3 2 29 pem my Programming plug 3 Letter T n m Figure 20 4 Plug arrow 5 Sensor notch Figure 21 3 Red LED 4 Yellow LED Ultra Sonic Boom System Rev C 2 5 Boom System 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 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 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 3 Locate relay to be tested and disconnect wire har ness connector from relay Remove relay from mount plate for testing 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 t
49. Page 4 13 Rev B 14 SPRAY HARNESS P13 POWER HARNESS SPRAY HARN CONN P15 MONITOR INPUT P10 PL MONITOR POWER q MASTER BOOM SW P12 SPRAY PRO MONITOR P5 SYSTEM PRESS SW J2 SUBP SW LOCK RATE SUPV SW LOCK RATE Workman 200 Spray System Spray Console Wire Harness Serial Numbers Below 260000000 Page 4 14 Rev B P17 P1 HOLD RELAY LH BOOM SW P7 TH BOOM LIFT SW P6 LH BOOM LIFT SW P9 RH FOAM MARK SW P3 RH BOOM SW PB LH FOAM MARK SW P16 FOOT SW P2 CTR BOOM SW PIO MONITOR POWER SWITCH SUPVSR SWITCH LOCK RATE 85
50. 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 NOTE A sequence of switch movements is necessary to engage the calibration mode Refer to the Sonic Boom Kit Installation Instructions for this sequence The sonic boom lightflashing slowly indicates that a sys 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 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 Sonic Boom System Optional Kit 3 1 16 Rev NOTE When troubleshooting an electrical problem on your Sonic Boom System referto 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 output
51. Wire connector Figure 28 4 1 Valve motor assembly 4 Spring 2 Piston valve assembly 5 Valve motor cover 3 Valve seal Workman 200 Spray System Page 3 27 2 Rev B Spray System Boom Valve Motor Serial Numbers Below 290999999 27 1 _____ 70 in Ib 8 N m Figure 29 1 Housing cover 12 Spring seat 23 Flat washer 2 Cover seal 13 O ring 24 Spring 3 Boom valve motor 14 Spindle housing 25 Flat washer 4 Phillips head screw 5 used 15 Phillips head screw 4 used 26 Cone 5 O ring 16 O ring 27 Screw 6 Lock washer 17 O ring 28 Boom valve manifold housing 7 Hand grip 18 Flat washer 29 Fork 8 Roller 19 Seat outer o ring 30 O ring 9 Roller pin 20 Seat 31 Balancing valve 10 Spindle 21 Seat inner o ring 32 Roll pin 11 Spring 22 Seat base 33 Balancing valve knob 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 Disassembly and Inspection Fig 29 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
52. boom valve motor disassembly see Spray Control in this section Spray System Page 3 28 Rev B 2 To remove the motor and spindle section assembly from the manifold assembly A Remove the fork item 29 that secures the motor and spindle sections to the manifold assembly B Lift the motor and spindle section assembly from the manifold 3 To allow easier separation of the motor and spindle sections make sure that boom valve motor is in the closed position green indicator is recessed into the spindle housing Remove four phillips head screws item 15 and separate spindle section from motor sec tion Workman 200 Spray System 4 Remove rear housing cover from boom valve motor to inspect motor components A Cam should be tight on shaft Cam surface should be free of wear and or scoring B The inside of motor housing should be free of 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 4 Center boom valve motor B The spindle can be disassembled by removing 2 Flowmeter 5 RH boom valve motor the screw at the bottom of the spindle shaft Take 3 LH boom valve motor note of washer spring
53. con necting rod and two crankshaft ball bearings onto crankshaft 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 ftHb 34 to secure connecting rods to crankshaft Workman 200 Spray System Page 3 13 D Position dust plate and felt seal on both ends of crankshaft 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 2 Place second pump casing onto assembly Pump casing surfaces should mate together 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 Figure 9 1 Closest connecting rod to right side 2 Rear connecting rod to left side Figure 10 1 Hex bolt 30 mm long 2 Hex bolt 55 mm long Spray System 4 Place diaphragm back disc and new diaphragm onto each connecting rod The connecting rods should ex tend above the diaphragms when correctly installed Fig 11 Position nylon washer and washer on each connecting rod and then thread hex bolt into connecting rod T
54. ee SONIC SENSOR TEC output exists to sonic sensors LED ON RIGHT RAISE TEC output exists to energize relays to raise right boom LED ON RIGHT LOWER TEC output exists to energize relays to lower right boom LED ON erect sneer DOR _ INDICATOR LAMP Sonic boom switch is in automatic position LED ON pod Sonic boom switch is in manual position LED OFF LEFT RAISE TEC output exists to energize relays to raise left boom LED ON iem LEO OFF _ LEFT LOWER TEC output exists to energize relays to lower left boom LED ON 7 erect sence te0 OFF 2 5 Boom System Workman 200 Page 3 2 23 Ultra Sonic Boom System Rev C Troubleshooting Chart The chart that follows contains suggestions that can be NOTE When troubleshooting an electrical problem on used to assist in diagnosing Ultra Sonic Boom System your Ultra Sonic Boom System refer to information re performance issues These suggestions are not all in garding the sonic boom light in this section Also use the clusive Also consider that there may be more than one Diagnostic Display see Special Tools in this chapter to cause for a machine problem test Toro electronic controller TEC inputs and outputs Light in sonic boom switch is not illu Sonic boom switch is the MANUAL position minated 2 Amp fuse in sonic boom fuse block is faulty all sonic boom func tions are affected Upper
55. lightly lubricate bushings item 12 with motor oil before assembly Connect boom actuator not shown to pivot bracket see Boom Actuator Installation Machines with Serial Numbers Above 260000000 in this section 2 Make sure that hinges item 1 are securely fastened to pivot bracket item 11 and boom item 5 The boom hinge uses four 4 backing plates between the boom and flange nuts 3 Position boom hinge to pivot bracket hinge Make sure that rubber boots item 2 are placed at hinge junc tions and that rib on boots are toward the top of the boom Fig 48 4 Insert two 2 cap screws item 9 through flat 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 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 Workman 200 Spray System 1 Rubber boot Page 3 43 Rev A Figure 48 2 Rib Figure 49 Spray System Boom Actuator Optional Serial Numbers Below 260000000 Figure 50 3 Boom actuator 4 Wire harness 1 Cotter pin 2 Clevis pin Remo
56. 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 Inspectthe foam sensor filter item 11 for damage or ex cessive debris buildup Replace filter if necessary Workman 200 Spray System Page 3 1 25 Rev NOORON gt Sonic sensor 8 Sensor bracket 9 Screw 2 used 10 Protection tube 11 U bolt 4 used 12 Lock nut 8 used 13 Sensor cover Spray boom RH shown Lock washer 2 used Nut 2 used Foam sensor filter Sensor shield Patch Sonic Boom System Optional Kit This page is intentionally blank Sonic Boom System Optional Kit 3 1 26 Rev B Workman 200 Spray System Table of Contents GENERAL INFORMATION Installation Instructions Precautions Concerning Chemicals Used in Spray Precautions for Removing or Adjusting Spray System SPECIAL TOOLS ELECTRICAL SCHEMATIC ULTRA SONIC BOOM SYSTEM OPERATION Sprayer Operation on Level Turf Downward Slope in Turf Encountered Rise in Turf Encountered Boom Level Changed by Operator During
57. power switch 4 Reconnect the harness connector to the switch after testing Install console panel to machine BACK OF SWITCH Figure 9 Workman 200 Spray System Page 2 7 Electrical System Hold and Boom Actuator Serial Numbers Above 260000000 Relays Workman sprayers with serial numbers below 260000000 use a single relay for the sprayer hold 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 located in the spray control enclosure The relays can be identified by a tag at the relay wire harness connector The relay used on sprayers with serial numbers below 260000000 Fig 11 has a different terminal layout than relays used on sprayers with serial numbers above 260000000 Fig 12 Relay operation and circuit logic is the same regardless of serial number Testing 1 Remove spray control enclosure faceplate locate relay that is to be tested and unplug wire harness con nector from relay 2 Connectmultimeter 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 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connectmultimeter ohms setting leads to relay ter minals
58. relays will lead to a change in boom actuator length and ultimately a change in boom height A LOWER BOOM HEIGHT IS DETECTED SO THE BOOM ACTUATOR RETRACTS TO RAISE BOOM SECTION Figure 5 Workman 200 Page 3 2 11 Ultra Sonic Boom System Rev C 95 gt OD o 20 m 1467 juang 1 _ uonisog uo1MS woog 9140 umoys woog 437 Besley Aq woog ul9 s S woog IIUOS 2 AANLOSLOYd SOIVNINS31 WHO 821 MOT NYO 9 90 NNY SOIVNIAS3L WHO 821 S 90 NNV 851 OL aassaud HOLIMS 1411 NI 90 Woods 1331 SONY T 2 ye L NI 8 um Pus mem rou Ut SNILOVH I3H YOLVNLOV 1481 ME ano xue wl Ky X ovid 904 HOLIMS 1417 L D e si NOO8 216 A zi 8 H3MOd STOIHSA lt lt OL SOVAYSLNI
59. sealant 7 Anti seize Lubricant RIGHT ubrican Loctite 242 Loctite 242 Figure 6 1 Spray pump assembly 11 Pressure hose 2 Elbow pressure 12 Flange head screw 4 used 3 Gasket 13 Pump drive shroud 4 Pressure tee fitting 14 Shroud bracket 5 O ring 15 Square key 6 Pressure dampener 16 Set screw 7 O ring 17 PTO driveshaft 8 Hosebarb 18 Flange nut 4 used 9 Nut 19 Flange nut 4 used 10 Hose clamp Spray System Page 3 10 Apply thread sealant Pump mount bracket Flange head screw 4 used Suction tee fitting Suction dampener Gasket Hosebarb Nut Hose clamp Suction hose Workman 200 Spray System Removal Fig 6 IMPORTANT Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Loosen hose clamp that secures suction hose item 28 to hosebarb item 25 Pull suction hose from hose barb 3 Loosen hose clamp that secures pressure hose item 11 to hosebarb item 8 Pull pressure hose from hosebarb 4 Remove PTO driveshaft item 17 from output shaft of transaxle PTO assembly 5 Remove four 4 flange head screws and flange nuts that secure pump assembly to pump mount bracket 6 Remove pump assembly with PTO driveshaft and drive shrouds attached from machine 7 R
60. spray control and then install spray control assembly to machine see Spray Control Assembly Serial Numbers Above 310000000 Installation in this section Piston Valve Service Fig 28 4 1 Remove hosebarb from bottom of valve motor to al low access to piston valve 2 Make sure that valve is closed If valve is not closed spring above piston valve will be under compression and may damage valve motor or piston valve during 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 3 Use 3mm allen wrench to loosen and remove piston valve assembly from valve motor Locate and retrieve spring from above piston valve 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 6 Position spring into valve motor housing Use 3mm allen wrench to secure piston valve assembly to valve motor 7 Secure hosebarb to bottom of valve motor Figure 28 2 1 Boom valve manifold 3 Regulating valve 2 Flowmeter Figure 28 3 1 Valve motor assembly 4 Socket screw 4 used 2 Valve motor cover 5 Phillips screw 2 used 3
61. the Toro Electronic Controller TEC to control electrical system operation The TEC is attached to a mounting plate under the dash panel Fig 24 Power is provided to the TEC when the vehicle ignition switch is ON A2 Amp fuse provides circuit protection for this logic power to the TEC The fuse is located in the UI tra Sonic Boom System fuse block under the dash pan el 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 Testing ofthe TEC inputs and outputs can be completed with the use of the Diagnostic Display see the Special Tools and Troubleshooting sections of this chapter 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 e
62. 0 39Gdl88 H 038 1HON 1H9IM gt gt AHVNOLLV LS Zor uss Lor vez uoivniov NO 95 M d ES 1331 me 30 19 05 35 DINOS 394005 YAMOd mm 08 28 45 GAHOLIMS OL 193414 x oes 8 v a YHOLWNLOV 1HOlH Old G3zibH3N3 LON 1331 HOLIMS 43MOd 14 Y 1OMINOO OINOMIOG T3 AWM v 9018 3sn4 1 vel SNLISS3H OInV 9 G3zibH3N3 LON Lid AV 138 INIS OIN Of Y SAL 30010 3 X 1331 AY OLAV NI AYWNOILWLS Move 9007 OLNV SA TYNNYW vez so1vniov 4304 HOLIMS 21 05 v a woog 1331 60d 3 1 6 Rev Workman 200 Spray System Sonic Boom System Optional Kit 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 ge
63. 3 2 28 14 to 16 ft Ib 19 to 21 N m Figure 17 1 Sonic sensor 4 Cover 2 Lower housing 5 Programming plug 3 Nut 2 used 6 Cap Figure 18 1 Sensor with cover 2 Sensor without cover Figure 19 3 Nut 2 used 1 Sonic sensor 2 Lower housing Workman 200 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 During normal operation the green LED and both yellow LED s should be illuminated The red LED will be off 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 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 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 Workman 200 1 Sonic sensor 1 Yellow LED 2 Green LED
64. 86 7 81 RELAY 30 PI6 INTERCONNECT MASTER BOOM FOOT SWITCH Al A3 A4 A5 BI 82 B3 B4 B5 CI C2 C3 C4 c3 PI SPRAY CONN HARNESS ECTOR Pid SPRAY HARNE CONNECTOR C A gt gt x LH BOOM CTR BOOM RH BOOM MASTER BOOM SYSTEM PRESSURE LH BOOM RH BOOM LH FOAM SWITC SWITCH SWITCH SWITCH SWITCH LIFT SWITCH LIFT SWITCH MARKER SWITCH PI P P3 P4 PS P6 P7 P8 6 1 8 1 3 4 5 7 3 1 4 5 6 7 4x 4 4 EON 4 i gt 5 8 1 23 4 5 6 12 4 5 6 6 1 8 x 8 j LEE x 3 5 98 z x z 3 amp a amp 3 E ig z 3 3 5 055 5 9 5 gt 3 3 E z 2 mm m Toa 015 A 3 ga Pp 5 5 8 2 58 15 5 3 2 2 5 5 EE d 5 5 om coc 3 D a BLACK x 5 t RED WHITE BLACK 3 L RED WHITE 5 1 RED WHITE BLUE GREEN RED 2 RED 3 RED 4 RED 5 6 1 BLACK 8 xz 5 VIOLET RED zou E VIOLET WHITE a g T n E BLUE RED zm GRAY ORANGE BLUE RED GRAY BLACK ENT GRAY 5 BROWN 4 SP2 BLACK BLACK PINK BLUE 3 PINK BLACK PINK WHITE RED WHITE RED BLACK BLACK D BROWN
65. ACTS TO RAISE BOOM SECTION Figure 6 Workman 200 Page 3 2 13 Ultra Sonic Boom System Rev C 2 5 Boom System voz so1vniov HOVE cOOT 3JALLO31O03d SOIVNINS31 WHO 021 MOT NYO 140d NOUVOINNWNOD MOT NYO SOIVNIAS31 WHO 821 MOT 9 90 NNY 5 Dunia YOSNIS 9 y Wood LH NL90NNY NI SONY 2 NI SONNY NO L NI gt eee HOLIMS 14 Woods 1331 NYO ZL NT Joi i R 38 1 30 9 vaz YOLWNLOW Avz SAL 3900 YOLVNLOV LHOIH OINOS NOSNAS Josuos 14513 KE MOT NYO TOMO 391 A9 OIA ME lt lt OND or Ni K lt L za x 1d MG 3GON 304 SI LNANI ea sa Peu si cu lt gt M
66. BLACK POWER SPRAYER CONTROL INTERCONNECT P2 Ih 27 SPRAY SYSTEM POWER Workman 200 Spray System Sprayer Power Harness Serial Numbers Below 260000000 Page 4 22 Rev B SPR AYER CONTROL TERCONNECT B P23 P22 P01 gl SPEED B o l A B A SENSOR LII J05 wl RIGHT BOOM RED LIFTS POWER J03 LEFT BOOM ORANGE LIFTS POWER dus ORANGE SENSOR YELLOW GREEN POI 101 BLACK GROUND J02 SPRAY SYSTEM PINK POWER J04 FOAM MARKER YELLOW POWER EN Ce Ek J03 CONTROL IET ED ER GROUND Q n E 1 LIFTS POWER 4 N 10 FOAM MARKER POWER SPRAY C POWER Workman 200 Spray System Sprayer Power Harness Serial Numbers Above 260000000 Page 4 23 Rev B
67. Component Testing Master Boom Switch The master boom switch is located on the spray control enclosure faceplate Fig 2 Testing 1 Remove spray control enclosure faceplate locate master boom switch and unplug wire harness connector from switch 2 The switch terminals are marked as shown in Figure 3 In the ON position continuity should exist between terminals 2 and 3 and also between terminals 5 and 6 In the OFF position continuity should exist between ter minals 1 and 2 and also between terminals 4 and 5 3 Reconnect the harness connectors to the switch af ter testing Install console panel to machine Electrical System Page 2 4 Figure 2 1 Master boom switch BACK OF SWITCH Figure 3 Workman 200 Spray System Rate Control and Boom Actuator Switches The rate control increase decrease switch is located on the spray control enclosure faceplate Fig 4 On machines equipped with the electric boom lift this is the same switch that is used to operate the boom actua tors Testing 1 Remove spray control enclosure faceplate locate switch to be tested and unplug wire harness connector from switch 2 The switch terminals are marked as shown in Figure 5 In the INCREASE or boom raise position continuity should exist between terminals 2 and 3 and also be tween terminals 5 and 6 In the neutral center position there should be no continuity between any swi
68. Disconnect wire harness connectors from regulating valve flowmeter and three 3 boom valve motors 4 Remove pressure gauge tube item 10 from coupler on pressure gauge port on right side of boom valve 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 IMPORTANT Before removing flowmeter from spray control assembly note direction of arrow on top of flowmeter Fig 23 3 The arrow should point toward boom valve manifold assembly 7 Separate spray control assembly as required using Figure 23 1 as a guide Discard all removed gaskets Assembly Fig 23 1 NOTE Coat all gaskets and o rings with vegetable oil before installation to reduce the chance of damage 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 2 Position spray control assembly to valve mounting bar and secure with eight 8 flange head screws flat washers and flange nuts Workman 200 Spray System Page 3 23 2 Rev B 3 Using labels placed during disassembly install hoses to correct locations on spray control assembly Secure hoses with hose clamps 4 Install pressure gauge tube item 10 to coup
69. E Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Replace all removed seals gaskets o rings and di aphragms 2 Assemble turret body using Figure 42 as a guide A The turret item 8 end with slightly larger bore and detent grooves needs to be orientated toward detent posts on body item 4 Fig 43 B Make sure to align notch on plug item 10 with groove in body item 4 as plug is installed C Install e clip 5 into body to secure assem bly Upper clamp O ring Pivot pin Body E clip Gasket 3 used Dust cap 2 used Turret O ring WONOARPONS 1 Body 2 Detent post Workman 200 Spray System Page 3 39 Figure 42 10 11 12 13 14 15 16 17 18 Figure 43 3 Plug Nozzle Nozzle cap O ring Seal Screw End cap Diaphragm Hose barb Detent groove Spray System Boom Frame Breakaway Pivot Assembly Serial Numbers Below 260000000 Figure 44 1 Hinge 8 Carriage screw 15 Cap screw 2 Breakaway pivot 9 Flat washer 16 Boom support 3 Spring 10 Cotter pin 17 Boom extension pipe 4 Washer 11 Clevis pin 18 Lock nut 4 used per side 5 Roll pin 12 Clevis pin 19 Flat washer 4 used per side 6 Hex nut 13 Main boom frame 20 Cap screw 4 used per side 7 Support bracket 14 Breakaway pivot assembly Spray System
70. FOMOT OOTY 2 35953 ENS HET ubi ATL vez uolvniov BT Se IB voz so1vniov 83MO1 1431 TTST H woog 19 w K lt auis aai r a DAU YOUU A AYZ SAL 30010 d nda NOS U3AOTIHSI lt gt ebd MP eee ane A 21007 amd T Te vina 79 4 am ona 3004 ome T WOO DINOS z ymd 9018 ISNA Ne SNILLJS3N OLNV VOC ONILIASSY OLNV VO Workman 200 12 2 Page 3 v C ic Boom System Re Ultra Son 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 lo
71. Fork 2 Ringnut 5 Hosebarb hose 8 Hosebarb hose from spray pump 3 Pressure relief valve 6 O ring Spray System Page 3 20 Workman 200 Spray System Removal Fig 18 IMPORTANT Make sure to remove and neutralize chemicals from tank and other components before disassembly Wear protective clothing chemical re sistant gloves and eye protection during repair 1 Park machine on a level surface stop engine 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 4 Remove pressure relief valve from spray tank using Figure 18 and 19 as guides Discard all removed o rings and gaskets 5 Disassemble pressure relief valve using Figure 20 as a guide Assembly Fig 18 NOTE Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Assemble and install pressure relief valve using Fig ure 18 19 and 20 as guides Replace all removed rings and gaskets 2 Check spray system for leaks Figure 19 1 Hose to pressure relief 3 Control supply hose 2 Hose from spray pump Figure 20 1 Nut 4 Cone 2 Seat 5 Relief valve housing 3 Spring Workman 200 Spray System Page 3 21 Spray System Spray Control Serial Numbers Below 290999999 Nut Threaded rod Washer Bushing O ring Cap O ring Tee piece H
72. GHER BOOM HEIGHT IS DETECTED SO THE 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 BOOM ACTUATOR EXTENDS TO LOWER BOOM SECTION Figure 4 Workman 200 Page 3 2 9 Ultra Sonic Boom System Rev C ct 2 OD 20 1467 jueuno 149 1 9 NOIO3NNOO HOVE dOOT__1NOd NOLIOINDAWOO voz so1vniov 3JALLO31O03d SOIVNINS31 WHO 821 MOT NYO MOT NYO SOIVNIAS31 WHO 821 MOT YOSNIS 9 y Wood LH Avz SAL 30010 scie 9 90 NNY rv iz S NI 90 NV NI 90 NNY G NI 2 NI E m lt L NI uonisog uo1MS woog 910 umoys woog 1 pejejunoou3 ny ur esiH ul9 s S woog IIUOS ef HOLIMS 141 Woods 1331 amp lt
73. LACK YELLOW 7 501 YELLOW 4 x PINK PINK E e 3 RED RED 2 5 WHITE BLACK m BLUE GREEN 1 BLACK A 8 8 BLUE RED AER B A VIOLET WHITE 8 0 BLUE RED C D E BLACK F CLEAR 6 BROWN SHIELD H 3 J 4 VIOLET RED K 5 BLACK PIT SP02 BLACK ORANGE YELLOW 8 155 GREEN C YELLOW D SP06 BLACK A GREEN BLACK 8 BLUE 5 ORANGE x gt 5 ae 5 04 REPE OE 5 5 YELLOW I Q PINK Siugas 52898952 Lau T 8 BLACK S2gzuu 55 2 56 56 PINK BLACK 473 4 442 44 458 BROWN mm 9 A2 M AS BI 82 B3 B4 B5 CI C3 ca C5 FM Co c a 122034 5 1220234 5 ere 28 2345 30 85 87 86 SPRAY HARNESS SPRAY HARNESS 30 85 87 87 86 30 85 BA 87 86 i 30 85 2 87 86 CONNECTOR CONNECTOR LEFT ACTUATOR RELAYS RIGHT ACTUATOR RELAYS Workman 200 Spray System RH FOAM MARKER SWITCH MONITOR INPUT SPRAY PRO MONITOR P23 POWER HARNESS P22 Spray Console Wire Harness Serial Numbers Above 310000000 Page 4 21 Rev B SPRAYER CONTROL INTERCONNECT A B 6 JI P1 SPEED SENSOR BLACK th A PINK BLUE SPEED p PINK BLACK SENSOR c PINK WHITE Ins Je SPRAY SYSTEM RED POWER 33 BOOM LIFTS RED WHITE POWER J4 FOAM MARKER RED
74. 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 A Ifthe correct output LED s do not illuminate verify that the required input switches are in the necessary positions to allow that function to occur B If the output LED s are on as specified but the booms do not function properly suspect a failed electrical component an open in the tested circuit or a non electrical problem e g binding of the boom hinge Repair as necessary C If each input switch is in the correct position and functioning correctly but the output LED s are not correctly illuminated this may indicate a TEC prob lem If this occurs contact your Toro Distributor for assistance 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 Figure 12 1 TEC controller location 2 Loopback connector 3 Diagnostic tether cap Workman 200 Outputs LED Operation DIAG LAMP Diagnostic lamp is ON or FLASHING LED ON or FLASHING
75. MONI TOR LH FOAM SL INPU MARKER SW ITCH Workman 200 Spray System Spray Console Wire Harness Serial Numbers From 270000001 to 290999999 Page 4 18 Rev B MONITOR POWER SWITCH SUPVSR SWITCH LOCK RATE P2 HOLD RELAY PIG OPTIONAL FOOT SWITCH 4 98 L8 VLE 69 0 LH BOOM CTR BOOM RH BOOM MASTER BOOM SYSTEM PRESSURE LH BOOM RH BOOM LH FOAM SWITCH SWITCH SWITCH SWITCH SWITCH LIFT SWITCH LIFT SWITCH MARKER SWITCH enl o Xo OT r3 4 56 8 palit 2 3 4 5 6 7 8 eu 1 2 38 4 8 6 7 8 2 3 4 5 6 7 8 poli 2 3 4 5 8 t 8 m 12 3 4 58 18 pal 2 3 4 5 6 7 8 1 N M Ti x z x x x Tm Sa o Zis ue
76. MONITOR E BLUE F VIOLET 6 BROWN H J VIOLET RED K BLACK GRAY SP02 BLACK ORANGE A YELLOW 15 05 GREEN P23 x YELLOW D BLACK 8 E POWER BLACK HARNESS A GREEN BLACK BLACK B BLUE ORANGE P22 RED 03 RED 5 04 D YELLOW 5 5 oO x 53 8 5 3 3 RED BLACK Zous 3 829606 8 EE 4 5 PINK BLACK 66 2 Tem ied a 6696 55 30 85 87A 87 86 30 85 87A 87 86 BROWN mo pat 21 pol A3 A5 81 83 B4 85 CI C C3 C4 C5 BT C B 222224 4 5 RIGHT ACTUATOR RELAYS ARNESS SPRAY HA 30 85 ae 87 87A 81 86 CONNECTOR CONNECT LEFT ACTUATOR RELAYS Workman 200 Spray System Spray Console Wire Harness Serial Numbers From 260000001 to 260999999 Page 4 17 Rev B P22 POWER HARNESS P23 P24 SUPERVISOR SW ITCH LOCK RATE P20 RIGHT P07 ACTUATOR P09 RH BOOM RELAY P19 LEFT ACTUATOR P03 P10 OPTIONAL MONITOR FOOT POWER RH BOOM SWITCH 201 OH MARKER RELAY SW ITCH LH BOOM SW ITCH SW ITCH d 12 SPRAY PRO MONITOR P04 P21 6547 p MASTER RIGHT 0444 BOOM ACTUATOR LIFT SWITCH RELAY 8 2 TS P11 P18 SPRAY LEFT HARNESS i ACTUATOR CONNEC TOR p P14 SWITCH RELAY P05 SYSTEM PRESSURE P15 P02 SW ITCH
77. OLIMS aE 9 L A 25 8 n8 ea 10 OL aassaug HOLIMS HOIVh LOV WOO8 LHOIY p gt NO jm 32018 35043 312 NOSN3S 91405 0018 ANNOYS gt 3 19IH3A 01 Q3193NNOO n8 38 a NS M 1331 3OSN3S INOS 324105 N3MOd 4 5 01102340 a3zibuaNa LON 3901M8 H 1331 v YOLVNLOV Wood 1331 60d r 1OMINOO SINOYLOST4 vois OD Y ANM 49018 3504 9M1d Move 4007 1304 SNIIS3N VOt A NOLLISOd NI OLNY SA HOLIMS DINOS Workman 200 Spray System B 1 14 Rev Page 3 I Kit iona ic Boom System Opt Son 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 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 Raise Boom When a boom actuator switch is pressed to raise a boom se
78. al 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 4 Always wear protective clothing chemical resistant gloves eye protection and other personal protective equipment as recommended by the chemical manufac turer 5 Properly dispose of chemical containers unused chemicals and chemical solution Precautions for Removing or Adjusting Spray System Components 1 Park vehicle on a level surface and apply the parking brake 2 Shut off the vehicle s engine and remove the key from the ignition switch 3 Disengage all power and wait until all moving parts have stopped Ultra Sonic Boom System Rev C Page 3 2 2 4 Remove chemicals from pump hoses and other spray components Thoroughly neutralize and rinse spray system before loosening or removing any spray system componeni s 5 Make sure spray system pressure is relieved before loosening any system component Workman 200 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 output
79. alize chemicals from spray components before disas sembly Wear protective clothing chemical resist ant 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 2 Label disconnected hoses for proper installation af ter repairs are completed 3 Remove agitation control valve using Figures 13 and 14 as guides 4 Disassemble agitation valve as required Fig 15 Installation Fig 13 NOTE Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Assemble agitation control valve Fig 15 Align ar row on valve handle with large hole in valve ball during assembly Fig 16 2 Install agitation valve using Figures 13 and 14 as guides 3 Check spray system for leaks Figure 14 1 Agitation control valve 3 Suction hose from tank 2 Control bypass hose 4 Suction hose to pump Figure 15 1 Valve housing 9 2 Ball seat 10 3 O ring 11 4 O ring 12 5 Washer 8 used 13 6 Cap screw 4 used 14 7 End cover 15 8 Screw 4 used 16 Figure 16 1 Valve handle arrow 2 Workman 200 Spray System Page 3 17 Screw Button Valve handle Disc O ring Spindle Valve ball Lock nut 4 used Valve ball large hole Spray System Agitation Nozzles Tank mounted N FRONT A RIGHT NOTE ARROWS SHOW FLUID FLOW DIRECTION
80. amiliar 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 While Operating 1 Sit on the seat when starting and operating the ma chine 2 Before starting the engine A Engage the parking brake B Make sure drive system is inthe NEUTRAL posi tion and the pump switch is OFF 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine radiator muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns Safety and Product Records 1 2 Rev To reduce the potential for injury or death com ply with the following safety instructions 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 5 Before getting off the seat A Ensure that drive system is in the NEUTRAL position B Set parking brake C Turn pump switch OFF D Stop engine and remove key from ignition switch Do not park on slopes unless wheels are chocked or blocked 6 Follow spray chemical manufacturer s recommen dations for handling precautions pro
81. ates of the following compo nents as inputs the sonic mode switch the two 2 boom actuator switches and the two 2 boom sonic sensors 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 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 attemptis 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 Sonic Boom System Optional Kit Page 3 1 24 Rev B Figure 12 3 Sonic boom fuse block 4 Relay 6 used 1 Mount plate 2 Electronic control unit Workman 200 Spray System 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 During sprayer operation the sonic boom sensor con tinually sends an impulse signal and then receives an
82. automat On affected boom the sonic boom sensor cover is on sensor or is ically follow ground irregularities hanging in sensor path Boom can be controlled with boom actuator switch 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 Sonic mode switch is not in the AUTO position ground irregularities Booms can be controlled with boom actuator Sonic boom sensor covers are on both sensors or are hanging in switches sensor path The filters on both sensors are dirty or damaged Calibration of the Sonic Boom sensors is incorrect The sonic sensor angle on both booms need adjustment Both sonic sensors or circuit wiring are faulty ECU or circuit wiring is faulty Workman 200 Spray System Page 3 1 21 Rev Sonic Boom System Optional Kit Service and Repairs Sonic Mode Switch The sonic mode switch is used as an input for the ECU to activate the Sonic Boom System This switch has three 3 positions automatic manual and off The sonic mode switch is located on the console If the sonic mode switch is in the automatic position the sonic sensors will be activated to allow automatic move ment of the boom The tips of the booms will remain at a constant distance from the ground The
83. boom switches can be used to raise lower the booms when the sonic mode switch is in the automatic position If the sonic mode switch is in the manual position the sonic sensors are disabled The boom switches are used to raise lower the booms 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 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 2 Park vehicle on a level surface stop engine engage parking brake and remove key from ignition switch 3 Disassemble console to gain access to sonic mode switch 4 Disconnect harness electrical connector from the sonic mode switch 5 The switch terminals are marked as shown in Figure 9 The circuit logic of the sonic mode switch is shown in the chart to the right With the use of a multimeter ohms setting the switch funct
84. ch 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 RETRIEVE FAULTS Diagnostic shunt wires are connected for fault retrieval LED ON LEFT SENSOR FAULT The TEC has detected an invalid reading from left sensor LED ON ee RIGHT SENSOR FAULT The TEC has detected an invalid reading from right sensor LED ON KEY RUN NOTE When the vehicle ignition switch is in the OFF position all Diagnostic Display LED s should be OFF 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 Page 3 2 21 7 lf 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 8 After input functions testing is complete disconnect the Diagnostic Display connector from the harness con nector Plug loopback connector into wire harness LED Operation Sonic boom switch in auto position LED ON Sonic boom switch not in auto position LED OFF Right b
85. 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 whena boom is to be lowered The non energized bridge relays provide current flow to the actuator so the actuator ex tends Testing 1 Park vehicle on a level surface stop engine engage parking brake and remove key from ignition switch 2 Locate relay to be tested and disconnect wire har ness connector from relay Remove relay from mount plate for testing 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 ofthe meter and test leads Subtract this val ue from from the measured value of the component you are testing 3 Using a multimeter verify that coil resistance be tween terminals 85 and 86 is from 71 to 88 ohms 4 Connectmultimeter 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 to terminal 85 Therelay terminals 30 and 87 should not have conti nuity as 12 VDC is removed from terminal 85 5 Disconnect voltage from terminal 85 and multimeter lead from term
86. chemical for the job 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 container labels and Material Safety Data Sheets 4 Always wear protective clothing chemical resistant gloves eye protection and other personal protective equipment as recommended by the chemical manufac turer 5 Properly dispose of chemical containers unused chemicals and chemical solution Precautions for Removing or Adjusting Spray System Components 1 Stop the vehicle and set the parking brake 2 Shut off the vehicle s engine and remove the key from the ignition switch 3 Disengage all power and wait until all moving parts have stopped 4 Remove chemicals from pump hoses and other spray components Thoroughly neutralize and rinse spray system before loosening or removing any spray system component s 5 Make sure line pressure is relieved before loosening any system component 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 be
87. ction 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 Workman 200 Spray System Page 3 1 15 Rev B 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 Sonic Boom System Optional Kit 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 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
88. ctrical System Page 2 10 Workman 200 Spray System TORO Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Precautions Concerning Chemicals Used in Spray System 3 Precautions for Removing or Adjusting Spray System Components 3 O Ring Seal 3 SPRAY SYSTEM FLOW DIAGRAM 4 SPRAY SYSTEM OPERATION 5 TROUBLESHOOTING 6 SERVICE AND REPAIRS 8 Suction Dampener 8 Pressure Dampener 9 Spray Pump 10 Spray Pump Service 12 Agitation Control Valve 16 Agitation Nozzles Tank Mounted 18 Pressure Relief Valve Tank Mounted 20 Spray Control Serial Numbers Below 290999999 22 Spray Control Serial Numbers Above 310000000 23 1 Flowmeter Serial Numbers Below 290999999 24 Flowmeter Serial Numbers Above 310000000 25 1 Rate Control Motor Serial Numbers Below 290999999 wand ake ert ee 26 Workman 200 Spray System Page 3 1 Chapter 3 Spray System Regulating Valve Assembly Serial Numbers Above 310000000 27 1 Boom Valve Motor Serial Numbers Below 290999999 Me
89. d 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 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 Check spray tank for leaks Figure 36 1 Suction strainer 3 Tank lid 2 Tank drain Figure 37 1 Tank suction tube 2 Tank drain Workman 200 Spray System Page 3 35 Spray System Tank Drain Figure 38 1 Drain handle 5 Gasket 9 Hose clamp 2 Nut 6 Ringnut 10 Drain hose 3 O ring 7 Chain 11 Spray tank 4 Bulkhead 8 Drain assembly Spray System Page 3 36 Workman 200 Spray System Disassembly Fig 38 IMPORTANT Make sure to remove and neutralize chemicals from tank and spray components before disassembly Wear protective clothing chemical 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 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
90. e 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 Figure 7 1 Spray control panel 2 Sonic boom switch While calibrating the Ultra Sonic Boom sensors itis 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 Ultra Sonic Boom System Rev C 9 5 Boom System 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 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 If the sonic boom system TEC controller detects an elec trical system malfunction fault during operation e g there is no signal coming from 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 d
91. e moved if they are faulty Ultra Sonic Boom System Rev C Page 3 2 26 Figure 13 1 Dash panel 2 Fuse blocks 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 Workman 200 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 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 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 Testing NOTE Bef
92. e 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 Figure 28 1 Rate control motor 2 Flowmeter 3 LH boom valve motor Workman 200 Spray System Page 3 27 4 Center boom valve motor 5 RH boom valve motor Spray System Regulating Valve Assembly Serial Numbers Above 310000000 Figure 28 1 1 Regulating valve motor 6 Elbow fitting 11 Lock nut 4 used 2 Hose barb 7 Mounting bracket 2 used 12 O ring 2 used 3 Flange 8 Fork 13 O ring 4 Adaptor 9 Washer 4 used 14 O ring 5 10 Cap screw 4 used The regulating valve allows the operator to vary the spray application rate The pressure increase decrease switch on the spray console energizes the regulating valve motor which adjusts the valve opening and allows some flow to bypass the spray booms NOTE The regulating valve affects flow to all spray booms Therefore a problem with the regulating valve will affect all booms and nozzles Removal and Inspection Fig 28 1 IMPORTANT Make sure to remove and neutralize chemicals from spray components before disas sembly Wear protective clothing chemical resist ant glove
93. e ee 28 Boom Valve Manifold Assembly Serial Numbers Above 310000000 31 1 Boom 32 Tank Suction 34 Tank Drath vate eee eoe HER 36 Turret Bodles pU ec 38 Turret Body Service 39 Boom Frame Breakaway Pivot Assembly Machines with Serial Numbers Below 260000000 40 Boom Hinge Machines with Serial Numbers Above 260000000 42 Boom Actuator Optional Machines with Serial Numbers Below 260000000 44 Boom Actuator Service Machines with Serial Numbers Below 260000000 46 Boom Actuator Machines with Serial Numbers Above 260000000 48 Boom Actuator Service Machines with Serial Numbers Above 260000000 50 Rev B Spray System Specifications Item Description Spray Pump Diaphragm Pump 29 GPM Spray Pressure Relief Valve Poppet Style 220 PSI Maximum Sprayer Tank 200 Gallon 757 Liter Polyethylene Suction Strainer 50 Mesh Stainless Steel Tank Mounted 30 Mesh and 90 Mesh Optional Spray System Page 3 2 Workman 200 Spray System General Information Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons animals plants soil or other property To eliminate environmental damage and personal injury 1 Select the proper
94. e to secure assembly Torque screw 70 in Ib 8 4 Position spindle section on motor section so that green indicator on spindle section is opposite the motor hand grip Secure spindle section to motor section with four phillips head screws item 15 5 Replace rear housing to boom valve motor Spray System Page 3 30 6 Position the motor and spindle section assembly to the manifold assembly The motor hand grip and boom supply hosebarb on manifold should be on the same side of the assembly Install the fork item 29 to secure the motor and spindle sections to the manifold 7 Assemble spray control assembly Install spray con trol to machine see Spray Control in this section 8 Operate spray system and check for leaks Workman 200 Spray System This page is intentionally blank Workman 200 Spray System Page 3 31 Spray System Boom Valve Manifold Assembly Serial Numbers Above 310000000 NOTE ARROWS SHOW FLUID FLOW DIRECTION Figure 32 1 1 Boom valve motor 3 used 8 Balancing valve assembly 14 O ring 3 used 2 Hose barb 3 used 9 Flange 15 Balancing valve assembly 2 used 3 Pressure gauge port 10 Fork 3 used 16 Washer 4 used 4 Flange 11 Fork 6 used 17 Cap screw 4 used 5 Flynut 12 O ring 4 used 18 Lock nut 4 used 6 Elbow fitting 13 O ring 4 used 19 Cap 7 Mounting bracket 2 used The sprayer system for serial numbers above 310000000 uses
95. 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 Sensors and protection tubes should be rotated above parallel with the ground for proper sonic sensor opera tion Refertothe Sonic Boom Kit Installation Instructions for sonic sensor setup information 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
96. ecked 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 SONIC BOOM DIAGNOSTIC ACE OUTPUT INPUT INPUT OUTPUT UNUSED I UNUSE TORO 94 8604 Figure 2 Workman 200 Spray System Page 3 1 3 Rev B Sonic Boom System Optional Kit Electrical Schematic 1 woog 21005 HOLIMS HOLVNLOV Woods 1331 4 HOLIMS HOLVNLOV INOO8 9 4g 4 Fe Jo T MOO1d 3504 JIOIHJA NIVN 1H9IM M o HOLIMS SOSNTS DINOS 32018 GNNOYD 43MOd 00 FIOIHSA NVA avus 01 Q3193NNOO NaS a 1337 OSN3S INOS 3941005 H3MOd QSHOLIMS OL 193410 AV 138 39dINag H SAL 30010 LHOIM 1 E voz uoivniov Lor NO
97. ector 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 3 Connectthe 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 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 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 6 Attempt to operate the desired function of the ma chine The appropriate output
98. emove four 4 flange head screws and flange nuts that secure pump drive shrouds item 13 to shroud bracket item 14 Remove pump drive shrouds 8 Loosen two 2 set screws item 16 that secure PTO drive shaft to pump shaft Separate PTO drive shaft from pump Locate and remove key from pump shaft 9 As needed remove pressure and suction compo nents from pump using Figure 6 as a guide Discard any removed o rings and gaskets Installation Fig 6 NOTE Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Apply thread sealant to threads of pressure tee 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 2 Install suction tee fitting and suction dampener to pump inlet Orientate tee toward right side of machine Fig 7 Workman 200 Spray System Page 3 11 3 Install elbow pressure pressure tee fitting and pressure dampener to pump outlet Orientate elbow to ward right side of machine Fig 7 4 Remove set screws item 16 from PTO driveshaft Clean threads of set screws and set screw threads in dri veshaft 5 Apply anti seize lubricant to pump shaft Position square key in pump shaft and slide PTO driveshaft fully onto pump shaft 6 Apply Loctite 242 or equivalent to threads of set screws Install set screws into PTO drive shaft to sec
99. er switch relay LED ON ENDE PET Workman 200 Spray System Page 3 1 19 Rev B Sonic Boom System Optional Kit 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 Problem Sonic boom light is not illuminated 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 Possible Cause Sonic mode switch is in the OFF position 5 amp or 10 amp fuse in sonic boom fuse block is faulty Electrical power from vehicle is not available all sonic boom func tions are affected Sonic boom light or circuit wiring is faulty Sonic mode switch or circuit wiring is faulty LED on one of the sonic boom sen Sonic boom sensor or circuit wiring is faulty 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 re
100. ers From 260000001 to 280000200 Page4 8 Rev B P13 RIGHT ACTUATOR Ld 19 TVS DIODE B gt e POS RH FOAM MARKER VALVE P09 RH SPRAY P06 LH FOAM VALVE MARKER VALVE CTR SPRAY VALVE P16 P12 3AMP LEFT ACTUATOR ES 01 lt 10 CONTROL VALVE P17 3AMP LH SP VALVE 3AMP POI RAY CONTROL HARNESS INT ERCONNECT Al Ae A3 A4 AS PI BI B 83 B4 BS CI C2 C3 C4 C BLUE BLACK BLUE WHITE P01 RAY CTR SPRAY VALVE FUSE 3AMP PIS ORANGE WHITE ORANGE BLACK P08 RH SPRAY VALVE FUSE 3AMP 16 GREEN BLACK GREEN WHITE RATE CO VALVE FUSE 3AMP co PIT TROL BROWN WHITE BLUE RED B 09 x 5 m 2 iul PIO RH SPRAY w E I 2 BA Po2 RATE CONTROL VALVE GRAY VIOLET BLUE FLO MEI CONTROL HARNESS INTERCONNECT PI4 C D BLACK ak BLACK N FOAM WHITE BLACK 2 COMPRESSER WHITE BLACK a 04 LL z 22 E MASTER ui FOAM
101. f 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 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 intime 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 The boom sensor target distance is initiated during initial sonic boom calibration and is typically set at twenty 20 inches Ifthe boom target distance changes when in au tomatic mode the TEC will energize the appropriate electrical relays The energized
102. 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 7 lf 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 SONIC BOOM DIAGNOSTIC ACE OUTPUT INPUT INPUT OUTPUT USED I UNUSED Figure 7 Sonic Boom System Optional Kit 2 Diagnostic Display Diagnostic Display Inputs LED Operation AUTO MODE L RAISE Sonic mode switch in auto position LED ON Sonic mode switch not in auto position LED OFF 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 R LOWER Right boom actuator switch in raise position LED ON Right boom actuator switch not in raise position LED OFF Right boom actuator switch in lower position LED ON Right boom actuator switch not in lower position LED OFF
103. g should be free of ex cessive moisture corrosion and dirt Workman 200 Spray System 2 Remove four 4 phillips head screws item 8 that secure spindle section to housing Remove spindle sec tion 3 Locate remove and discard o ring item 11 and seal item 14 4 Remove valve item 13 and inspect for wear and or damage Replace if needed 5 If needed the spindle shaft can be removed by 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 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 rat
104. g 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 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 Actuator Freeplay Inspection Over time actuator operation may be affected by air captured in the reservoir oil An excessive amount of air in the actuator oil will allow excessive actuator freeplay Excessive freeplay will allow spray boom bouncing when driving over severe terrain Measure actuator freeplay using the following proce dure 1 Move the vehicle to an open area and lower the spray booms to the spray position 2 Lift up on the boom at the last triangular gusset with a 25 pound 11 4 kg force Support boom in that posi tion 3 Using anon permanent felt tipped marker mark the cylinder rod at the outside of the cylinder seal 4 Release the spray boom and allow it to return to the spray fully lowered position 5 Determine the actuator freeplay by measuring the distance from the mark on the cylinder rod to the cylinder seal The freeplay should be less than 0 100 2 5 mm If excessive freeplay is found bleed air from actuator Spray System 3 50 Rev A Actuator Air Bleeding If actuat
105. he meter and test leads Subtract this val ue from from the measured value of the component you are testing 4 Using a multimeter verify that coil resistance be tween terminals 85 and 86 is from 71 to 88 ohms 5 Connectmultimeter 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 6 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 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 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 Figure 22 4 Cap screw 4 used 5 Lock washer 4 used 6 Nut 4 used 1 Mount plate 2 U bolt clamp 2 used 3 Relay 4 used 30 B6 wp 85 87a 87 Figure 23 3 Normally closed term 4 Normally open term 1 Coil terminal 2 Common terminal Workman 200 Toro Electronic Controller TEC The Ultra Sonic Boom System uses
106. iagnos tic Display in a dry secure indoor location and not on machine Verify Diagnostic Display Input Functions 1 Park vehicle on a level surface stop the engine and apply the parking brake 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 Workman 200 Spray System Page 3 1 17 Rev B 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 6 The Diagnostic Display will illuminate the LED associated with each ofthe inputs whenthat input switch is closed Individually change each ofthe switches from opento closed e
107. iagnostic 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 If the diagnostic lamp does not illuminate when the igni tion switch is turned to the ON position possible causes are e 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 The diagnostic lamp or circuit wiring is faulty e TEC controller fuse s are faulty e The TEC controller is faulty 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 Figure 8 1 Spray control panel 2 Diagnostic lamp Figure 9 1 TEC controller location 3 Diagnostic tether cap 2 Loopback connector 4 Diagnostic shunt wires Ultra Sonic Boom System Rev C Page 3 2 18 Workman 200 Retrieving Fault Codes 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 ret
108. inal 87 6 Connectmultimeter 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 Workman 200 Spray System Page 3 1 23 Rev B 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 Figure 10 5 Cap screw 4 used 6 Lock washer 4 used 7 Nut 4 used 860 87A gs 9 Figure 11 3 Normally closed term 4 Normally open term Mount plate Electronic control unit Sonic boom fuse block Relay 6 used 30 86 85 87a 87 30 1 Coil terminal 2 Common terminal Sonic Boom System Optional Kit 6 To 45 E 9g 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 Power is provided to the ECU when the vehicle ignition switch is ON A5 amp fuse provides circuit protection for this logic power to the ECU The fuse is located in the Sonic Boom System fuse block The ECU monitors the st
109. ions 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 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 8 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 9 Battery gases can explode Keep cigarettes sparks and flames away from the battery 10 To assure optimum performance and continued safety of the machine use genuine Toro replacement parts and accessories Replacement parts and acces sories made by other manufacturers may result in non conformance with safety standards and the warranty may be voided Safety and Product Records 2 Oo gt 55 a This page is intentionally blank Safety and Product Records Page 1 4 Workman 200 Spray System Chapter 2
110. ions 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 Sonic Boom System Optional Kit 3 1 22 Rev 6 If the sonic mode switch tests correctly and circuit problem still exists check wire harness see Electrical Schematic and Wire Harness Drawings in this chapter 7 After testing is completed connect wire harness connector to the sonic mode switch Figure 8 1 Spray control console 2 Sonic mode switch BACK OF SWITCH Figure 9 SWITCH CLOSED OPEN POSITION CIRCUITS CIRCUITS AUTOMATIC 243 2 1 5 6 5 4 MANUAL Workman 200 Spray System 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 ofthe 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 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
111. l connectors from rate control motor flowmeter and three 3 boom valve motors from ma chine electrical harness 4 Remove pressure gauge tube from coupler on back of flowmeter housing Fig 23 5 Remove three 3 flange head screws that secure spray control assembly to valve mounting bar Remove spray control assembly from machine 6 Remove spray control components as required us ing Figure 21 as a guide Discard all removed o rings and gaskets Assembly Fig 21 NOTE Coat all o rings with vegetable oil before instal lation to reduce the chance of damage during assembly 1 Install spray control components using Figure 21 as a guide Replace all removed o rings and gaskets 2 Before installing rod Item 2 into assembly thread nut item 1 fully onto rod end that has fewer threads Make sure that o ring Item 3 is not damaged during installation over rod To secure assembly torque nut 71 in Ib 8 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 Rate control motor Flowmeter LH boom valve motor
112. lay 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 Sonic Boom System Optional Kit 3 1 20 Rev Workman 200 Spray System Possible Cause One of the boom actuators will not 30 amp auto resetting fuse for affected boom actuator is faulty extend 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 Loop back connector is unplugged from wire harness connector extend 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
113. lectrical system 1 Dash panel 1 Mount plate Workman 200 Page 3 2 31 Figure 24 2 TEC controller Figure 25 4 Nut 4 used 2 U bolt clamp 2 used 5 Cap screw 4 used 3 TEC controller Ultra Sonic Boom System Rev C 2 5 Boom System This page is intentionally blank Ultra Sonic Boom System Rev C Page 3 2 32 Workman 200 Table of Contents ELECTRICAL SCHEMATICS Serial Numbers Below 260000000 Serial Numbers Above 260000000 WIRE HARNESS DRAWINGS Spray System Wire Harness Serial Numbers Below 260000000 Spray System Wire Harness Serial Numbers From 260000001 to 280000200 Spray System Wire Harness Serial Numbers From 280000201 to 290999999 Spray System Wire Harness Serial Numbers Above 310000000 Spray Console Wire Harness Serial Numbers Below 260000000 Spray Console Wire Harness Serial Numbers From 260000001 to 260999999 Spray Console Wire Harness Serial Numbers From 270000001 to 290999999 Spray Console Wire Harness Serial Numbers Above 310000000 Sprayer Power Harness Serial Numbers Below 260000000 Sprayer Power Harness Serial Numbers Above 260000000
114. ler on pressure gauge port on right side of boom valve man ifold assembly 5 Using labels placed during disassembly secure wire harness connectors to regulating valve flowmeter and three 3 boom valve motors 6 Operate spray system and check for leaks Repair all leaks before returning the sprayer to service Figure 23 2 1 Boom valve manifold 3 2 Flowmeter Regulating valve NOTE ARROW DIRECTION TO BOOM VALVE MANIFOLD FROM REGULATING VALVE Figure 23 3 Spray System Flowmeter Serial Numbers Below 290999999 71 in Ib 8 N m NOTE ARROWS SHOW FLUID FLOW DIRECTION Figure 24 1 Nut 11 Fork 20 O ring 2 Threaded rod 12 Screw 21 Flowmeter rotor shaft 3 Washer 13 Control valve bracket 22 Flowmeter rotor 4 Bushing 14 Rate control motor housing 23 Flow sensor 5 O ring 15 O ring 24 Nut 6 Cover 16 Hosebarb 25 End cap 7 O ring 17 Hose control bypass 1 26 LH boom control motor 8 Tee piece 18 Coupler pressure gauge 27 Center boom control motor 9 Hose control supply 1 19 Flowmeter housing 28 RH boom control motor 10 Hose clamp Spray System Page 3 24 Rev Workman 200 Spray System 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 Park machine on a level surface st
115. low 310000000 It is recommended that O rings be replaced every two 2 years or whenever a valve is loosened Workman 200 Spray System Page3 3 Rev B TORO SPRAYER O RING SEAL KIT PART NO 106 4846 Figure 1 Spray System Spray System Flow Diagram BOOM BY PASS BOOM CONTROL BOOM SUPPLY PRESSURE N FLOWMETER Z PRESSURE DAMPENER PRESSURE GAUGE 3 gt z lt oc a TOP MOUNTED SUCTIO amp SCREEN PRESSURE RELIEF PRESSURE PRESSURE CONTROL 2 E a H 2 E Ki J 2 7 SE CONNECTED TO PTO AGITATORS 4 DIAPHRAGM PUMP SUCTION DAMPENER AGITATION CONTROL SUCTION PRESSURE AGITATION BOOM SUPPLY FLOW DIRECTION Workman 200 Spray System Spray System Flow Diagram Spray System Page 3 4 Workman 200 Spray System Spray System Operation 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 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 a
116. m aged parts 8 Discard and replace all removed gaskets and rings Workman 200 Spray System Page 3 47 Assembly Fig 53 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 3 Install new o rings into rear of cover tube Slide cov er tube gasket and cover tube over ball screw 4 Place washer on ball screw shaft Position woodruff key and then slide clutch and second washer onto shaft 5 Place thick washer intermediate gear and thin washer onto front housing support pin Make sure that intermediate gear engages both motor gear and clutch 6 Position housing gasket to front housing Slide rear housing over gears 7 Secure rear housing A Thread one 1 screw item 1 through rear hous ing and into front housing B Install four 4 washer head screws through cover tube C Torque screw item 1 to 20 in Ib 2 3 Torque four washer head screws to 70 in lb 7 9 N m Spray System Boom Actuator Serial Numbers Above 260000000 Figure 54 1 Boom actuator 2 used 5 Locknut 4 used 9 Clevis strap 2 used 2 Carriage screw 4 used 6 Flange nut 2 used 10 Boom pivot bracket 3 Boom frame 7 Flange head screw 2 used 11 Clevis pin 2 used 4 Washer plate 8 Pivot pin 2 used 12 Cotter pin 2 u
117. m System Optional Kit 8ld SAL 30010 PK ONILOWHLAY vez uo1vniov 2 YOLWNLOV WOO8 1H9IH Old Vid seu M Y aazioH3N3 39 l898 H 1H9IM 1467 10 291pU uang ui YOUMS PON 9IuoS umoys woog 14614 esiH 9 woog 205 HOLIMS HOLVNLOV Wood 1331 aazibu3N3 1H9IM HOLIMS 43MOd Llid Ave SAL 30010 Bit 15 vez uo1vniov n 28 0 oo 4 HOLIMS HOLVNLOV WOOd LHOIY 8 2920 8 8 gt 8 E TW TWE 219 LON 1331 HOLIMS 1OSINOO OINO310313 aaziogaNa LON 390ING H 1331 v 8 YOLWNLOV wood 1331 60d 535018 ASN4 319IH3A NIV 305435 DINOS 42018 m 310IH3A NIVA OL Q3193NNOO BB em Oros 8 0 1337 MOSN3S OINOS 394105 YAMOd vem G3HOLIMS OL 193919 2 a 09 Y AYM 19018 3503 vel SNILISS3N WOE 9M1d MOVE 3001 1304 q 3 M
118. machine Workman 200 Page 3 2 27 49 __ nn Figure 15 1 Spray control panel 2 Sonic boom switch BACK OF SWITCH Figure 16 SWITCH CLOSED OPEN POSITION CIRCUITS CIRCUITS MANUAL 2 3 2 1 5 6 5 4 AUTOMATIC 2 1 2 3 5 4 5 6 Ultra Sonic Boom System Rev Ultra Sonic Boom System 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 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 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 The sonic sensors and their circuit wiring can be
119. 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 Boom lift switch or circuit wiring for affected boom actuator is faulty extend or retract A problem exists with the affected boom actuator Neither of the boom actuators will Loopback connector is unplugged from wire harness connector all extend or retract 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 The LED s on one of the sonic boom Sonic boom sensor or circuit wiring is faulty sensors are not illuminated The LED s on both of the sonic Sonic boom switch is in the MANUAL position boom sensors are not illuminated 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 Workman 200 On affected boom the sonic boom sensor cover is on sensor On affected boom calibration of the sonic boom sensors is incor rect
120. n 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 7 When oil level is correct use a 12 volt DC power sup Figure 56 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 Ib 5 1 to 6 8 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 3 51 Rev Spray System This page is intentionally blank Spray System Page 3 52 Workman 200 Spray System Table of Contents GENERAL INFORMATION 2 Installation Instructions 2 Precautions Concerning Chemicals Used in Spray 2 Precautions for Removing or Adjusting Spray System 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
121. nd connectors A suction dampener placed in the suction line dampens suction pulses to smooth suction flow Suction valves positioned in the pump valve chamber prevent fluid from being pumped back into the suction line when the connecting rods change direction Leaks in the suction line will cause system problems and often will be indicated by er ratic suction line jumping and pump noise Once to the pump the fluid is pushed by the upward stroke of the pumps connecting rods and diaphragms to the pressure side of the spray system through hoses connectors control valves and spray nozzles A pres sure dampener at the pump outlet smooths system pressure pulsation Pressure valves positioned in the pump head prevent fluid from being drawn back into the pump Maximum pressure in the system is limited by a pressure relief valve located in the tank A pressure gauge indicates system pressure Workman 200 Spray System Page 3 5 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
122. nd replace it Fig 3 1 2 Suction dampener Figure 2 3 Suction hose 1 2 O ring Spray System Page 3 8 Figure 3 3 Dampener housing 4 Diaphragm Workman 200 Spray System Pressure Dampener The pressure dampener is mounted to the pressure line at the spray pump Fig 4 and is used to smooth system pressure pulsation Adjust air pressure on the pressure dampener from 12 to 15 PSI 82 to 1 03 bar IMPORTANT Any fluid in the pressure dampener will include spray system chemicals so take neces sary precautions when working with the dampener Use appropriate protective equipment protective clothing chemical resistant gloves and eye protec tion If fluid is present when pressure in the dampener is checked the diaphragm in the pressure dampener is damaged and should be replaced Dampener Service Fig 5 IMPORTANT Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components 1 Loosen and remove cap screws and nuts that secure diaphragm between housings 2 Remove diaphragm from dampener 3 Replace diaphragm and reassemble dampener 1 Workman 200 Spray System Page 3 9 Spray pump Spray pump O ring Hex nut 12 used Rear housing Figure 4 2 Figure 5 5 6 7 8 Pressure dampener Diaphragm Front housing Cap screw 12 used Air valve Spray System Spray Pump FRONT Apply thread
123. neration 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 Workman 200 Spray System 3 1 7 Rev B Sonic Boom System Optional Kit ANY MJ 8ld SAL 30010 PS 15 d3ZIDYANA LON 1 91 HOLIMS 43MOd 1 M E ago 578 321999 9 LON lt LHOIY 8 0 1 ul YOUMS IUOS umous woog 427 pn 9 woog HOLIMS HOLVNLOW woos 1331 40 HOLIMS HOLVNLOV INOO8
124. ng as the sensor height remains the same as the calibrated height the spray boom will remain at a fixed distance from the ground for spraying accuracy If the sprayer operator should press a boom 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 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 Ifa 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 Tore 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 OPERATOR PRESSES LEFT BOOM LIFT SWITCH SO THE LEFT BOOM ACTUATOR RETR
125. nnect positive multimeter test lead to the sensor connector gray striped wire terminal and the negative multimeter lead to the connector black wire terminal Fig 14 Set multimeter to ohms setting IMPORTANT Incorrect jumper wire connections during testing can damage the sensor 9 Usinga 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 10 Set multimeter to DC volts setting 11 The multimeter should display very low voltage when ametal object is held near the sensor tip The multimeter should display battery voltage when the metal object is moved away from the sensor tip 12 After testing is complete remove jumper wires re sistor and multimeter leads from sensor connector 13 Replace speed sensor if necessary 14 After testing is complete remove jumper wires and multimeter leads from sensor connector Reinstall speed sensor into transaxle and secure with cap screw and lock washer Reconnect speed sensor to wire har ness 1 Workman 200 Spray System 2 9 Figure 13 Transaxle assembly 2 Traction speed sensor 1K ohm resistor Figure 14 Speed sensor 4 Red striped wire Sensor tip 5 Gray striped wire Sensor connector 6 Black wire Rev B Electrical System Electrical System This page is intentionally blank Ele
126. om stops raising The boom sensor target distance is initiated during initial sonic boom calibration and is typically set at twenty 20 inches When in automatic mode the booms will not move if the target distance change is three 3 inches or less inner dead band Once the target distance 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 LOWER BOOM HEIGHT IS DETECTED SO ACTUATOR RETRACTS TO RAISE BOOM SECTION Figure 5 Workman 200 Spray System 3 1 11 Rev Sonic Boom System Optional Kit 8ld AVE SAL 30010 PK AH VNOILLV LS vez uo1vniov jueun 167 uang ui 9po N 2 05 umoys woog Ye esreu Aq woog 9 woog 21 05 951 o1 dassaud HOLIMS HOLWN LOV woos 1331 d3ZIDY3N3 LON 1H IY HOLIMS a3ziou3Na LON 28 133 8 0 39dlJ8 H AVI 2 YOLWNLOV INOO8 LHOIY Qld Lid SNL 30010 ONILOVY LAY voz uo1vniov Y YOLVNLOV wood 1331 60d aaziouaN3 AV 13M j9l88 H 1331 vas 8 UU N M i
127. onic control unit ECU This is a quick way to de termine which electrical component is malfunctioning NOTE Anopen output e g an unplugged connector or a broken wire cannot be detected with the Diagnostic Display 1 Park vehicle on a level surface stop the engine and engage the parking brake 2 Locate Sonic Boom System wire harness and loop back connector under the vehicle dash panel Carefully unplug loopback connector from harness connector 3 Connectthe Diagnostic Display connector to the har ness connector Make sure correct overlay decal is posi tioned on the Diagnostic Display see Special Tools in this chapter 4 Turn the ignition switch to the ON position NOTE The red text on the Diagnostic Display overlay decal refers to input switches and the green text refers to ECU outputs 5 Make sure that the OUTPUTS DISPLAYED LED 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 Diagnostic Display Outputs L BOOM RAISE R BOOM RAISE POWER ON ERROR 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 6 Attempt
128. oom lift switch in raise position LED ON Right boom lift switch not in raise position LED OFF 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 boom lift switch in lower position LED ON Left boom lift switch not in lower position LED OFF Ignition key is in ON position LED ON Ignition key is in OFF position LED 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 sensoris the problem source e g switch circuit wiring Ultra Sonic Boom System Rev C Ultra Sonic Boom System Verify Diagnostic Display Output Functions 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 Anopen output e g an unplugged connector or a broken wire cannot be detected with the Diagnostic Display 1 Park machine on alevel surface stop the engine and engage the parking brake 2 Locate Ultra Sonic Boom wire harness communica tion port and loopback conn
129. op 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 4 Clean rotor rotor shaft and flowmeter sensor if re quired see Operator s Manual 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 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 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 ins
130. or 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 2 Make sure thatthe actuator cylinder is fully retracted IMPORTANT To prevent actuator damage use vise with protective jaws when clamping actuator 3 Place the actuator in a vise making sure that actuator is clamped in the area identified in Figure 55 Use just enough clamping force to hold the housing securely Make sure that the reservoir plug is orientated up 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 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 6 When oil appears clear 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 7 Install the reservoir plug and torque from 45 to 60 in Ib 5 1 to 6 8 N m 8 If reservoir oil was milky use power supply to con
131. or 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 Workman 200 Spray System Page 3 1 13 Rev B Ifa 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 Sonic Boom System Optional Kit 81 30010 vez uo1vniov YOLWNLOV INOO8 LHOIY Old a3zibH3N3 LON 3 LHOIY 1H9IM HOLIMS 43MOd w 1467 10 291pu uang jueun U91IMS apo 21 umoys woog 1uBiH 16071 woog enuen 9 woog 21 05 HOLIMS HOLVNLOV Woods 1331 Lld SAL 30010 AH vNOLLVLS uo1vniov 5 2 a3zibH3N3 LON 1331 H
132. ore 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 1 Park vehicle on a level surface stop engine engage parking brake and remove key from ignition switch 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
133. orque bolt to 60 ft lb 81 5 Make sure that pump casings align and then secure pump casing assembly by torquing five 5 bolts to 32 ft Ib 43 6 Secure diaphragm covers to pump using hex bolts 4 per cover Torque bolts to 55 ft lb 75 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 Figure 11 same side of the pump as the crankshaft grease fitting 1 Diaphragm 2 Connecting rod Outlet valves should be installed with the spring up and away from cover and should be on the same side of the pump as the crankshaft extension 8 Place valve chamber over valves noting orientation of chamber inlet and outlet Secure valve chamber with two 2 hex bolts Torque bolts 60 ft lb 81 N m Figure 12 1 Inlet suction 3 Outlet valve 2 Inlet valve Spray System Page 3 14 Workman 200 Spray System This page is intentionally blank Workman 200 Spray System 3 15 Spray System Agitation Control Valve FRONT P d RIGHT NOTE ARROWS SHOW FLUID FLOW DIRECTION Figure 13 1 Agitation control valve 4 O ring 7 Connector 2 Fork 5 O ring 8 Pump suction hose 3 Hosebarb hose to agitation nozzles 6 Hosebarb hose from spray control Spray System Page 3 16 Workman 200 Spray System Removal Fig 13 IMPORTANT Make sure to remove and neutr
134. ose control supply 1 10 Hose clamp 11 Fork 12 Screw 13 Control valve bracket 14 Rate control valve housing Figure 21 Rate control motor Screw 4 used Screw O ring Lock washer Handgrip Flowmeter assembly Flowmeter housing Hose control bypass 1 Hosebarb O ring End cap Hose boom bypass 1 Hosebarb IMPORTANT Rate control and boom valve motors may have a fuse for circuit protection Make sure that correct fuse is installed in the in line fuse hold er located in the motor harness Spray System Page 3 22 Rev B NOTE ARROWS SHOW FLUID FLOW DIRECTION Fork Joiner LH boom valve motor manifold O ring End cap Joiner Boom valve bracket O ring 3 used Hosebarb boom supply 3 used Nut 3 used Coupler pressure gauge Center boom valve motor manifold RH boom valve motor manifold Workman 200 Spray System 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 Removal Fig 21 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 3 Unplug electrica
135. 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 6 Position spring into valve motor housing Use 3mm allen wrench to secure piston valve assembly to valve motor 7 Secure hosebarb to bottom of valve motor Workman 200 Spray System Page 3 31 2 Rev B Figure 32 2 1 Boom valve manifold 3 Regulating valve 2 Flowmeter TT ET Se Figure 32 3 1 Valve motor assembly 2 Valve motor cover 3 Wire connector 4 Socket screw 4 used 5 Phillips screw 2 used Figure 32 4 1 Valve motor assembly 2 Piston valve assembly 3 Valve seal 4 Spring 5 Valve motor cover Spray System Boom Bypass NOTE ARROW SHOWS FLUID FLOW DIRECTION Figure 33 1 Boom bypass elbow 4 Gasket 7 Hosebarb hose 2 O ring 5 Fork 8 Hosebarb hose 3 Bulkhead fitting 6 Bulkhead nut Spray System 3 32 Workman 200 Spray System Disassembly Fig 33 IMPORTANT Make sure to remove and neutralize chemicals from tank and spray components before disassembly Wear protective clothing chemical re sistant gloves and eye protection during repair lt 1 Park machine a level surface stop engine en Y NS gage parking brake and remove key from the ignition switch 2 Drain spray tank see Operator s Manual 3 Disassemble boom bypass
136. rding 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 4 Always wear protective clothing chemical resistant gloves eye protection and other personal protective equipment as recommended by the chemical manufac turer 5 Properly dispose of chemical containers unused chemicals and chemical solution Precautions for Removing or Adjusting Spray System Components 1 Park vehicle ona level surface and apply the parking brake 2 Shut off the vehicle s engine and remove the key from the ignition switch 3 Disengage all power and wait until all moving parts have stopped Sonic Boom System Optional Kit 3 1 2 Rev B 4 Remove chemicals from pump hoses and other spray components Thoroughly neutralize and rinse spray system before loosening or removing any spray system component s 5 Make sure spray system pressure is relieved before loosening any system component Workman 200 Spray System Special Tools Diagnostic Display The Diagnostic Display Fig 1 can be connected to the Sonic Boom wire harness communication connector to verify correct electrical functions ofthe Sonic Boom Sys tem Electronic control unit ECU inputs and outputs for the Sonic Boom System can be ch
137. regarding application rate based on input from the flowmeter and the ground speed sensor in the trans axle Flow for tank agitation comes from flow that is bypassed by the rate control valve A manual agitation control valve directs flow to four agitation nozzles in the spray tank Spray System Troubleshooting Spray System Workman 200 Spray System Workman 200 Spray System 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 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 3 7 Spray System Service and Repairs Suction Dampener The suction dampener is mounted to the suction line at the spray pump Fig 2 and is used to dampen suction pulses and smooth suction flow During pump operation the suction dampener diaphragm will move IMPORTANT Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components A damaged suction dampener diaphragm will allow a suction leak and will cause improper pump operation If the diaphragm is damaged remove diaphragm from dampener housing a
138. rieve 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 3 Remove diagnostic tether cap from diagnostic shunt wires and connect the two 2 shunt wires together 4 Turn ignition switch to the ON position 5 Monitor the diagnostic lamp for fault code s 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 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 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 necessar
139. rrect boom actuator extension Tighten end nut to secure cle vis adjustment Figure 51 1 Boom actuator 3 Jam nut 2 Adjustable clevis 4 nut Figure 52 1 Breakaway pivot gusset 3 Boom actuator 2 Boom frame slot Workman 200 Spray System Page 3 45 Spray System Boom Actuator Service Serial Numbers Below 260000000 Figure 53 1 Screw 8 Thick washer 15 Motor assembly 2 Rear housing 9 Hex nut 2 used 16 Ball screw and brake assembly 3 Washer 10 Motor gear 17 Washer head screw 4 used 4 Woodruff key 11 Housing gasket 18 Cover tube 5 Clutch 12 Front housing 19 O ring 6 Thin washer 13 Cover tube gasket 20 O ring 7 Intermediate gear 14 Motor seal Spray System Page3 46 Rev A Workman 200 Spray System Disassembly Fig 53 1 Remove four 4 washer head screws that secure cover tube Remove one 1 screw item 1 that retains rear housing Slide rear housing and housing gasket from assembly 2 Slide thin washer intermediate gear and thick wash er from front housing support pin 3 In order remove washer clutch woodruff key and second washer from ball screw shaft 4 Pull cover tube from front housing Remove cover tube gasket 5 Loosen and remove two 2 hex nuts that secure mo tor to front housing Slide motor motor gear and motor seal from front housing 6 Remove ball screw and brake assembly from front housing 7 Clean actuator components Replace worn or da
140. rs From 270000001 to 290999999 RH FOAM MARKER SWITCH MONITOR INPUT SPRAY PRO MONITOR POWER HARNESS P22 Page 4 19 Rev B P22 POWER HARNESS 67A P23 P20 RIGHT ACTUATOR gt P19 LEFT 07 RH BOOM RELAY S ne SW ITCH P01 RH FOAM RELAY UR MARKER SWITCH LH BOOM SW ITCH SW ITCH P11 P21 65 47 RIGHT Jagi LH BOOM ACTUATOR 49099 LIFT RELAY SWITCH SPRAY oe HARNESS 567 ACTUATOR CONNECTOR RELAY P08 TR CTR BOOM LH FOAM SW ITCH MARKER SWITCH Workman 200 Spray System Spray Console Wire Harness Serial Numbers Above 310000000 Page 4 20 Rev B MASTER BOOM SWITCH P24 SUPERVISOR SWITCH LOCK RATE P10 OPTIONAL MONITOR FOOT T POWER SW ITCH SW ITCH POL POS SYSTEM PRESSURE SW ITCH 15 INPUT MONITOR P12 pag HR J SPRAY PRO MONITOR MONITOR POWER SWITCH SUPVSR SWITCH LOCK RATE HOLD RELAY PIG OPTIONAL FOOT SWITCH 4 98 18 YL8 98 0
141. s Figure 6 1 Spray control console 2 Sonic boom light While calibrating the Sonic Boom sensors it is best to perform the calibration process on turf A shiny surface e g cement shop floor can skew sensor signals Also ensure the calibration area is free of buildings trees un derground plumbing and other machines that could in terfere with sensor signals Workman 200 Spray System Diagnostic Display The Sonic Boom System is equipped with an electronic control unit ECU which controls machine sonic boom electrical functions The ECU monitors various input switches e g boom actuator switches sonic boom sen sors and energizes outputs to actuate relays for ap propriate machine functions For the ECU to control the machine as desired each of the inputs switches and sensors and outputs relays must be connected and functioning properly The Diagnostic Display See Special Tools in this chap ter is a tool to help the technician verify correct electrical functions of the machine IMPORTANT The Diagnostic Display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When use of the Diagnostic Display is 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 D
142. s and eye protection during repair 1 Remove spray control assembly from machine and separate regulating valve assembly from spray control see Spray Control Assembly Serial Numbers Above 310000000 Removal in this section Spray System Page 3 271 Rev B 2 Disassemble regulating valve assembly as needed using Figure 28 1 as a guide Discard all removed O rings and gaskets NOTE There are limited replacement parts available for regulating valve motor assembly Check your parts catalog for parts that are available 3 To remove valve motor cover from regulating valve motor Fig 28 3 A Loosen three 3 screws that secure valve motor cover to valve motor assembly B Carefully lift and rotate cover from valve motor C Unplug wire connections and remove cover D Make sure that screws that secure valve motor are tight Workman 200 Spray System Assembly Fig 28 1 1 Toinstall 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 NOTE Coatall O rings with vegetable oil before instal lation to reduce the chance of damage during assembly 2 Assemble regulating valve assembly using Figure 28 1 as a guide 3 Attach regulating valve assembly to
143. s 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 Figure 1 communication connector Machine will not oper ELECTRIC ate without loopback connector installed on wire SONIC BOOM harness Store Diagnostic Display dry secure indoor location and not on machine OUTPUT INPUT INPUT OUTPUT UNUSED AUTO UNUSED UNUSED MODE DIAG RIGHT UNUSED UNUSED LAMP RAISE SONIC RIGHT LEFT SENSOR UNUSED SENSOR LOWER FAULT UNUSED LEFT RIGHT SENSOR UNUSED RAISE FAULT RIGHT LEFT UNUSED UNUSED RAISE LOWER RIGHT RETRIEVE UNUSED UNUSED LOWER FAULTS 2 La 5 Boom System INDICATOR UNUSED UNUSED UNUSED LAMP LEFT UNUSED KEY UNUSED RAISE RUN LEFT UNUSED LOWE INPUTS DISPLAYED UNUSED UNUSED OUTPUTS DISPLAYED e TORO 119 9431 Figure 2 Workman 200 Page 3 2 3 Ultra Sonic Boom System Rev C Electrical Schematic 45 6 woog eif
144. sed Spray System 3 48 Rev A Workman 200 Spray System Removal Fig 54 1 Park machine on a level surface place spray booms in the transport raised position stop engine engage parking brake and remove key from the ignition switch 2 Disconnect boom actuator from machine wire har ness 3 Remove pivot pin item 8 that secures actuator to clevis strap item 9 on boom frame 4 Remove cotter pin item 11 from clevis pin item 12 Support boom actuator and slide clevis pin from boom pivot bracket Remove actuator from machine Workman 200 Spray System Page 3 49 Rev A Installation Fig 54 1 Position boom actuator to boom frame and boom pivot bracket 2 Secure actuator to boom pivot bracket with clevis pin and cotter pin 3 Secure actuator to clevis strap on boom frame with pivot pin 4 Connect boom actuator to machine wire harness Spray System 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 During and after operation the actuator may be very hot To avoid possible burns allow the ac tuator to cool before working on it Actuator Circuit Protection Each boom actuator is protected internally by a thermal circuit breaker In case of actuator overheating the ther mal breaker will trip causin
145. should exist between switch termi nals A and D Inthe 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 3 Reconnect the harness connectors to the switch af ter testing Install console panel to machine Electrical System Page 2 6 Rev B Figure 6 1 Supervisor key switch SERIAL NUMBER BELOW 270000000 OFF FRONT OF SWITCH BACK OF SWITCH Figure 7 SERIAL NUMBER ABOVE 270000000 OFF LOCKED 4 wy ON UNLOCKED B C BACK OF SWITCH Figure 8 Workman 200 Spray System Boom Control and Monitor Power Switches The three boom control on off and monitor power switches are located on the spray control enclosure faceplate Fig 8 Testing 1 Remove spray control enclosure faceplate locate boom control switch and unplug wire harness connector from switch 2 The switch terminals are marked as shown in Figure 9 In the ON position continuity should exist between terminals 2 and 3 and also between terminals 5 and 6 In the OFF position continuity should exist between ter minals 1 and 2 and also between terminals 4 and 5 9 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
146. tal 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 Figure 25 1 Rotor shaft 2 Rotor Figure 26 1 Rate control motor 4 Center boom valve motor 2 Flowmeter 5 RH boom valve motor 3 LH boom valve motor Workman 200 Spray System Page 3 25 Spray System Flowmeter Serial Numbers Above 310000000 NOTE ARROW DIRECTION NOTCH THREAD SEALANT Figure 26 1 1 Flowmeter body 4 Downstream hub 7 Sensor assembly 2 Rotor magnet assembly 5 Retaining ring 2 used 8 Cable clamp 3 Upstream hub with bearing 6 Turbine stud with bearing 9 Screw Spray System 3 25 1 Rev B Workman 200 Spray System Removal and Inspection Fig 26 1 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 3 Clean rotor item 2 both hubs items 3 and 4 and
147. tch 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 3 Reconnect harness connector to the switch after testing Install console panel to machine Workman 200 Spray System Page 2 5 Rev Figure 4 1 Rate control switch 2 Boom actuator switch BACK OF SWITCH Figure 5 Electrical System m 5 N gt 170 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 supervisor key switch and remove wire harness connec tors from switch 2 Test switch for continuity as follows A For sprayers with serial numbers below 270000000 Fig 7 when the key is in the ON posi tion continuity should exist between the two switch terminals In the OFF position there should be no continuity between the switch terminals B For sprayers with serial numbers above 270000000 Fig 8 when the key is in the ON posi tion continuity
148. tective equipment and mixing proportions Workman 200 Spray System Maintenance and Service 1 Before servicing or making adjustments turn PTO off put shift lever in neutral stop engine set parking brake and remove key from the switch 2 Prior to servicing sprayer components determine what chemical s have been used in the sprayer Follow precautions and recommendations printed on chemical container labels or Material Safety Data Sheets when servicing sprayer components Use appropriate protec tive equipment protective clothing chemical resistant gloves and eye protection 3 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 4 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 5 If major repairs are ever needed or assistance is 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 Decals Numerous safety and instruction decals are affixed to the Workman 200 Spray System If any decal becomes illegible or damaged install a new decal Part numbers are listed in your Parts Catalog Order replacement de cals from your Authorized Toro Distributor Product Records Insert Operator s Manual Installation Instruct
149. 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 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 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 itis recommended to have the caps installed on the sensors for sensor protection 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 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 Ultra Sonic Boom System Rev C Page
150. the sensor height remains the same as the calibrated height the spray boom section will remain at a fixed distance from the ground for spraying accuracy When a spray boom section encounters a downward slope in the turf the time necessary for the sensor to 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 acurrent path to the boom actuator causing the actuator to extend and the boom section to lower This maintains the boom height at the calibrated distance from the ground Once the boom section is lowered to the calibrated distance the elapsed time between the sensor signal generation and the received echo returns to the correct timeframe and the boom stops lowering A HIGHER BOOM HEIGHT IS DETECTED The boom sensor target distance is initiated during initial sonic boom calibration and is typically set at twenty 20 inches When in automatic mode the booms will not move if the target distance change is three 3 inches or less inner dead band Once the target distance 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 SO ACTUATOR EXTENDS TO LOWER BOOM SECTION SLOPE Figure 4 Workman 200 Spray System Page 3 1 9 Rev B Sonic Boo
151. 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 The boom control switches on the operator spray con sole are used to energize the boom valve motors and openthe boom valves The open boom valves allow sys tem flow to reach the appropriate boom section right center or left Disassembly Fig 32 1 IMPORTANT Make sure to remove and neutralize chemicals from spray components before disas sembly Wear protective clothing chemical resist ant gloves and eye protection during repair Spray System 3 311 Rev 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 NOTE There are limited replacement parts available for boom valve motor assembly Check your parts cata log for parts that are available 3 To remove cover from boom valve Fig 32 3 A Loosen three 3 screws that secure valve motor cover to valve motor assembly B Carefully lift and rotate cover from valve motor Workman 200 Spray System C Unplug wire connections and remove cover D Make sure that screws that secure valve motor are tight Assembly Fig 32 1 1
152. 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 and the engine not running A Ifthe correct output LED s do not illuminate verify that the required input switches are in the necessary positions to allow that function to occur B If the output LED s are on as specified but the booms do not function properly suspect a failed electrical component an open in the tested circuit or a non electrical problem e g binding of the boom hinge Repair as necessary C If each input switch is in the correct position and functioning correctly but the output LED s are not correctly illuminated this indicates an ECU problem If this occurs contact your Toro Distributor for assis tance 7 After output functions testing is complete discon nectthe Diagnostic Display connector from the harness connector and plug loopback connector into wire har ness Diagnostic Display LED Operation 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 ECU output exists to energize left power switch relay LED ON BOOM MOTOR ECU output exists to energize right pow
153. tract and extend the actuator cylinder 3 times Repeat steps 2 through 7 until oil is clear 9 When actuator oil is clear and plug has been installed use power supply to fully contract the actuator cylinder Remove actuator from vise and install on ma chine Workman 200 Spray System Actuator Oil Level 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 1 Thoroughly clean the exterior of the actuator to pre vent contaminates from entering the actuator VISE CLAMPING 2 Make sure that the actuator cylinder is fully retracted AREA 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 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 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 i
154. ts is necessary to engage the calibration mode Refer to the Sonic Boom Kit Installation Instructions for this sequence 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 Aslowly 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 Workman 200 Page 3 2 17 NOTE When troubleshooting an electrical problem on your Ultra Sonic Boom System refer to information r
155. ure PTO shaft to pump shaft 7 Position pump drive shrouds item 13 to shroud bracket item 14 Install four 4 flange head screws and flange nuts to secure shrouds to bracket 8 Position pump on pump mount bracket Install flange head screws and flange nuts to pump and mount brack et Secure pump to mount bracket 9 Attach PTO driveshaft to output shaft of transaxle PTO assembly 10 Install pressure and suction hoses to correct barb fit tings Secure hoses with hose clamps Figure 7 1 Elbow pressure 2 Suction hose Spray System Spray Pump Service 1 Valve chamber 2 Valve inlet position 3 O ring 4 Diaphragm cover 5 Hex bolt 6 Washer 7 Diaphragm 8 Diaphragm back disc 9 Nylon washer 10 Lock washer Spray System Figure 8 Hex bolt Ball bearing crankshaft Dust plate Pump casing Hex bolt 30 mm long 3 used Hex bolt 4 used per cover Hex bolt 55 mm long 2 used Felt seal Hex nut Page 3 12 26 60 ft lb 81 Connecting rod Ball bearing connecting rod Grease fitting Crankshaft Hex nut 5 used Valve outlet position Hex bolt 2 used Washer 2 used Poly o ring Workman 200 Spray System Disassembly Fig 8 IMPORTANT Make sure to remove and neutralize chemicals from pump before disassembly Wear protective clothing chemical resistant gloves and eye protection during pump repair NOTE
156. using Figures 33 and 34 as guides Discard all removed o rings and gaskets 4 Assembly Fig 33 Figure 34 3 2 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 Page 3 33 Spray System Tank Suction NOTE ARROW SHOWS FLUID FLOW DIRECTION Figure 35 1 Suction hosebarb 7 Expansion pin 13 Suction hose 2 O ring 8 Bulkhead gasket 14 Suction tube 3 Screen vane 9 Bulkhead nut 15 Suction tube foot 4 Suction screen 10 O ring 16 Spray tank 5 Fork 11 Hosebarb 17 Hose clamp 6 Filter housing 12 Hose clamp 18 Suction hose 1 1 2 Spray System Page 3 34 Workman 200 Spray System NOTE If suction tube in tank develops an air leak spray performance will diminish when tank level reaches the leak Removal Fig 35 IMPORTANT Make sure to remove and neutralize chemicals from tank and spray components before disassembly Wear protective clothing chemical re sistant gloves and eye protection during repair 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Remove suction strainer from spray tank see Oper ator s Manual 3 Raise tank li
157. val Fig 50 1 Park machine on a level surface lower booms stop engine engage parking brake and remove key from the ignition switch 2 Label actuator electrical leads to ease reassembly Unplug boom actuator connector wires from machine harness 3 Support boom to prevent it from falling Remove cot ter pins and clevis pins that attach boom actuator to cen ter and side boom 4 Pull boom actuator from machine Spray System Page3 44 Rev A 5 Adjustable clevis Installation Fig 50 1 Position boom actuator to clevis attachment points on center and side booms 2 Install clevis pins and cotter pins to secure actuator to boom assembly 3 Plugactuator connector wires into machine harness Make sure that operator switches engage correct actua tor A Leftside actuator connector has orange and blue wires B Right side actuator connector has yellow and green wires Workman 200 Spray System Adjustment 1 Loosen end nut that secures adjustable clevis to boom frame Fig 51 Position jam nut as close as pos sible to adjustable clevis Tighten end nut to secure cle vis 2 Fully raise side boom with the boom actuator The boom actuator should fully extend and ratchet 3 With the boom actuator at full extension the break away pivot gusset should just touch the center boom frame slot Fig 52 4 If needed loosen end nut that secures adjustable clevis and readjust jam nut on clevis to allow co
158. wer until the operator re leases the boom actuator switch Workman 200 Page 3 2 15 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 Ultra Sonic Boom System Rev C 2 La 2 Boom System This page is intentionally blank Ultra Sonic Boom System Rev C Page 3 2 16 Workman 200 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 UI tra Sonic Boom System Operation in this chapter 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 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 NOTE A sequence of switch movemen
159. y contact your Toro distribu tor to retrieve older fault codes After necessary service has been performed discon nect diagnostic shunt wires and insert shunt leads into diagnostic tether cap Lower operator seat 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 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 Atthe 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 Page 3 2 19 Ultra Sonic Boom System Rev C 2 La 5 Boom System 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

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