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Page 3 - Table Of Contents
Rev. C Workman 200 Spray System Table Of Contents Chapter 1 -- Safety and Product Records Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 3 . . . . . . . . . . . . . . . . Product Records 1 -- 3 . . . . . . . . . . . . . . . . . . . ....
Page 5 - Chapter 1; Table of Contents; Safety and; Safety and Product Records
Chapter 1 Safety and Product Records Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . ...
Page 6 - Safety Instructions; To reduce the potential for injury or death, com-; Before Operating
Rev. B Workman 200 Spray System Page 1 -- 2 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 co...
Page 7 - Maintenance and Service; Safety and Instruction Decals
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 reco...
Page 9 - Chapter 2; Electrical System; Electrical System
Rev. B Workman 200 Spray System Page 2 -- 1 Electrical System Chapter 2 Electrical System Table of Contents ELECTRICAL SCHEMATIC and ELECTRICAL HARNESS and CONNECTOR DRAWINGS 2 . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT TESTING 4 . . . . . . . . . ....
Page 11 - Special Tools; Multimeter; Electrical
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 ...
Page 12 - Component Testing; Master Boom Switch; Testing; BACK OF SWITCH
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 Figur...
Page 13 - Rate Control and Boom Actuator Switches
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 op...
Page 14 - Supervisor Key Switch
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. The supe...
Page 15 - Boom Control and Monitor Power Switches
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 swit...
Page 16 - Hold and Boom Actuator (Serial Numbers Above 260000000) Relays
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 fo...
Page 17 - Traction Speed Sensor; B A
Rev. B Workman 200 Spray System Page 2 -- 9 Electrical 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...
Page 19 - Chapter 3; Spray System; Spray System
Rev. B Workman 200 Spray System Page 3 -- 1 Spray System Chapter 3 Spray System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Precautions Concerning Chemicals Used in Spray System 3 . . . ....
Page 20 - Specifications
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 Spr...
Page 21 - General Information; Precautions Concerning Chemicals Used in Spray System; SPRAYER
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. To eliminate environmental damage and personal injury: 1. Select the proper chemical for the job....
Page 22 - Spray System Flow Diagram
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 PRESSURE DAMPENER CONTROL SUCTION DAMPENER DIAPHRAGM PUMP BOOM CONTROL Workman 200 Spray System Workman...
Page 23 - Spray System Operation
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 propor...
Page 24 - Troubleshooting; Problem
Workman 200 Spray System Page 3 -- 6 Spray System Troubleshooting Problem Possible Cause Spray system leaks fluid. Fitting(s), hose(s), or tube(s) are loose or damaged. O--ring(s) or seal(s) are missing or damaged. Spray tank drain valve is leaking. Fluid leaking from bottom of spray pump. Faulty di...
Page 26 - Service and Repairs; Suction Dampener; IMPORTANT: Make sure to neutralize and remove
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. IMPORTAN...
Page 27 - Pressure Dampener
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 (.82 to 1.03 bar). IMPORTANT: Any fluid ...
Page 28 - Spray Pump
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 clamp 11. Pressure hose 12. Flange head screw (4 used) 13. Pump drive shroud 14. Shroud brack...
Page 30 - Spray Pump Service
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. Valve chamber 11. Hex bolt 20. Connecting rod 2. Valve (inlet posit...
Page 34 - Agitation Control Valve
Workman 200 Spray System Page 3 – 16 Spray System Agitation Control Valve 1. Agitation control valve 2. Fork 3. Hosebarb/hose (to agitation nozzles) 4. O–ring 5. O–ring 6. Hosebarb/hose (from spray control) 7. Connector 8. Pump suction hose Figure 13 A A 1 2 3 4 5 4 7 8 6 8 FRONT RIGHT NOTE: ARROWS ...
Page 40 - IMPORTANT: Rate control and boom valve motors
Rev. B Workman 200 Spray System Page 3 -- 22 Spray System Spray Control (Serial Numbers Below 290999999) 1. Nut 2. Threaded rod 3. Washer 4. Bushing 5. O--ring 6. Cap 7. O--ring 8. Tee piece 9. Hose: control supply (1”) 10. Hose clamp 11. Fork 12. Screw 13. Control valve bracket 14. Rate control val...
Page 48 - IMPORTANT: Make sure to remove and neutralize
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. Gasket 8. Phillips head screw (4 used) 9. Rate valve ...
Page 56 - Boom Valve Manifold Assembly (Serial Numbers Above 310000000)
Rev. B Page 3 -- 31.1 Workman 200 Spray System Spray System Boom Valve 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. Balancing valve assembl...
Page 58 - Boom Bypass
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. Hosebarb/hose 8. Hosebarb/hose Figure 33 FRONT RIGHT A A 1 2 3 4 5 6 7 8 5 NOTE: ARROW SHOWS FLUID FLOW DIRECTION
Page 60 - Tank Suction
Workman 200 Spray System Page 3 – 34 Spray System Tank 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 11. Hosebarb 12. Hose clamp 13. Suction hose 14. Suction tube 15. Suction tube foot 1...
Page 62 - Tank Drain
Workman 200 Spray System Page 3 – 36 Spray System Tank Drain 1. Drain handle 2. Nut 3. O–ring 4. Bulkhead 5. Gasket 6. Ringnut 7. Chain 8. Drain assembly 9. Hose clamp 10. Drain hose 11. Spray tank Figure 38 3 1 2 4 6 9 7 8 10 11 5 FRONT RIGHT
Page 64 - Turret Bodies
Workman 200 Spray System Page 3 – 38 Spray System Turret Bodies 1. Turret body (w/90 o elbow) 2. 90 o elbow (1 used) 3. Screw 4. Turret body (w/double hose barb) 5. Turret body (w/single hose barb) 6. Single hose barb (3 used) 7. Double hose barb (7 used) 8. Turret body clamp 9. Hose barb (for 90 o ...
Page 65 - Turret Body Service
Turret Body Service Disassembly (Fig. 42) 1. Pull e–clip from body and slide plug with o–ring from body. 2. Disassemble turret body using Figure 42 as a guide. 3. Discard all removed seals, gaskets, o–rings, and di- aphragms. Assembly (Fig. 42) NOTE: Coat all o–rings with vegetable oil before instal...
Page 67 - CAUTION; Spring in breakaway pivot is under tension. To
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...
Page 79 - Sonic Boom System
Rev. C Workman 200 Spray System Page 3.1 -- 1 Sonic Boom System (Optional Kit) Chapter 3.1 Sonic Boom System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Installation Instructions 2 . . . . . . . . . . . . . . . . . . . . . . Precautions Concerning Chemicals Used...
Page 80 - Installation Instructions
Rev. B Workman 200 Spray System Page 3.1 -- 2 Sonic Boom System (Optional Kit) 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 p...
Page 81 - Diagnostic Display
Rev. B Workman 200 Spray System Page 3.1 -- 3 Sonic Boom System (Optional Kit) Special Tools Diagnostic Display The Diagnostic Display (Fig. 1) can be connected to the Sonic Boom wire harness communication connector to verify correct electrical functions of the Sonic Boom Sys- tem. Electronic contro...
Page 82 - Electrical Schematic; Sonic
Rev. B Workman 200 Spray System Page 3.1 -- 4 Sonic Boom System (Optional Kit) Electrical Schematic Sonic B oom System RI GHT B OOM ACT U AT O R SWIT CH LE FT B OOM ACT U AT O R SWIT CH RI GHT B OOM ACT U AT O R LE FT B OOM ACT U AT O R
Page 84 - Sonic Boom System Operation
Rev. B Workman 200 Spray System Page 3.1 -- 6 Sonic Boom System (Optional Kit) Sonic Boom System Operation Sonic B oom System Power C urrent Control C urrent Indicator Light Current (IN A UT O P O S ITIO N) (N O T ENERG IZ E D) (N O T ENERG IZ E D) (N O T ENERG IZ E D) (N O T ENERG IZ E D) (S TA T I...
Page 85 - Sprayer Operation on Level Turf; LEVEL GROUND
Rev. B Workman 200 Spray System Page 3.1 -- 7 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 the...
Page 87 - Downward Slope in Turf Encountered; SLOPE
Rev. B Workman 200 Spray System Page 3.1 -- 9 Sonic Boom System (Optional Kit) 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 ...
Page 89 - Rise in Turf Encountered; RISE
Rev. B Workman 200 Spray System Page 3.1 -- 11 Sonic Boom System (Optional Kit) Rise in Turf Encountered During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then rece...
Page 91 - Boom Level Changed by Operator During Automatic Operation
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 automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually s...
Page 93 - Manual Boom Operation; Raise Boom
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. When the sonic boom switch i...
Page 94 - Sonic Boom Light; Sonic Boom Calibration
Rev. B Workman 200 Spray System Page 3.1 -- 16 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). N...
Page 98 - Troubleshooting Chart
Rev. B Workman 200 Spray System Page 3.1 -- 20 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 b...
Page 100 - Sonic Mode Switch
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. The sonic mode switch is loca...
Page 101 - Relays
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 ...
Page 103 - Sonic Sensor; IMPORTANT: Do not spray water at or on the sen-
Rev. B Workman 200 Spray System Page 3.1 -- 25 Sonic Boom System (Optional Kit) 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 son...
Page 105 - Ultra Sonic Boom System
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 1 Chapter 3.2 Ultra Sonic Boom System (Optional Kit) Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Installation Instructions 2 . . . . . . . . . . . . . . . . . . . . . . Precautions Concerning Chemicals Use...
Page 108 - raS
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 4 Electrical Schematic U lt raS o n icB o o mS ys te m Electrical Schematic LE F T BO O M LIF T SW IT CH SO N IC B OOM R IGH T B OO M SWI T CH LIF T S W IT CH IN T E R FA C E TO VEHI C LE POW E R 7.5 A 2A 7.5 A 7.5 A A B AB
Page 110 - Ultra Sonic Boom System Operation
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 6 Ultra Sonic Boom System Operation U lt raS o n icB o o mS ys te m Power C ur rent C ontrol C ur rent Indicato r Lig ht Curr en t S pr ay er O pe ra tio n on Le ve lT ur f So ni c B oom Swi tch in Auto mat ic P os itio n LE F T B OOM LI F T S...
Page 121 - Ultra Sonic Boom Calibration
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 17 Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and com- ponents used on the Ultra Sonic Boom System (see Ul- tra Sonic Boom System Operation in this chapter). NOTE: W...
Page 122 - Diagnostic Lamp
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 18 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 posi...
Page 130 - Sonic Boom Fuses
Workman 200 Ultra Sonic Boom System (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 fuses protect circui...
Page 131 - Sonic Boom Switch
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 27 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...
Page 132 - Sonic Sensors
Workman 200 Ultra Sonic Boom System (Rev. C) Page 3.2 -- 28 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 ...
Page 137 - Chapter 4; Electrical Diagrams
Rev. B Workman 200 Spray System Electrical Diagrams Page 4 -- 1 Chapter 4 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS Serial Numbers Below 260000000 3 . . . . . . . . . . . . . Serial Numbers Above 260000000 4 . . . . . . . . . . . . . WIRE HARNESS DRAWINGS Spray System Wire Harness ...
Page 142 - Spray System Wire Harness
Rev. B Page 4 -- 6 Workman 200 Spray System Spray System Wire Harness (Serial Numbers Below 260000000)
Page 150 - Spray Console Wire Harness
Rev. B Page 4 -- 14 Workman 200 Spray System Spray Console Wire Harness (Serial Numbers Below 260000000)
Page 158 - Sprayer Power Harness
Rev. B Page 4 -- 22 Workman 200 Spray System Sprayer Power Harness (Serial Numbers Below 260000000) PINK/BLUE PINK/BLACK PINK/WHITE RED BLACK RED/WHITE RED/BLACK
