Instruction/ maintenance manual of the product 41229 Toro
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(Models 41229 and 41235) P ART NO. 03124SL (Rev . C) Service Manual W orkman R 200 Spray Syst em Preface The pur pose of t his public ation is to pr ovide the servic e technic ian with inf orm ation for t roubles hooting, t esting, and repair of maj or syst ems and co mponents on the Workman 200 S pray S yst em (Models 41229 and 41235).
Workma n 200 Sp ray System This page is intent ionall y blank ..
Rev . C Workma n 200 Sp ray System T able Of Contents Cha pte r 1 - - Saf et y and Pr oduct Re cords Safe ty Instruc tio n s 1 - - 2 .......................... Safet y and I nst ruc tion Dec als 1 - - 3 ................ Produc t Records 1 - - 3 ......
Workma n 200 Sp ray System This page is intent ionall y blank ..
Chapter 1 Safety and Product Records T able of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . .
Rev . B Workma n 200 Sp ray System Page 1 - - 2 Sa fet y and Pr oduct R ec ords Safety Instructions The W orkman 200 Spray Syst em is des igned and test ed t o offer s afe s ervic e when operat ed and main- tained properly .
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 .
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Rev . B Workman 200 Spray System Page 2 - - 1 Electrical System Chapter 2 Electrical System T able of Contents ELECTRICAL SCHEMA TIC and ELECTRICAL HARNESS and CONNECTOR DRA WINGS 2 ..... SPECIAL TOOLS 3 ............................. COMPONENT TESTING 4 .
Electrical Schematic and Electrical Harness and Connector Drawings The electrical schematic and other electrical drawings f o r the W orkman 200 Spray System are located in Chap - ter 4 – Electrical Diagrams.
Special T ools Multimeter The multimeter can test electrical components and cir- cuits for current, resistance, or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt– Ohm–Amp multimeter when testing electrical circuits.
Component T esting Master Boom Switch The master boom switch is located on the spray control enclosure faceplate (Fig. 2). T esting 1. Remove spray control enclosure faceplate, locate master boom switch and unplug wire harness connector from switch. 2.
Rev . B Workman 200 Spray System Page 2 - - 5 Electrical 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.
Rev . B Workman 200 Spray System Page 2 - - 6 Electrical System 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.
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). T esting 1. Remove spray control enclosure faceplate, locate boom control switch and unplug wire harness connector from switch.
Rev . B Workman 200 Spray System Page 2 - - 8 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.
Rev . B Workman 200 Spray System Page 2 - - 9 Electrical System T raction Speed Sensor The traction speed sensor is attached to the upper transaxle cover (Fig.
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Rev . B Workman 200 Spray System Page 3 - - 1 Spray System Chapter 3 Spray System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Precautions Concerning Chemicals Used in Spray System 3 .
Specifications Item Description Spray Pump Diaphragm Pump, 29 GPM Spray Pressure Relief V alve Poppet Style, 220 PSI Maximum Sprayer T ank 200 Gallon (757 Liter), Polyethylene Suction Strainer 50 Mesh.
Rev . B Workman 200 Spray System Page 3 - - 3 Spray System General Information Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons, animals, plants, soil, or other property . T o eliminate environmental damage and personal injury: 1.
FLOWMETER Page 3 – 4 Spray System Spray System Flow Diagram Spray System Flow Diagram SUCTION PRESSURE FLOW DIRECTION PRESSURE RELIEF PRESSURE CONTROL PRESSURE PRESSURE GAUGE & SCREEN PRESSURE P.
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.
Workman 200 Spray System Page 3 - - 6 Spray System T roubleshooting Problem Possible Cause Spray system leaks fluid. Fitting(s), hose(s), or tube(s) are loose or damaged. O - -ring(s) or seal(s) are missing or damaged. Spray tank drain valve is leaking.
Workman 200 Spray System Page 3 - - 7 Spray System Erratic spray operation from booms. Clogged strainer . Damaged suction dampener . Damaged pressure dampener . Console boom switch(es) dirty , corroded, or damaged. Rate control motor worn or sticking.
Workman 200 Spray System Page 3 – 8 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.
Workman 200 Spray System Page 3 – 9 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 (.
Workman 200 Spray System Page 3 – 10 Spray System Spray Pump 1. Spray pump assembly 2. Elbow (pressure) 3. Gasket 4. Pressure tee fitting 5. O–ring 6. Pressure dampener 7. O–ring 8. Hosebarb 9. Nut 10. Hose clam p 1 1. Pressure hose 12. Flange head screw (4 used) 13.
Removal (Fig. 6) IMPORT ANT : 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.
Spray Pump Service 9 10 11 12 13 14 7 8 15 17 18 1 2 3 4 5 6 5 6 8 7 9 12 13 14 10 18 19 20 21 22 23 16 26 21 20 4 28 32 ft–lb (43 N–m) 55 ft–lb (75 N–m) 25 ft–lb (34 N–m) 60 ft–lb (81 N–m) 60 ft–lb (81 N–m) 3 2 25 25 27 Figure 8 1.
Disassembly (Fig. 8) IMPORT ANT : Make sure to remove and neutralize chemicals from pump before disassembly . Wear protective clothing, chemical resistant gloves, and eye protection during pump repair . NOTE: Many pump components can be easily re- versed.
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. 1 1). Position nylon washer and washer on each connecting rod and then thread hex bolt into connecting rod.
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Workman 200 Spray System Page 3 – 16 Spray System Agitation Control V alve 1. Agitation control valve 2. Fork 3. Hosebarb/hose (to agitation nozzles) 4.
Removal (Fig. 13) IMPORT ANT : 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.
Workman 200 Spray System Page 3 – 18 Spray System Agitation Nozzles (T ank mounted) 1. Agitation supply 2. T ee fitting 3. Hosebarb/hose 4. O–ring 5. Connector 6. Bulkhead nut 7. Gasket 8. Bulkhead fitting 9. Hosebarb 10. Agitation nozzle 1 1. Nut 12.
Disassembly (Fig. 17) IMPORT ANT : Make sure to remove and neutralize chemicals from tank and other components before disassembly . W ear 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.
Workman 200 Spray System Page 3 – 20 Spray System Pressure Relief V alve (T ank Mounted) 1. Hosebarb/hose 2. Ringnut 3. Pressure relief valve 4. Gasket 5.
Removal (Fig. 18) IMPORT ANT : Make sure to remove and neutralize chemicals from tank and other components before disassembly . W ear 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.
Rev . B W orkman 200 Spray System Page 3 - - 22 Spray System Spray Control (Serial Numbers Below 290999999) 1. Nut 2. Threaded rod 3. W asher 4. Bushing 5. O - - ring 6. Cap 7. O - - ring 8. T ee piece 9. Hose: control supply (1”) 10. Hose clamp 1 1.
IMPORT ANT : 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.
Rev . B Page 3 - - 23.1 Workman 200 Spray System Spray System Spray Control (Serial Numbers Above 310000000) 1. Flange nut (2 used) 2. Flange nut (8 used) 3. Flange head screw (2 used) 4. V a lve mount 5. Flange head screw (8 used) 6. Gasket (2 used) 7.
Rev . B Page 3 - - 23.2 Workman 200 Spray System Spray System Disassembly (Fig. 23.1) IMPORT ANT : 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 .
Rev . B W orkman 200 Spray System Page 3 - - 24 Spray System Flowmeter (Serial Numbers Below 290999999) 1. Nut 2. Threaded rod 3. W asher 4. Bushing 5. O - - ring 6. Cover 7. O - - ring 8. T ee piece 9. Hose: control supply (1”) 10. Hose clamp 1 1. Fork 12.
Removal and Inspection (Fig. 24) IMPORT ANT : 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.
Rev . B Page 3 - - 25.1 Workman 200 Spray System Spray System Flowmeter (Serial Numbers Above 310000000) 2 3 6 8 9 1 5 7 4 5 NOTCH SEALANT NOTCH THREAD NOTE ARROW DIRECTION 1. Flowmeter body 2. Rotor/magnet assembly 3. Upstream hub with bearing 4. Downstream hub 5.
Rev . B Page 3 - - 25.2 Workman 200 Spray System Spray System Removal and Inspection (Fig. 26.1) IMPORT ANT : 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 .
Rev . B Workman 200 Spray System Page 3 - - 26 Spray System Rate Control Motor (Serial Numbers Below 290999999) 1. Phillips head screw (5 used) 2. Lock washer 3. Hand grip 4. O - - ring 5. Phillips head screw (4 used) 6. Rate control motor assembly 7.
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 1 1) and seal (item 14). 4. Remove valve (item 13) and inspect for wear and/or damage. Replace if needed.
Rev . B Page 3 - - 27.1 Workman 200 Spray System Spray System Regulating V alve Assembly (Serial Numbers Above 310000000) Figure 28.1 2 3 6 8 9 10 11 13 1 5 7 12 14 4 10 7 11 9 12 1. Regulating valve motor 2. Hose barb 3. Flange 4. Adaptor 5. Flynut 6.
Rev . B Page 3 - - 27.2 Workman 200 Spray System Spray System Assembly (Fig. 28.1) 1. T o install valve motor cover to regulating valve motor (Fig. 28.3): A. Connect cover wires to motor wires. Make sure that cover wire color is the same as the motor wire color when connecting wires.
Rev . B Workman 200 Spray System Page 3 - - 28 Spray System Boom V alve Motor (Serial Numbers Below 290999999) 1. Housing cover 2. Cover seal 3. Boom valve motor 4. Phillips head screw (5 used) 5. O - - ring 6. Lock washer 7. Hand grip 8. Roller 9. Roller pin 10.
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.
3. Assemble spindle section by reversing disassembly process. Align green indicator tab on spindle to slot in spindle housing. Install screw into bottom of spindle to secure assembly . T orque screw 70 in–lb (8 N–m). 4. Position spindle section on motor section so that green indicator on spindle section is opposite the motor hand grip.
Spray System This page is intentionally blank. Workman 200 Spray System Page 3 – 31 Spray System.
Rev . B Page 3 - - 31.1 Workman 200 Spray System Spray System Boom V alve Manifold Assembly (Serial Numbers Above 310000000) Figure 32.1 1. Boom valve motor (3 used) 2. Hose barb (3 used) 3. Pressure gauge port 4. Flange 5. Flynut 6. Elbow fitting 7. Mounting bracket (2 used) 8.
Rev . B Page 3 - - 31.2 Workman 200 Spray System 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. T o install cover to boom valve motor (Fig. 32.3): A. Connect cover wires to motor wires.
Workman 200 Spray System Page 3 – 32 Spray System Boom Bypass 1. Boom bypass elbow 2. O–ring 3. Bulkhead fitting 4. Gasket 5. Fork 6. Bulkhead nut 7.
Disassembly (Fig. 33) IMPORT ANT : Make sure to remove and neutralize chemicals from tank and spray components before disassembly . W ear 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.
Workman 200 Spray System Page 3 – 34 Spray System T ank Suction 1. Suction hosebarb 2. O–ring 3. Screen vane 4. Suction screen 5. Fork 6. Filter housing 7. Expansion pin 8. Bulkhead gasket 9. Bulkhead nut 10. O–ring 1 1. Hosebarb 12. Hose clamp 13.
NOTE: If suction tube in tank develops an air leak, spray performance will diminish when tank level reaches the leak. Removal (Fig. 35) IMPORT ANT : Make sure to remove and neutralize chemicals from tank and spray components before disassembly . W ear protective clothing, chemical re - sistant gloves, and eye protection during repair .
Workman 200 Spray System Page 3 – 36 Spray System T ank Drain 1. Drain handle 2. Nut 3. O–ring 4. Bulkhead 5. Gasket 6. Ringnut 7. Chain 8. Drain assembly 9.
Workman 200 Spray System Page 3 – 37 Spray System Disassembly (Fig. 38) IMPORT ANT : Make sure to remove and neutralize chemicals from tank and spray components before disassembly . W ear protective clothing, chemical re- sistant gloves, and eye protection during repair .
Workman 200 Spray System Page 3 – 38 Spray System T urret Bodies 1. T urret body (w/90 o elbow) 2. 90 o elbow (1 used) 3. Screw 4. T urret body (w/double hose barb) 5. T urret body (w/single hose barb) 6. Single hose barb (3 used) 7. Double hose barb (7 used) 8.
T urret 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.
Rev . A Workman 200 Spray System Page 3 - - 40 Spray System Boom Frame Breakaway Pivot Assembly (Serial Numbers Below 260000000) 1. Hinge 2. Breakaway pivot 3. Spring 4. W asher 5. Roll pin 6. Hex nut 7. Support bracket 8. Carriage screw 9. Flat washer 10.
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 .
Rev . A Workman 200 Spray System Page 3 - - 42 Spray System Boom Hinge (Serial Numbers Above 260000000) 1. Hinge (2 used per boom) 2. Rubber boot (2 used per hinge) 3. Backing plate (4 used per hinge) 4. Flange nut (4 used per hinge) 5. Boom (RH shown) 6.
1 Assembly (Fig. 47) 1. I f pivot bracket (item 1 1) was removed from machine, lightly lubricate bushings (item 12) with motor oil before assembly . Connect boom actuator (not shown) to pivot bracket (see Boom Actuator Installation (Machines with Serial Numbers Above 260000000) in this section).
Rev . A Workman 200 Spray System Page 3 - - 44 Spray System Boom Actuator (Optional) (Serial Numbers Below 260000000) 1. Cotter pin 2. Clevis pin 3. Boom actuator 4. Wire harness 5. Adjustable clevis Figure 50 2 3 1 4 1 2 3 FRONT RIGHT 5 5 Removal (Fig.
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. T ighten end nut to secure cle- vis. 2. Fully raise side boom with the boom actuator . The boom actuator should fully extend and ratchet.
Rev . A Workman 200 Spray System Page 3 - - 46 Spray System Boom Actuator Service (Serial Numbers Below 260000000) 1. Screw 2. Rear housing 3. W asher 4. Woodruff key 5. Clutch 6. Thin washer 7. Intermediate gear 8. Thick washer 9. Hex nut (2 used) 10.
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.
Rev . A Workman 200 Spray System Page 3 - - 48 Spray System Boom Actuator (Serial Numbers Above 260000000) 1. Boom actuator (2 used) 2. Carriage screw (4 used) 3. Boom frame 4. W asher plate 5. Lock nut (4 used) 6. Flange nut (2 used) 7. Flange head screw (2 used) 8.
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.
Rev . A Workman 200 Spray System Page 3 - - 50 Spray System Boom Actuator Service (Serial Numbers Above 260000000) IMPORT ANT : Do not dismantle, repair or modify the boom actuator . Internal components are not avail- able for the actuator . If an actuator is damaged or worn, replace actuator .
Actuator 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 .
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Rev . C Workman 200 Spray Syste m Page 3.1 - - 1 Sonic Boom System (Optional Kit) Chapter 3.1 Sonic Boom System T able of Contents GENERAL INFORMA T ION 2 ..................... Installation Instructions 2 ...................... Precautions Concern ing Chemicals Used in Spray System 2 .
Rev . B Workman 200 Spray System Page 3.1 - - 2 Sonic Boom System (Optional Kit) General Information Installation Instructions The Sonic Boom Kit I nstallation Instructions provides in- formation regarding the installation, operation and gen- eral maintenance for your Sonic Boom System.
Rev . B Workman 200 Spray System Page 3.1 - - 3 Sonic Boom System (Optional Kit) Special T ools Diagnostic Display The Diagnostic Display (Fig. 1) can be connected to the Sonic Boom wire harness communication connector to verify correct electrical functions of the Sonic Boom Sys- tem.
Rev . B Workman 200 Spray System Page 3.1 - - 4 Sonic Boom System (Optional Kit) Electrical Schematic Sonic Boom System RIGHT BOOM ACTUA TOR SWITCH LEFT BOOM ACTUA TOR SWITCH RIGHT BOOM ACTUA TOR LEFT.
Rev . B Workman 200 Spray System Page 3.1 - - 5 Sonic Boom System (Optional Kit) This page is intentionally blank..
Rev . B Workman 200 Spray System Page 3.1 - - 6 Sonic Boom System (Optional Kit) Sonic Boom System Operation Sonic Boom System Power Current Control Current Indicator Light Current (IN AUTO POSITION) .
Rev . B Workman 200 Spray System Page 3.1 - - 7 Sonic Boom System (Optional Kit) Sprayer Operation on Level T urf During sprayer operation with the sonic boom switch in the automatic position (sonic b.
Rev . B Workman 200 Spray System Page 3.1 - - 8 Sonic Boom System (Optional Kit) Sonic Boom System Power Current Control Current Indicator Light Current (IN AUTO POSITION) (ENERGIZED) (NOT ENERGIZED) .
Rev . B Workman 200 Spray System Page 3.1 - - 9 Sonic Boom System (Optional Kit) Downward Slope in T urf Encountered During sprayer operation with the sonic boom switch in the automatic position (soni.
Rev . B Workman 200 Spray System Page 3.1 - - 10 Sonic Boom System (Optional Kit) Sonic Boom System Power Current Control Current Indicator Light Current (IN AUTO POSITION) (NOT ENERGIZED) (ENERGIZED).
Rev . B Workman 200 Spray System Page 3.1 - - 1 1 Sonic Boom System (Optional Kit) Rise in T urf Encountered During sprayer operation with the sonic boom switch in the automatic position (sonic boom l.
Rev . B Workman 200 Spray System Page 3.1 - - 12 Sonic Boom System (Optional Kit) Sonic Boom System Power Current Control Current Indicator Light Current (IN AUTO POSITION) (ENERGIZED) (NOT ENERGIZED).
Rev . B Workman 200 Spray System Page 3.1 - - 13 Sonic Boom System (Optional Kit) Boom Level Changed by Operator During Automatic Operation During sprayer operation with the sonic boom switch in the a.
Rev . B Workman 200 Spray System Page 3.1 - - 14 Sonic Boom System (Optional Kit) Sonic Boom System Power Current Control Current Indicator Light Current (IN MANUAL POSITION) (NOT ENERGIZED) (ENERGIZE.
Rev . B Workman 200 Spray System Page 3.1 - - 15 Sonic Boom System (Optional Kit) Manual Boom Operation During sprayer operation with the sonic boom switch in the manual position, the spray booms will remain in posi- tion unless the operator presses a boom actuator switch.
Rev . B Workman 200 Spray System Page 3.1 - - 16 Sonic Boom System (Optional Kit) T roubleshooting 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).
Rev . B Workman 200 Spray System Page 3.1 - - 17 Sonic Boom System (Optional Kit) Diagnostic Display The Sonic Boom System is equipped with an electronic control unit (ECU) which controls machine sonic boom electrical functions. The ECU monitors various input switches (e.
Rev . B Workman 200 Spray System Page 3.1 - - 18 Sonic Boom System (Optional Kit) Diagnostic Display Inputs Diagnostic Display LED Operation AUTO MODE Sonic mode switch in auto position: LED ON Sonic .
Rev . B Workman 200 Spray System Page 3.1 - - 19 Sonic Boom System (Optional Kit) V erify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the electronic control unit (ECU).
Rev . B Workman 200 Spray System Page 3.1 - - 20 Sonic Boom System (Optional Kit) T roubleshooting 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.
Rev . B Workman 200 Spray System Page 3.1 - - 21 Sonic Boom System (Optional Kit) Problem Possible Cause One of the boom actuators will not extend. 30 amp auto resetting fuse for affected boom actuator is faulty . Power switch relay or circuit wiring for affected boom actuator is faulty .
Rev . B Workman 200 Spray System Page 3.1 - - 22 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.
Rev . B Workman 200 Spray System Page 3.1 - - 23 Sonic Boom System (Optional Kit) 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 .
Rev . B Workman 200 Spray System Page 3.1 - - 24 Sonic Boom System (Optional Kit) 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.
Rev . B Workman 200 Spray System Page 3.1 - - 25 Sonic Boom System (Optional Kit) Sonic Sensor T wo (2) identical sonic sensors are used in the Sonic Boom System.
Rev . B Workman 200 Spray System Page 3.1 - - 26 Sonic Boom System (Optional Kit) This page is intentionally blank..
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 1 Chapter 3.2 Ultra Sonic Boom System (Optional Kit) T able of Contents GENERAL INFORMA T ION 2 ..................... Installation Instructions 2 ...................... Precautions Concerni ng Chemicals Used in Spray System 2 .
Wor k ma n 2 0 0 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 2 General Information Installation Instructions The Ultra Sonic Boom Kit Installation Instruction s pro- vides information regarding the installation, operation and general maintenance f or your Ultra Sonic Boom System.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 3 Special T ools Diagnostic Display The Diagnostic Display (Fig. 1) can be conn ected to the Ultra Sonic Boom wire ha rness communication connec- tor to verify c orrect electrical functions of the Ultra Sonic Boom System.
Wor k ma n 2 0 0 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 4 Electrical Schematic U l t r aS o n i cB o o mS y s t e m Electrical Schematic LEFT BOOM LIFT SWITCH SONIC BOOM RIGHT BOOM SWITCH LIFT SWITCH INTER FACE TO VEHICLE POWER 7.5A 2A 7.5A 7.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 5 This page is intentionally blank. Ultra Sonic Boom System.
Wor k ma n 2 0 0 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 6 Ultra Sonic Boom System Operation U l t r aS o n i cB o o mS y s t e m Power Current Control Current Indicator Light Current Spray er .
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 7 Sprayer Operation on Level T urf During sprayer operation with the s onic boom switch in the automatic position (son ic boom light is illuminated), the boom mounted sonic b oom sensors continua lly send impulse signals and then receive echoe s as the signals bounce of f the turf.
Wor k ma n 2 0 0 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 8 Ultra Sonic Bo om System Power Current Control Current Indicator Light Current Downward Slope in T urf Encountered (Left Boom Shown) Sonic Boom Switch in Automatic Position LEFT BOOM LIFT SWI TCH SONIC BO OM RIGHT BOOM SWITCH LIFT SWITCH INTERF ACE TO VEHICLE POWER 7.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 9 Downward Slope in T urf Encountered During sprayer operation with the s onic boom switch in the automatic position (son ic boom light is illuminated), the boom mounted sonic b oom sensors continua lly send impulse signals and then receive echoe s as the signals bounce of f the turf.
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 10 Ultra Sonic Bo om System Power Current Control Current Indicator Light Current Rise in T urf Encountered (Right Boom Shown) Sonic Boom Switch in Automatic Position LEFT BOOM LIFT SWI TCH SONIC BO OM RIGHT BOOM SWITCH LIFT SWITCH INTERF ACE TO VEHICLE POWER 7.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 1 1 Rise in T urf Encountered During sprayer operation with the s onic boom switch in the automatic position (son ic boom light is illuminated), the boom mounted sonic b oom sensors continua lly send impulse signals and then receive echoe s as the signals bounce of f the turf.
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 12 Ultra Sonic Bo om System Power Current Control Current Indicator Light Current Boom Level Changed by Operator (Raise Left Boom Shown) Sonic Boom Switch in Automatic Position LEFT BOOM LIFT SWITCH SONIC BO OM RIGHT BOOM SWITCH LIFT SWITCH INTERF ACE TO VEHICLE POWER 7.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 13 Boom Level C hanged by Operator Dur ing Automatic Operation During sprayer operation with the s onic boom switch in the automatic positio.
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 14 Ultra Sonic Bo om System Power Current Control Current Indicator Light Current Manual Boom Operation (Lower Right Boom Shown) Sonic Boom Switch in Manual Position LEFT BOOM LIFT SWI TCH SONIC BO OM RIGHT BOOM SWITCH LIFT SWITCH INTERF ACE TO VEHICLE POWER 7.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 15 Manual Boom Oper ation During sprayer operation with the s onic boom switch in the manual positi on, the spray booms will remain in posi- tion unless the operator presses a boom lift switch.
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Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 17 T roubleshooting For effective trouble shooting and repair s, there must be a good understanding of th e electrical circuits and com- ponents used on the Ultra So nic Boom System (see Ul- tra Sonic Boom System Operation in this c hapter).
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 18 Diagnosti c 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.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 19 Retrieving Fault Codes All Ultra Sonic B oom System fault cod es are retained i n the TEC controller memory . The three (3) most recent fault codes that have occurred within the las t forty (40) hours of operati on can be retri eved using the diagnostic lamp.
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 20 Diagnosti c Displa y The Ultra Sonic Boo m System is equipped with the T oro electronic controller (TEC) which controls machin e son- ic boom electrical function s. The TEC monitors various input switches (e.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 21 CAUTION When testing TEC inputs with the Diagnostic Dis- play , boom actuators may be energized c ausing the spray booms to move. Be cautious of poten- tial sprayer compone nt movement while verify - ing inputs with the Diagnostic Display .
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 22 V erify Diagnostic Display Output Functions The Diagnostic Display al so has the ability to detect which output boom actuators or lights (sonic boom or diagnostic) are en ergized by the T oro electronic control- ler (TEC).
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 23 Diagnostic Display Outputs Diagnostic Display LED Operation DIAG LAMP Diagnostic lamp is ON or FLASHING: LED ON or FLASHING Diagnostic la.
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 24 T roubleshooting Chart The chart that follows contains suggestions th at can be used to assist in diagnosin g Ultra Sonic Boom System performance issues. These su ggestions are not all - - in- clusive.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 25 Problem Possible Cause One of the booms does not automat- ically follow ground irregularities. B o o mc a nb ec o n t r o l l e dw i t hb o o m lift switch. On affected boo m, the sonic boom sensor co ver is on sensor .
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 26 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 fus es protec t circuits as follo ws: 1.
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 27 Sonic Boom Switch The sonic boom switch is used as an in put for the T oro electronic controller (TEC) to activate the Ultra Sonic Boom System. T his switch has t wo (2) positio ns: auto- matic and m anual.
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 28 Sonic Sensors T wo (2) identical sonic sensors are used in the Ultra Sonic Boom System .
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 29 Sonic Sensor LED Window The sonic senso r includes a LED window that id entifies sensor status during sprayer oper ation during operation of the Ultra Sonic Boom system (Fig. 21). T o view the LED window , carefully remove cover from sonic sensor .
Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 30 Relays The Ultra So nic Boom Sy stem uses fo ur (4) i dentical r e- lays to control the boom actuators and ultimately the boom height. T wo (2) of the relay s control the righ t boom actuator and the other two (2) relays control the left boom actuator .
Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 31 T oro Electronic Controller (TEC) The Ultra Sonic Boom System uses the T oro Electronic Controller (TEC) to control e lectrical system operation. The TEC is attached to a mounting plate under th e dash panel (Fig.
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Rev . B Workman 200 Spray Syste m Electrical Diagra ms Page 4 - - 1 Chapter 4 Electrical Diagrams T able of Contents ELECTRICAL SCHEMA TI CS Serial Numbers B elow 260000 000 3 ............. Serial Numbers Above 260 000000 4 ............. WIRE HARNESS DRA WINGS Spray System Wire Harness (Serial Numb ers Below 260000000) 6 .
This page is intentionally blank. Electrical Diagrams Page 4 – 2 Workman 200 Spray System.
7 7 7 8 BK 8 7 8 8 7 BU Y BK Y BK A B C D E F G H J K PK/W PK/W VIO/W VIO/R R/W GN/W GN/BK PK 8 BU/GN 8 BK W/BK HOLD (+) (–) FOAM PK/BU A B C GY GY/OR BU/BK BU/W R/BK R/W R/BK 7 GN/W PK BK BU/R BU/R.
Page 4 – 4 Rev . A Electrical Schematic W orkman 200 Spray System (Serial Numbers Above 260000000).
Rev . B Page 4 - - 5 This page is intent ional ly blank ..
Rev . B Page 4 - - 6 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial N umbers Below 260000000).
Rev . B Page 4 - - 7 W orkman 200 Spray S yst em Spray System W ire Harness BLUE/RED BLUE/ BLACK BLUE/ WHIT E ORANGE/B LACK ORANGE/W HIT E GREEN/WH ITE GREEN/BLACK GRA Y ORANGE GREEN YELLO W GRA Y/ORA.
Rev . B Page 4 - - 8 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial Numbers From 260000001 to 280000200).
Rev . B Page 4 - - 9 RED BLUE/ BLACK YELLO W ORANGE/W HIT E ORANGE/B LACK GREEN/BLACK GREEN/WH ITE BROWN/WH ITE BLUE/RED VIOLET GRA Y BLUE BLUE GREEN RED YELLO W BLUE YELLO W RED GREEN GREEN BLUE BLAC.
Rev . B Page 4 - - 10 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial Numbers From 280000201 to 290999999).
Rev . B Page 4 - - 1 1 W orkman 200 S pray S ystem Spray S ystem Wire Har n ess (Serial N umbers From 280000201 to 290999999) RED YELLO W ORANGE/W HIT E ORANGE/B LACK GREEN/BLACK GREEN/WH ITE BROWN/WH.
Rev . B Page 4 - - 12 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial Numbers Above 310000000).
Rev . B Page 4 - - 13 W orkman 200 S pray S ystem Spra y Sy st em Wi re Harn e ss (Serial Numbers Above 310000000) RED YELLO W ORANGE/W HIT E ORANGE/B LACK GREEN/BLACK GREEN/WH ITE BROWN/WH ITE BLUE/R.
Rev . B Page 4 - - 14 W orkman 200 S pray Sy stem S p r a yC o n s o l eW i r eH a r n e s s (Serial N umbers Below 260000000).
Rev . B Page 4 - - 15 W orkman 200 Spray S yst em Spr ay Console W ir e Har ness BLUE/RED RED BLACK RED RED BLUE/RED BROWN BLACK BLACK RED RED PINK BLACK BLUE/ WHIT E BLUE/ WHIT E BLACK BROWN RED PINK.
Rev . B Page 4 - - 16 W orkman 200 S pray Sy stem S p r a yC o n s o l eW i r eH a r n e s s (Serial Numbers From 260000001 to 260999999).
Rev . B Page 4 - - 17 BLACK RED PINK BLACK BLUE/ WHIT E BROWN ORANGE/ BL ACK ORANGE/ BL ACK PINK/B LACK BROWN BLACK BLUE/ WHIT E PINK PINK BLACK BLACK PINK/B LACK RED PINK BLUE/RED BLUE/RED BLACK VIOL.
Rev . B Page 4 - - 18 W orkman 200 S pray Sy stem S p r a yC o n s o l eW i r eH a r n e s s (Serial Numbers From 270000001 to 290999999).
Rev . B Page 4 - - 19 W orkman 200 Spray S ystem Spr ay Console W ir e Har ness (Serial Numbers From 270000001 to 290999999) BLACK VIO LET/ WHIT E BLUE/R ED BLUE/R ED BRO WN VIO LET/ RED BLACK BLACK R.
Rev . B Page 4 - - 20 W orkman 200 S pray Sy stem S p r a yC o n s o l eW i r eH a r n e s s (Serial Numbers Above 310000000).
Rev . B Page 4 - - 21 W orkman 200 S pray S ystem Spr ay Console W ir e Har ness (Serial Numbers Above 310000000) RED BLUE GR EEN PINK BLACK PINK/B LACK BRO WN VIO LET/ RED BLACK BLUE/R ED BLUE/R ED B.
Rev . B Page 4 - - 22 W orkman 200 S pray Sy stem Sprayer P ower Harness (Serial N umbers Below 260000000) PINK/BL UE PINK/B LACK PINK/W HITE RED BLACK RED/WHITE RED/BLA CK.
Rev . B Page 4 - - 23 W orkman 200 S pray S ystem Sprayer P ower Harness (Serial Numbers Above 260000000) PINK BLACK RED ORA NGE GR EEN YELLOW ORA NGE YELLOW.
An important point after buying a device Toro 41229 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toro 41229 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toro 41229 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toro 41229 you will learn all the available features of the product, as well as information on its operation. The information that you get Toro 41229 will certainly help you make a decision on the purchase.
If you already are a holder of Toro 41229, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toro 41229.
However, one of the most important roles played by the user manual is to help in solving problems with Toro 41229. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toro 41229 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
