PART NO. 03124SL (Rev. C) Service Manual (Models 41229 and 41235) WorkmanR 200 Spray System Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Workman 200 Spray System (Models 41229 and 41235). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS.
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Table Of Contents 3 -3 -3 -3 -3 -3 -- 2 3 4 5 6 8 Chapter 3.1 -- Sonic Boom System (Optional Kit) General Information . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 3 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 4 Sonic Boom System Operation . . . . . . . . . . . . . 3.1 -- 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 16 Service and Repairs . . . . . . . . . . . . .
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Safety and Product Records Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . . PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions The Workman 200 Spray System is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
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 protective equipment: protective clothing, chemical resistant gloves, and eye protection. 3.
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Chapter 2 Electrical System Table of Contents Workman 200 Spray System 2 3 4 4 5 6 7 Electrical System ELECTRICAL SCHEMATIC and ELECTRICAL HARNESS and CONNECTOR DRAWINGS . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . Master Boom Switch . . . . . . . . . . . . . . . . . . . . . . . . . Rate Control and Boom Actuator Switches . . . . . . Supervisor Key Switch . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic and Electrical Harness and Connector Drawings The electrical schematic and other electrical drawings for the Workman 200 Spray System are located in Chapter 4 – Electrical Diagrams.
Special Tools Multimeter The multimeter can test electrical components and circuits for current, resistance, or voltage. Electrical System NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.
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.
Rate Control and Boom Actuator Switches The rate control (increase/decrease) switch is located on the spray control enclosure faceplate (Fig. 4). On machines equipped with the electric boom lift, this is the same switch that is used to operate the boom actuators. Testing 2 1 2. The switch terminals are marked as shown in Figure 5. In the INCREASE or boom raise position, continuity should exist between terminals 2 and 3 and also between terminals 5 and 6.
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.
Boom Control and Monitor Power Switches The three boom control (on/off) and monitor power switches are located on the spray control enclosure faceplate (Fig. 8). 2 Testing 1. Remove spray control enclosure faceplate, locate boom control switch and unplug wire harness connector from switch. 1 Electrical System 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.
Hold and Boom Actuator (Serial Numbers Above 260000000) Relays Workman sprayers with serial numbers below 260000000 use a single relay for the sprayer hold function. Sprayers with serial numbers above 260000000 use the hold relay and four (4) additional relays for the boom actuators. The hold and boom actuator relays are located in the spray control enclosure. The relays can be identified by a tag at the relay wire harness connector. The relay used on sprayers with serial numbers below 260000000 (Fig.
Traction Speed Sensor The traction speed sensor is attached to the upper transaxle cover (Fig. 13). It uses a magnetically based, Hall Effect integrated circuit. As the differential in the transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the sensor. The red striped connector wire is the positive lead, the black wire is the ground lead, and the gray striped wire is the signal output. 2 1 Electrical System Testing 6.
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Chapter 3 Spray System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Precautions Concerning Chemicals Used in Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Precautions for Removing or Adjusting Spray System Components . . . . . . . . . . . . . . . . . . . . . . . 3 O--Ring Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPRAY SYSTEM FLOW DIAGRAM . . . . . . . . . . .
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 Spray System 50 Mesh, Stainless Steel, Tank Mounted (30 Mesh and 90 Mesh Optional) Page 3 – 2 Workman 200 Spray System
General Information Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons, animals, plants, soil, or other property. To eliminate environmental damage and personal injury: 1. Select the proper chemical for the job. 2. Carefully read the directions printed on the chemical manufacturer’s labels before handling chemicals. Instructions on chemical manufacturer’s container labels regarding mixing proportions should be read and strictly followed. 4.
Spray System SUCTION PRESSURE AGITATION BOOM SUPPLY FLOW DIRECTION AGITATION AGITATION CONTROL VALVE SUCTION DAMPENER AGITATORS (4) TANK DIAPHRAGM PUMP CONNECTED TO PTO Page 3 – 4 PRESSURE CONTROL VALVE PRESSURE PRESSURE RELIEF VALVE FLOWMETER PRESSURE GAUGE TOP MOUNTED TANK DRAIN VALVE TOP MOUNTED SUCTION & SCREEN PRESSURE PRESSURE DAMPENER BOOM SUPPLY BOOM CONTROL VALVES BOOM BY–PASS Spray System Flow Diagram Workman 200 Spray System Spray System Flow Diagram Workman 200 Spray System
Spray System Operation The downward stroke of the pumps’ connecting rods and diaphragms create suction to allow fluid to be drawn from the spray tank to the pump through the suction tube, suction strainer, hoses, and connectors. A suction dampener placed in the suction line dampens suction pulses to smooth suction flow. Suction valves positioned in the pump valve chamber prevent fluid from being pumped back into the suction line when the connecting rods change direction.
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 diaphragm(s) in spray pump. Excessive suction hose vibration. Suction screen in tank is plugged. Spray pump suction line has an air leak. Suction tube in spray tank has air leak. Suction line is restricted. Suction dampener diaphragm is damaged.
Erratic spray operation from booms. Clogged strainer. Damaged suction dampener. Damaged pressure dampener. Console boom switch(es) dirty, corroded, or damaged. Rate control motor worn or sticking. Boom valve motor seat loose or damaged. Boom valve motor actuating cam worn or sticking. No spray output from one spray boom. Hoses on boom are pinched or kinked. Boom valve motor for affected boom not opening. Console boom switch dirty, corroded, or damaged. Low spray rate from one nozzle.
Service and Repairs Suction Dampener The suction dampener is mounted to the suction line at the spray pump (Fig. 2) and is used to dampen suction pulses and smooth suction flow. During pump operation, the suction dampener diaphragm will move. 2 IMPORTANT: Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components. 1 A damaged suction dampener diaphragm will allow a suction leak and will cause improper pump operation.
Pressure Dampener The pressure dampener is mounted to the pressure line at the spray pump (Fig. 4) and is used to smooth system pressure pulsation. Adjust air pressure on the pressure dampener from 12 to 15 PSI (.82 to 1.03 bar). 2 IMPORTANT: Any fluid in the pressure dampener will include spray system chemicals so take necessary precautions when working with the dampener. Use appropriate protective equipment: protective clothing, chemical resistant gloves, and eye protection.
Spray Pump Apply thread sealant FRONT RIGHT Anti–seize Lubricant 7 4 12 Loctite #242 9 8 11 10 13 16 6 14 2 3 5 1 28 17 27 16 15 26 25 13 24 Loctite #242 18 22 5 23 19 20 Apply thread sealant 21 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spray pump assembly Elbow (pressure) Gasket Pressure tee fitting O–ring Pressure dampener O–ring Hosebarb Nut Hose clamp Spray System 11. 12. 13. 14. 15. 16. 17. 18. 19.
IMPORTANT: Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen hose clamp that secures suction hose (item 28) to hosebarb (item 25). Pull suction hose from hosebarb. 3. Loosen hose clamp that secures pressure hose (item 11) to hosebarb (item 8). Pull pressure hose from hosebarb. 4.
Spray Pump Service 26 1 60 ft–lb (81 N–m) 2 25 28 3 2 25 55 ft–lb (75 N–m) 4 9 4 3 5 60 ft–lb (81 N–m) 16 6 7 8 7 5 6 8 18 24 9 11 10 13 12 14 12 13 21 14 20 23 15 22 32 ft–lb (43 N–m) 10 17 27 18 20 21 19 25 ft–lb (34 N–m) Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Valve chamber Valve (inlet position) O–ring Diaphragm cover Hex bolt Washer Diaphragm Diaphragm back disc Nylon washer Lock washer Spray System 11. 12. 13. 14. 15. 16. 17. 18. 19.
D. Position dust plate and felt seal on both ends of crankshaft. Disassembly (Fig. 8) IMPORTANT: Make sure to remove and neutralize chemicals from pump before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during pump repair. NOTE: Many pump components can be easily reversed. During disassembly, make note of component position (e.g. crankshaft, valve chamber) to assure correct assembly. 1. Remove two (2) hex bolts that retain valve chamber to pump.
4. Place diaphragm back disc and new diaphragm onto each connecting rod. The connecting rods should extend above the diaphragms when correctly installed (Fig. 11). Position nylon washer and washer on each connecting rod and then thread hex bolt into connecting rod. Torque bolt to 60 ft–lb (81 N–m). 2 1 5. Make sure that pump casings align and then secure pump casing assembly by torquing five (5) bolts to 32 ft– lb (43 N–m). 6. Secure diaphragm covers to pump using hex bolts (4 per cover).
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Agitation Control Valve 8 A FRONT RIGHT 1 4 4 2 7 3 6 5 A 8 NOTE: ARROWS SHOW FLUID FLOW DIRECTION Figure 13 1. Agitation control valve 2. Fork 3. Hosebarb/hose (to agitation nozzles) Spray System 4. O–ring 5. O–ring 6. Hosebarb/hose (from spray control) Page 3 – 16 7. Connector 8.
IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 4 3 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2 2. Label disconnected hoses for proper installation after repairs are completed. 3. Remove agitation control valve using Figures 13 and 14 as guides. 4. Disassemble agitation valve as required (Fig 15).
Agitation Nozzles (Tank mounted) FRONT RIGHT 7 6 8 C 4 15 17 9 16 11 11 19 4 10 11 12 9 12 B 7 A 18 16 2 C 4 13 14 8 6 4 1 6 B 20 23 2 5 22 8 7 A 10 21 3 11 NOTE: ARROWS SHOW FLUID FLOW DIRECTION Figure 17 1. 2. 3. 4. 5. 6. 7. 8. Agitation supply Tee fitting Hosebarb/hose O–ring Connector Bulkhead nut Gasket Bulkhead fitting Spray System 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly (Fig. 17) Assembly (Fig. 17) IMPORTANT: Make sure to remove and neutralize chemicals from tank and other components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. NOTE: Coat all o–rings with vegetable oil before installation to reduce the chance of damage during assembly. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1.
Pressure Relief Valve (Tank Mounted) FRONT RIGHT 5 6 A 8 7 4 3 A 2 1 NOTE: ARROWS SHOW FLUID FLOW DIRECTION Figure 18 1. Hosebarb/hose 2. Ringnut 3. Pressure relief valve Spray System 4. Gasket 5. Hosebarb/hose 6. O–ring Page 3 – 20 7. Fork 8.
Removal (Fig. 18) IMPORTANT: Make sure to remove and neutralize chemicals from tank and other components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain spray tank (see Operator’s Manual). 3. Label disconnected hoses for proper installation after repairs are completed. Figure 19 1. Hose to pressure relief 2.
Spray Control (Serial Numbers Below 290999999) NOTE: ARROWS SHOW FLUID FLOW DIRECTION 19 17 18 20 FRONT 16 RIGHT 39 15 21 14 71 in--lb (8 N--m) 8 7 11 22 7 2 7 1 3 4 5 23 12 25 10 6 24 10 71 in--lb (8 N--m) 9 13 41 40 31 29 29 29 30 29 5 26 3 1 7 30 7 29 7 28 10 12 32 32 34 7 32 32 33 12 32 34 36 35 35 32 27 38 37 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 4 3 1 Removal (Fig. 21) 5 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3. Unplug electrical connectors from rate control motor, flowmeter, and three (3) boom valve motors from machine electrical harness. 4.
Spray Control (Serial Numbers Above 310000000) 10 FRONT 9 RIGHT 11 5 12 8 2 6 1 7 5 6 13 13 14 4 15 17 8 3 18 16 12 19 20 NOTE: ARROWS SHOW FLUID FLOW DIRECTION Figure 23.1 1. 2. 3. 4. 5. 6. 7. 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 8. 9. 10. 11. 12. 13. 14.
Disassembly (Fig. 23.1) IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Label all spray control assembly hoses for proper installation after repairs are completed. Loosen hose clamps and disconnect hoses from spray control. 3.
Flowmeter (Serial Numbers Below 290999999) 24 21 23 18 22 FRONT 20 14 RIGHT 6 8 7 11 19 7 2 7 1 3 5 4 17 12 10 13 10 15 16 71 in--lb (8 N--m) 28 9 71 in--lb (8 N--m) 7 25 5 27 3 1 26 NOTE: ARROWS SHOW FLUID FLOW DIRECTION Figure 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Nut Threaded rod Washer Bushing O--ring Cover O--ring Tee piece Hose: control supply (1”) Hose clamp Spray System 11. 12. 13. 14. 15. 16. 17. 18. 19.
Removal and Inspection (Fig. 24) IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen and remove nut that secures flow sensor to flowmeter housing. Carefully remove flow sensor from housing. 4.
Flowmeter (Serial Numbers Above 310000000) NOTE ARROW DIRECTION NOTCH 7 9 NOTCH 8 5 4 5 1 2 3 6 THREAD SEALANT Figure 26.1 1. Flowmeter body 2. Rotor/magnet assembly 3. Upstream hub with bearing Spray System 4. Downstream hub 5. Retaining ring (2 used) 6. Turbine stud with bearing Page 3 -- 25.1 Rev. B 7. Sensor assembly 8. Cable clamp 9.
Removal and Inspection (Fig. 26.1) 3 IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1 2 1. Remove spray control assembly from machine and separate flowmeter from spray control (see Spray Control Assembly (Serial Numbers Above 310000000) Removal in this section). 2. Disassemble flowmeter as required using Figures 26.1 and 26.3 as guides. 3.
Rate Control Motor (Serial Numbers Below 290999999) 1 2 3 1 4 5 6 7 8 11 9 12 13 14 10 Figure 27 1. 2. 3. 4. 5. Phillips head screw (5 used) Lock washer Hand grip O--ring Phillips head screw (4 used) 6. 7. 8. 9. 10. Rate control motor assembly Gasket Phillips head screw (4 used) Rate valve spindle section Rate control valve housing The rate control motor allows the operator to vary the spray application rate.
2. Remove four (4) phillips head screws (item 8) that secure spindle section to housing. Remove spindle section. 1 3. Locate, remove, and discard o–ring (item 11) and seal (item 14). 4 3 5 2 4. Remove valve (item 13) and inspect for wear and/or damage. Replace if needed. 5. If needed, the spindle shaft can be removed by removing lock nut that secures cone (item 12) to shaft. NOTE: Many individual components for the rate control motor and spindle section are not available separately.
Regulating Valve Assembly (Serial Numbers Above 310000000) 10 7 1 3 12 11 4 7 10 9 5 12 6 13 14 11 8 2 9 Figure 28.1 1. 2. 3. 4. 5. Regulating valve motor Hose barb Flange Adaptor Flynut 6. 7. 8. 9. 10. Elbow fitting Mounting bracket (2 used) Fork Washer (4 used) Cap screw (4 used) The regulating valve allows the operator to vary the spray application rate.
Assembly (Fig. 28.1) 3 1. To install valve motor cover to regulating valve motor (Fig. 28.3): 1 2 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: Coat all O--rings with vegetable oil before installation to reduce the chance of damage during assembly. Figure 28.2 1. 2.
Boom Valve Motor (Serial Numbers Below 290999999) 9 8 1 10 4 11 12 5 13 14 7 6 2 15 16 17 19 3 4 28 29 18 30 20 21 22 23 32 24 25 26 27 31 33 70 in--lb (8 N--m) Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Housing cover Cover seal Boom valve motor Phillips head screw (5 used) O--ring Lock washer Hand grip Roller Roller pin Spindle Spring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
4. Remove rear housing cover from boom valve motor to inspect motor components. 1 4 3 5 A. Cam should be tight on shaft. Cam surface should be free of wear and/or scoring. 2 B. The inside of motor housing should be free of excessive moisture, corrosion, and dirt. C. The cam bearing surface in the housing cover should be inspected for excessive wear. 5. Inspect and disassemble spindle section (Fig. 31). A. Inspect spindle roller surface for wear or scoring.
3. Assemble spindle section by reversing disassembly process. Align green indicator tab on spindle to slot in spindle housing. Install screw into bottom of spindle to secure assembly. Torque screw 70 in–lb (8 N–m). 4. Position spindle section on motor section so that green indicator on spindle section is opposite the motor hand grip. Secure spindle section to motor section with four phillips head screws (item 15). 5. Replace rear housing to boom valve motor. Spray System 6.
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Boom Valve Manifold Assembly (Serial Numbers Above 310000000) 3 1 NOTE: ARROWS SHOW FLUID FLOW DIRECTION 17 7 1 9 1 12 16 12 12 7 10 13 5 11 6 12 14 13 18 8 2 4 18 11 16 15 19 Figure 32.1 1. 2. 3. 4. 5. 6. 7. Boom valve motor (3 used) Hose barb (3 used) Pressure gauge port Flange Flynut Elbow fitting Mounting bracket (2 used) 8. 9. 10. 11. 12. 13.
C. Unplug wire connections and remove cover. 3 D. Make sure that screws that secure valve motor are tight. 1 2 Assembly (Fig. 32.1) 1. To install cover to boom valve motor (Fig. 32.3): A. Connect cover wires to motor wires. Make sure that cover wire color is the same as the motor wire color when connecting wires. B. Carefully rotate cover onto valve motor taking care to not damage wires. C. Tighten screws to secure cover to valve motor. Figure 32.2 1. 2. Boom valve manifold Flowmeter 3.
Boom Bypass 1 FRONT 8 5 2 RIGHT 3 A 4 6 A 5 7 NOTE: ARROW SHOWS FLUID FLOW DIRECTION Figure 33 1. Boom bypass elbow 2. O–ring 3. Bulkhead fitting Spray System 4. Gasket 5. Fork 6. Bulkhead nut Page 3 – 32 7. Hosebarb/hose 8.
Disassembly (Fig. 33) IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 2 1 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain spray tank (see Operator’s Manual). 3. Disassemble boom bypass using Figures 33 and 34 as guides. Discard all removed o–rings and gaskets. Assembly (Fig.
Tank Suction 1 2 FRONT 18 17 3 RIGHT 4 5 6 16 7 8 10 9 11 12 13 14 15 NOTE: ARROW SHOWS FLUID FLOW DIRECTION Figure 35 1. 2. 3. 4. 5. 6. Suction hosebarb O–ring Screen vane Suction screen Fork Filter housing Spray System 7. 8. 9. 10. 11. 12. Expansion pin Bulkhead gasket Bulkhead nut O–ring Hosebarb Hose clamp Page 3 – 34 13. 14. 15. 16. 17. 18.
NOTE: If suction tube in tank develops an air leak, spray performance will diminish when tank level reaches the leak. 3 Removal (Fig. 35) IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2.
Tank Drain FRONT 11 RIGHT 1 2 3 4 5 6 7 8 9 10 Figure 38 1. 2. 3. 4. Drain handle Nut O–ring Bulkhead Spray System 5. 6. 7. 8. Gasket Ringnut Chain Drain assembly Page 3 – 36 9. Hose clamp 10. Drain hose 11.
Disassembly (Fig. 38) 3 IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Drain spray tank (see Operator’s Manual). 3.
Turret Bodies 6 7 3 8 3 5 4 2 9 3 CENTER BOOM SUPPLY LEFT BOOM SUPPLY RIGHT BOOM SUPPLY 1 5 4 4 4 1 4 5 4 4 4 5 Figure 41 1. Turret body (w/90o elbow) 2. 90o 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 90o elbow) Removal (Fig. 41) Installation (Fig.
Turret Body Service Disassembly (Fig. 42) 1 1. Pull e–clip from body and slide plug with o–ring from body. 18 2. Disassemble turret body using Figure 42 as a guide. 3 3. Discard all removed seals, gaskets, o–rings, and diaphragms. 7 5 2 6 4 17 8 9 Assembly (Fig. 42) 16 1. Replace all removed seals, gaskets, o–rings, and diaphragms. B. Make sure to align notch on plug (item 10) with groove in body (item 4) as plug is installed. C. Install e–clip (item 5) into body to secure assembly.
Boom Frame Breakaway Pivot Assembly (Serial Numbers Below 260000000) 6 5 7 4 3 8 9 2 1 10 10 16 15 6 14 18 17 12 11 13 11 19 20 12 Figure 44 1. 2. 3. 4. 5. 6. 7. Hinge Breakaway pivot Spring Washer Roll pin Hex nut Support bracket Spray System 8. 9. 10. 11. 12. 13. 14. Carriage screw Flat washer Cotter pin Clevis pin Clevis pin Main boom frame Breakaway pivot assembly Page 3 -- 40 15. 16. 17. 18. 19. 20. Rev.
Disassembly (Fig. 44) 2 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Support boom to prevent it from falling. Remove cap screw and hex nut that secure boom support to breakaway assembly. 3. Remove hex nut, flat washer, and carriage screw that secure support bracket to breakaway pivot. Slide support bracket from breakaway assembly. 1 4 CAUTION Figure 45 1. Breakaway pivot 2. Support bracket 3. Boom support 4.
Boom Hinge (Serial Numbers Above 260000000) 16 15 8 19 18 17 14 9 FRONT 10 RIGHT 20 1 12 3 4 2 13 11 7 10 9 5 8 6 Figure 47 1. 2. 3. 4. 5. 6. 7. Hinge (2 used per boom) Rubber boot (2 used per hinge) Backing plate (4 used per hinge) Flange nut (4 used per hinge) Boom (RH shown) Tee fitting Flange hd screw (4 used per hinge) 8. 9. 10. 11. 12. 13. 14. Lock nut Cap screw Flat washer Pivot bracket Bushing (2 used per pivot bracket) Flange head screw Pivot pin Disassembly (Fig.
Assembly (Fig. 47) 1. If pivot bracket (item 11) was removed from machine, lightly lubricate bushings (item 12) with motor oil before assembly. Connect boom actuator (not shown) to pivot bracket (see Boom Actuator Installation (Machines with Serial Numbers Above 260000000) in this section). 2. Make sure that hinges (item 1) are securely fastened to pivot bracket (item 11) and boom (item 5). The boom hinge uses four (4) backing plates between the boom and flange nuts. 2 UP 1 Figure 48 1. Rubber boot 2.
Boom Actuator (Optional) (Serial Numbers Below 260000000) 5 FRONT RIGHT 5 1 2 3 4 1 3 2 Figure 50 1. Cotter pin 2. Clevis pin 3. Boom actuator 4. Wire harness 5. Adjustable clevis Removal (Fig. 50) Installation (Fig. 50) 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position boom actuator to clevis attachment points on center and side booms. 2. Label actuator electrical leads to ease reassembly.
Adjustment 1. Loosen end nut that secures adjustable clevis to boom frame (Fig. 51). Position jam nut as close as possible to adjustable clevis. Tighten end nut to secure clevis. 2. Fully raise side boom with the boom actuator. The boom actuator should fully extend and ratchet. 2 3. With the boom actuator at full extension, the breakaway pivot gusset should just touch the center boom frame slot (Fig. 52). 4.
Boom Actuator Service (Serial Numbers Below 260000000) 20 18 70 in--lb (7.9 N--m) 15 16 14 12 11 9 20 in--lb (2.3 N--m) 19 10 7 6 1 4 17 70 in--lb (7.9 N--m) 13 8 3 3 5 2 1. 2. 3. 4. 5. 6. 7. Screw Rear housing Washer Woodruff key Clutch Thin washer Intermediate gear Spray System 8. 9. 10. 11. 12. 13. 14. Figure 53 Thick washer Hex nut (2 used) Motor gear Housing gasket Front housing Cover tube gasket Motor seal Page 3 -- 46 Rev. A 15. 16. 17. 18. 19. 20.
Disassembly (Fig. 53) Assembly (Fig. 53) 1. Remove four (4) washer head screws that secure cover tube. Remove one (1) screw (item 1) that retains rear housing. Slide rear housing and housing gasket from assembly. 1. Position ball screw and brake assembly to front housing. Take care to not disturb brake components. 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.
Boom Actuator (Serial Numbers Above 260000000) 1 2 12 11 9 10 8 7 6 4 3 5 Figure 54 1. 2. 3. 4. Boom actuator (2 used) Carriage screw (4 used) Boom frame Washer plate Spray System 5. 6. 7. 8. Lock nut (4 used) Flange nut (2 used) Flange head screw (2 used) Pivot pin (2 used) Page 3 -- 48 Rev. A 9. 10. 11. 12.
Removal (Fig. 54) Installation (Fig. 54) 1. Park machine on a level surface, place spray booms in the transport (raised) position, stop engine, engage parking brake and remove key from the ignition switch. 1. Position boom actuator to boom frame and boom pivot bracket. 2. Disconnect boom actuator from machine wire harness. 3. Remove pivot pin (item 8) that secures actuator to clevis strap (item 9) on boom frame. 3. Secure actuator to clevis strap on boom frame with pivot pin. 4.
Boom Actuator Service (Serial Numbers Above 260000000) IMPORTANT: Do not dismantle, repair or modify the boom actuator. Internal components are not available for the actuator. If an actuator is damaged or worn, replace actuator. CAUTION Actuator Air Bleeding If actuator freeplay is excessive, air bleeding of the actuator should be performed using the following procedure: 1. Thoroughly clean the exterior of the actuator to prevent contaminates from entering the actuator.
Actuator Oil Level RESERVOIR PLUG Under normal conditions, actuator oil level should remain constant. If any oil is spilled from the reservoir during air bleeding, the oil level in the actuator should be checked and adjusted. 1. Thoroughly clean the exterior of the actuator to prevent contaminates from entering the actuator. 2. Make sure that the actuator cylinder is fully retracted.
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Chapter 3.1 Sonic Boom System Table of Contents TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . Sonic Boom Light . . . . . . . . . . . . . . . . . . . . . . . . . . Sonic Boom Calibration . . . . . . . . . . . . . . . . . . . . . Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Sonic Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Installation Instructions The Sonic Boom Kit Installation Instructions provides information regarding the installation, operation and general maintenance for your Sonic Boom System. Refer to that publication for additional information when servicing the machine. Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons, animals, plants, soil and other property. To eliminate environmental damage and personal injury: 1. Select the proper chemical for the job. 2.
Special Tools Diagnostic Display The Diagnostic Display (Fig. 1) can be connected to the Sonic Boom wire harness communication connector to verify correct electrical functions of the Sonic Boom System. Electronic control unit (ECU) inputs and outputs for the Sonic Boom System can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85--4750 Toro Part Number for Overlay (English): 94--8604 IMPORTANT: The Diagnostic Display must not be left connected to the machine.
Sonic Boom System (Optional Kit) Page 3.1 -- 4 Rev.
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Sonic Boom System (Optional Kit) Page 3.1 -- 6 Rev.
Sprayer Operation on Level Turf During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo.
Sonic Boom System (Optional Kit) Page 3.1 -- 8 Rev.
Downward Slope in Turf Encountered During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo.
Sonic Boom System (Optional Kit) Page 3.1 -- 10 Rev.
Rise in Turf Encountered During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo.
Sonic Boom System (Optional Kit) Page 3.1 -- 12 Rev.
Boom Level Changed by Operator During Automatic Operation During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo.
Sonic Boom System (Optional Kit) Page 3.1 -- 14 Rev.
Manual Boom Operation During sprayer operation with the sonic boom switch in the manual position, the spray booms will remain in position unless the operator presses a boom actuator switch. When the sonic boom switch is in the manual position, the sonic boom light should be illuminated. The operator will control the boom position with the boom actuator switches.
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on the Sonic Boom System (see Sonic Boom System Operation in this chapter). NOTE: When troubleshooting an electrical problem on your Sonic Boom System, refer to information regarding the sonic boom light in this section. Also, use the Diagnostic Display (see Special Tools in this chapter) to test electronic control unit (ECU) inputs and outputs.
Diagnostic Display For the ECU to control the machine as desired, each of the inputs (switches and sensors) and outputs (relays) must be connected and functioning properly. The Diagnostic Display (see Special Tools in this chapter) is a tool to help the technician verify correct electrical functions of the machine. IMPORTANT: The Diagnostic Display must not be left connected to the machine. It is not designed to withstand the environment of the machine’s every day use.
Diagnostic Display Inputs Diagnostic Display LED Operation AUTO MODE Sonic mode switch in auto position: LED ON Sonic mode switch not in auto position: LED OFF L RAISE Left boom actuator switch in raise position: LED ON Left boom actuator switch not in raise position: LED OFF L LOWER Left boom actuator switch in lower position: LED ON Left boom actuator switch not in lower position: LED OFF R RAISE Right boom actuator switch in raise position: LED ON Right boom actuator switch not in raise position
Verify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the electronic control unit (ECU). This is a quick way to determine which electrical component is malfunctioning. NOTE: An open output (e.g. an unplugged connector or a broken wire) cannot be detected with the Diagnostic Display. NOTE: It may be necessary to toggle between “INPUTS DISPLAYED” and “OUTPUTS DISPLAYED” several times to perform the following step.
Troubleshooting Chart The chart that follows contains suggestions that can be used to assist in diagnosing Sonic Boom System performance issues. These suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem. NOTE: When troubleshooting an electrical problem on your Sonic Boom System, refer to information regarding the sonic boom light in this section.
Problem Possible Cause One of the boom actuators will not extend. 30 amp auto resetting fuse for affected boom actuator is faulty. Power switch relay or circuit wiring for affected boom actuator is faulty. Boom actuator switch or circuit wiring for affected boom actuator is faulty. Affected boom actuator or circuit wiring is faulty. Neither of the boom actuators will extend. Loop back connector is unplugged from wire harness connector. 5 amp or 10 amp fuse in sonic boom fuse block is faulty.
Service and Repairs Sonic Mode Switch The sonic mode switch is used as an input for the ECU to activate the Sonic Boom System. This switch has three (3) positions: automatic, manual and off. The sonic mode switch is located on the console. If the sonic mode switch is in the automatic position, the sonic sensors will be activated to allow automatic movement of the boom. The tips of the booms will remain at a constant distance from the ground.
Relays The Sonic Boom System uses six (6) identical relays to control the boom actuators and ultimately the boom height. Three (3) of the relays control the right actuator and the other three (3) relays control the left actuator. The electronic control unit (ECU) controls the operation of the relays. The relays are located on a mounting plate under the vehicle dash panel (Fig. 10) and can be identified by a label on the wire harness connector.
Electronic Control Unit (ECU) The Sonic Boom System uses an electronic control unit (ECU) to control electrical system operation. The ECU is attached to a mounting plate under the vehicle dash panel (Fig. 12). 3 Power is provided to the ECU when the vehicle ignition switch is ON. A 5 amp fuse provides circuit protection for this logic power to the ECU. The fuse is located in the Sonic Boom System fuse block.
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 continually sends an impulse signal and then receives an echo as the signal bounces off the turf.
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Chapter 3.2 Ultra Sonic Boom System (Optional Kit) Table of Contents TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . Sonic Boom Light . . . . . . . . . . . . . . . . . . . . . . . . . . Ultra Sonic Boom Calibration . . . . . . . . . . . . . . . . Diagnostic Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . .
General Information Installation Instructions The Ultra Sonic Boom Kit Installation Instructions provides information regarding the installation, operation and general maintenance for your Ultra Sonic Boom System. Refer to that publication for additional information when servicing the machine. Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons, animals, plants, soil and other property. To eliminate environmental damage and personal injury: 1.
Special Tools Diagnostic Display The Diagnostic Display (Fig. 1) can be connected to the Ultra Sonic Boom wire harness communication connector to verify correct electrical functions of the Ultra Sonic Boom System. Toro electronic controller (TEC) inputs and outputs for the Ultra Sonic Boom System can be checked using the Diagnostic Display.
Ultra Sonic Boom System (Rev. C) Page 3.2 -- 4 LEFT BOOM LIFT SWITCH RIGHT BOOM LIFT SWITCH SONIC BOOM SWITCH Ultra Sonic Boom System Electrical Schematic INTERFACE TO VEHICLE POWER 2A 7.5A 7.5A 7.
Ultra Sonic Boom System This page is intentionally blank. Workman 200 Page 3.2 -- 5 Ultra Sonic Boom System (Rev.
Ultra Sonic Boom System (Rev. C) Page 3.2 -- 6 LEFT BOOM LIFT SWITCH RIGHT BOOM LIFT SWITCH SONIC BOOM SWITCH Sprayer Operation on Level Turf Sonic Boom Switch in Automatic Position Power Current Control Current Indicator Light Current Ultra Sonic Boom System INTERFACE TO VEHICLE POWER 2A 7.5A 7.5A 7.
Sprayer Operation on Level Turf During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echoes as the signals bounce off the turf. The Toro electronic controller (TEC) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo.
Ultra Sonic Boom System (Rev. C) Page 3.2 -- 8 Workman 200 LEFT BOOM LIFT SWITCH RIGHT BOOM LIFT SWITCH SONIC BOOM SWITCH Downward Slope in Turf Encountered (Left Boom Shown) Sonic Boom Switch in Automatic Position Power Current Control Current Indicator Light Current Ultra Sonic Boom System INTERFACE TO VEHICLE POWER 2A 7.5A 7.5A 7.
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.
Ultra Sonic Boom System (Rev. C) Page 3.2 -- 10 Workman 200 LEFT BOOM LIFT SWITCH RIGHT BOOM LIFT SWITCH SONIC BOOM SWITCH Rise in Turf Encountered (Right Boom Shown) Sonic Boom Switch in Automatic Position Power Current Control Current Indicator Light Current Ultra Sonic Boom System INTERFACE TO VEHICLE POWER 2A 7.5A 7.5A 7.
Rise in Turf Encountered During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echoes as the signals bounce off the turf. The Toro electronic controller (TEC) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo.
Ultra Sonic Boom System (Rev. C) Page 3.2 -- 12 Workman 200 LEFT BOOM LIFT SWITCH (PRESSED TO RAISE) RIGHT BOOM LIFT SWITCH SONIC BOOM SWITCH Boom Level Changed by Operator (Raise Left Boom Shown) Sonic Boom Switch in Automatic Position Power Current Control Current Indicator Light Current Ultra Sonic Boom System INTERFACE TO VEHICLE POWER 2A 7.5A 7.5A 7.
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 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.
Ultra Sonic Boom System (Rev. C) Page 3.2 -- 14 Workman 200 LEFT BOOM LIFT SWITCH RIGHT BOOM LIFT SWITCH (PRESSED TO LOWER) SONIC BOOM SWITCH Manual Boom Operation (Lower Right Boom Shown) Sonic Boom Switch in Manual Position Power Current Control Current Indicator Light Current Ultra Sonic Boom System INTERFACE TO VEHICLE POWER 2A 7.5A 7.5A 7.
Manual Boom Operation During sprayer operation with the sonic boom switch in the manual position, the spray booms will remain in position unless the operator presses a boom 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.
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Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on the Ultra Sonic Boom System (see Ultra Sonic Boom System Operation in this chapter). NOTE: When troubleshooting an electrical problem on your Ultra Sonic Boom System, refer to information regarding the sonic boom light and diagnostic lamp in this section.
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 panel (Fig. 8). 1 When the ignition switch is moved to the ON position and the Ultra Sonic Boom System electrical system is functioning properly, the diagnostic lamp will be illuminated for approximately three (3) seconds and then will turn off. The diagnostic lamp should remain off during normal sonic boom operation.
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 retrieve these fault codes from the controller memory, perform the following steps: 1. Make sure that ignition switch is OFF. 2.
Diagnostic Display The Ultra Sonic Boom System is equipped with the Toro electronic controller (TEC) which controls machine sonic boom electrical functions. The TEC monitors various input switches (e.g. sonic boom switch, boom lift switches, sonic boom sensors) and energizes outputs (e.g. boom actuators, diagnostic lamp) for appropriate machine functions. For the TEC to control the machine as desired, each of the inputs (switches and sensors) and outputs (e.g.
7. If appropriate LED does not toggle on and off when switch state is changed, perform test of switch and/or check all wiring and connections to that switch. Replace any defective switches and repair any damaged wiring. CAUTION When testing TEC inputs with the Diagnostic Display, boom actuators may be energized causing the spray booms to move. Be cautious of potential sprayer component movement while verifying inputs with the Diagnostic Display. 8.
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 controller (TEC). This is a quick way to determine which electrical component is malfunctioning. 6. Attempt to operate the desired function of the machine. The appropriate output LED’s should illuminate on the Diagnostic Display to indicate that the TEC is turning on that function (see Outputs and LED Operation chart on next page).
Diagnostic Display Outputs Diagnostic Display LED Operation DIAG LAMP Diagnostic lamp is ON or FLASHING: LED ON or FLASHING Diagnostic lamp is not ON or FLASHING: LED OFF SONIC SENSOR TEC output exists to sonic sensors: LED ON No TEC output to sonic sensors: LED OFF RIGHT RAISE TEC output exists to energize relays to raise right boom: LED ON No TEC output to energize relays to raise right boom: LED OFF RIGHT LOWER TEC output exists to energize relays to lower right boom: LED ON No TEC output to ene
Troubleshooting Chart The chart that follows contains suggestions that can be used to assist in diagnosing Ultra Sonic Boom System performance issues. These suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem. NOTE: When troubleshooting an electrical problem on your Ultra Sonic Boom System, refer to information regarding the sonic boom light in this section.
Problem Possible Cause One of the booms does not automatically follow ground irregularities. Boom can be controlled with boom lift switch. On affected boom, the sonic boom sensor cover is on sensor. On affected boom, calibration of the sonic boom sensors is incorrect. 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. Neither boom automatically follows ground irregularities.
Service and Repairs Sonic Boom Fuses Fuses for the Ultra Sonic Boom system are included in the fuse blocks attached to the mounting plate under the dash panel (Fig. 13). 1 Fuse Identification and Function The upper row of fuses protect circuits as follows: 1. The upper, extreme left 2 Amp fuse protects power supply for TEC logic. 2. The upper, middle left 7.5 Amp fuse is not used. 3. The upper, middle right 7.5 Amp fuse protects TEC output circuits (sonic boom switch light and boom actuator power supply).
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: automatic and manual. The sonic boom switch is located on the spray control panel (Fig. 15). 1 If the sonic boom switch is in the automatic position, the sonic sensors will be activated to allow automatic movement of the booms. The tips of the booms will remain at a constant distance from the ground.
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 operation with the sonic boom switch in the automatic position, the sonic sensors will provide inputs for the Toro electronic controller (TEC) to keep the booms at a constant distance from the ground.
Sonic Sensor LED Window The sonic sensor includes a LED window that identifies sensor status during sprayer operation during operation of the Ultra Sonic Boom system (Fig. 21). To view the LED window, carefully remove cover from sonic sensor. The LED window includes four (4) LED’s. 2 3 During normal operation, the green LED and both yellow LED’s should be illuminated. The red LED will be off. 4 If there is some interference with normal sensor operation, the red LED will be flashing.
Relays The Ultra Sonic Boom System uses four (4) identical relays 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 actuator extends (boom raise) or retracts (boom lower).
Toro Electronic Controller (TEC) The Ultra Sonic Boom System uses the Toro Electronic Controller (TEC) to control electrical system operation. The TEC is attached to a mounting plate under the dash panel (Fig. 24). 1 Power is provided to the TEC when the vehicle ignition switch is ON. A 2 Amp fuse provides circuit protection for this logic power to the TEC. The fuse is located in the Ultra Sonic Boom System fuse block under the dash panel.
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Chapter 4 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATICS Serial Numbers Below 260000000 . . . . . . . . . . . . . 3 Serial Numbers Above 260000000 . . . . . . . . . . . . . 4 WIRE HARNESS DRAWINGS Spray System Wire Harness (Serial Numbers Below 260000000) . . . . . . . . . . . . . . . . . . . . . . . . . 6 Spray System Wire Harness (Serial Numbers From 260000001 to 280000200) . . . . . . . . . . . . .
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R/BK R/W R R SPRAY VALVE LS BOOM SWITCH 1 2 3 4 5 6 FUSE BLOCK 4 WAY 1 2 FOAM 3 4 BOOM LIFT 5 6 SPRAY SYSTEM 7 8 8 BU/BK R BU/W (+) BK SPRAY VALVE CTR.
Workman 200 Spray System Electrical Schematic (Serial Numbers Above 260000000) Page 4 – 4 Rev.
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Workman 200 Spray System Spray System Wire Harness (Serial Numbers Below 260000000) Page 4 -- 6 Rev.
BROWN/WHITE GREEN/BLACK ORANGE/WHITE BLUE/BLACK YELLOW GREEN ORANGE BLUE GRAY/ORANGE GRAY/BLACK GRAY BLUE/RED BROWN/WHITE GREEN/WHITE GREEN/BLACK ORANGE/BLACK ORANGE/WHITE BLUE/WHITE BLUE/BLACK BLACK WHITE/BLACK WHITE/BLACK BLACK BLACK BLACK BLUE/GREEN YELLOW/BLUE Workman 200 Spray System Spray System Wire Harness (Serial Numbers Below 260000000) Page 4 -- 7 Rev.
Workman 200 Spray System Spray System Wire Harness (Serial Numbers From 260000001 to 280000200) Page 4 -- 8 Rev.
YELLOW GREEN GREEN YELLOW RED BLUE BLUE RED BROWN/WHITE GREEN/BLACK ORANGE/WHITE BLUE/BLACK GREEN BLUE/BLACK YELLOW BLUE RED BLUE VIOLET GRAY BLUE/RED BROWN/WHITE GREEN/WHITE GREEN/BLACK ORANGE/BLACK ORANGE/WHITE BLUE/WHITE BLACK BLACK WHITE/BLACK WHITE/BLACK BLACK BLACK BLUE/GREEN YELLOW/BLUE Workman 200 Spray System Spray System Wire Harness (Serial Numbers From 260000001 to 280000200) Page 4 -- 9 Rev.
Workman 200 Spray System Spray System Wire Harness (Serial Numbers From 280000201 to 290999999) Page 4 -- 10 Rev.
Workman 200 Spray System Spray System Wire Harness (Serial Numbers From 280000201 to 290999999) Page 4 -- 11 Rev.
Workman 200 Spray System Spray System Wire Harness (Serial Numbers Above 310000000) Page 4 -- 12 Rev.
Workman 200 Spray System Spray System Wire Harness (Serial Numbers Above 310000000) Page 4 -- 13 Rev.
Workman 200 Spray System Spray Console Wire Harness (Serial Numbers Below 260000000) Page 4 -- 14 Rev.
RED BLACK PINK YELLOW GREEN ORANGE BLUE GREEN/WHITE GREEN/BLACK ORANGE/WHITE ORANGE/BLACK BLUE/WHITE BLUE/BLACK BLUE/RED BLUE/RED BLACK BLACK BLACK BLUE/GREEN WHITE/BLACK BLACK BLACK RED RED/WHITE WHITE/BLACK BLUE/GREEN RED/WHITE RED RED RED RED BLACK VIOLET/RED VIOLET/WHITE GRAY/ORANGE GRAY/BLACK GRAY BROWN PINK/BLUE PINK/BLACK PINK/WHITE RED/BLACK RED/WHITE BLACK BROWN Workman 200 Spray System Spray Console Wire Harness (Serial Numbers Below 260000000) Page 4 -- 15 R
Workman 200 Spray System Spray Console Wire Harness (Serial Numbers From 260000001 to 260999999) Page 4 -- 16 Rev.
PINK PINK/BLACK BLACK BLUE/WHITE GREEN/WHITE GREEN/BLACK ORANGE/BLACK ORANGE BLACK YELLOW BLACK BLACK RED RED GREEN RED BLACK BLUE PINK BLACK BLACK BLACK ORANGE PINK BLACK BROWN ORANGE/WHITE RED BLUE/BLACK BLACK PINK BLACK YELLOW YELLOW BLUE/GREEN WHITE/BLACK BLACK BLUE/RED BLUE/RED VIOLET/WHITE VIOLET BLUE BROWN BLACK VIOLET/RED GRAY BLACK ORANGE GREEN YELLOW YELLOW BLACK BLUE BLACK ORANGE BLACK RED RED RED Workman 200 Spray System Spray Console Wire Harness (Se
Workman 200 Spray System Spray Console Wire Harness (Serial Numbers From 270000001 to 290999999) Page 4 -- 18 Rev.
BLACK PINK PINK/BLACK BROWN RED PINK BLACK RED RED BLACK BLACK BLACK BLACK ORANGE BLACK BLACK ORANGE BLACK BLACK BLUE RED GREEN YELLOW PINK BLUE/BLACK BLUE/WHITE ORANGE/WHITE ORANGE/BLACK GREEN/BLACK GREEN/WHITE BLACK PINK BLACK YELLOW YELLOW BLUE/GREEN WHITE/BLACK BLACK BLUE/RED BLUE/RED VIOLET/WHITE BROWN VIOLET GRAY BLUE BLACK VIOLET/RED BLACK ORANGE GREEN YELLOW YELLOW BLACK ORANGE BLACK RED RED Workman 200 Spray System Spray Console Wire Harness (Serial Numbers From 2
Workman 200 Spray System Spray Console Wire Harness (Serial Numbers Above 310000000) Page 4 -- 20 Rev.
BLACK PINK PINK/BLACK ORANGE/WHITE BLACK CLEAR SHIELD GREEN/WHITE GREEN/BLACK ORANGE/BLACK BLACK RED RED PINK BLACK RED BLACK BLACK BLACK ORANGE BLACK BLACK ORANGE BLACK PINK BLACK BROWN BLUE/WHITE RED BLUE/BLACK BLACK BLACK YELLOW YELLOW BLUE/GREEN WHITE/BLACK BLACK BLUE/RED BLUE/RED VIOLET/WHITE BLACK BROWN SHIELD CLEAR VIOLET/RED BLACK BLACK ORANGE GREEN YELLOW YELLOW BLACK GREEN BLUE ORANGE BLACK YELLOW RED RED Workman 200 Spray System Spray Console Wire Harness
BLACK PINK/BLUE PINK/BLACK PINK/WHITE RED RED/WHITE RED/BLACK Workman 200 Spray System Sprayer Power Harness (Serial Numbers Below 260000000) Page 4 -- 22 Rev.
RED ORANGE ORANGE YELLOW GREEN BLACK PINK YELLOW Workman 200 Spray System Sprayer Power Harness (Serial Numbers Above 260000000) Page 4 -- 23 Rev.