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Manual Toro 41235

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  • Toro 41235 - page 1

    (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). REFE R TO T ...

  • Toro 41235 - page 2

    Workma n 200 Sp ray System This page is intent ionall y blank . ...

  • Toro 41235 - page 3

    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 ........................... Chap ter 2 - - E lect rical System Elect rical S chemat ic and E lect rical H ...

  • Toro 41235 - page 4

    Workma n 200 Sp ray System This page is intent ionall y blank . ...

  • Toro 41235 - page 5

    Chapter 1 Safety and Product Records T able of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND ...

  • Toro 41235 - page 6

    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 . Alt hough haz ard cont rol and accident prevent ion are part ially dependent upon t he des ign and configur ation of t he mac ...

  • Toro 41235 - page 7

    Maintenance and Service 1. Before servicing or making adjustments, turn PTO off, put shift lever in neutral, stop engine, set parking brake, and remove key from the switch. 2. Prior to servicing sprayer components, determine what chemical(s) have been used in the sprayer . Follow precautions and recommendations printed on chemical container labels ...

  • Toro 41235 - page 8

    This page is intentionally blank. Safety and Product Records Page 1 – 4 Workman 200 Spray System ...

  • Toro 41235 - page 9

    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 ....................... Master Boom Switch 4 ......................... Rate Control and Boom Act ...

  • Toro 41235 - page 10

    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. Electrical System Page 2 – 2 Workman 200 Spray System ...

  • Toro 41235 - page 11

    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. Th e high impedance (internal resistance) of a digital me - ter in the voltage mode will make sure that excess cur- r ...

  • Toro 41235 - page 12

    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. Th e switch terminals are marked as shown in Figure 3. In the ON position, continuity should exis ...

  • Toro 41235 - page 13

    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. T esting 1. Remove s ...

  • Toro 41235 - page 14

    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 supervisor key switch used on sprayers with serial n ...

  • Toro 41235 - page 15

    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. 2. Th e switch terminals are marked as shown in Figure 9. In ...

  • Toro 41235 - page 16

    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. ...

  • Toro 41235 - page 17

    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. 13). It uses a magnetically based, Hall Effect integrated circuit. As the differential in the transaxle turns, the sensor accurately senses the move- ment of the dif ferential ring gear teet ...

  • Toro 41235 - page 18

    This page is intentionally blank. Electrical System Page 2 – 10 Workman 200 Spray System ...

  • Toro 41235 - page 19

    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 ............................. Precautions for Removing or Adjusting Spray System Components 3 ...... ...

  • Toro 41235 - page 20

    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, Stainless Steel, T ank Mounted (30 Mesh and 90 Mesh Optional) Spray System Page 3 – 2 W orkman 200 Spray System ...

  • Toro 41235 - page 21

    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. Select the proper chemical for the job. 2. Carefully read the directions printed on t ...

  • Toro 41235 - page 22

    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 200 Spray System AGIT A TION BOOM SUPPL Y AGIT ...

  • Toro 41235 - page 23

    Spray System Operation The Workman 200 Spray System uses a positive dis- placement diaphragm pump to move spray solution from the spray tank to the boom nozzles. The spray pump is self–priming and has a dry crankcase. The pump is driven by the transaxle PTO kit output shaft at a speed that is proportional to the ground speed of the vehicle. It sh ...

  • Toro 41235 - page 24

    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. Fluid leaking from bottom of spray pump. Faulty diaphragm(s) in spray pump. Excessive suction ho ...

  • Toro 41235 - page 25

    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. Boom valve motor seat loose or damaged. Boom valve motor actuating cam worn or sticking. No spray ...

  • Toro 41235 - page 26

    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. IMPORT ANT : Make sure to neutralize and remove chemica ...

  • Toro 41235 - page 27

    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). IMPORT ANT : Any fluid in the pressure dampener will include spray sy ...

  • Toro 41235 - page 28

    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. Pump drive shroud 14. Shroud bracket 15. Square key 16. Set screw 17. PTO dr ...

  • Toro 41235 - page 29

    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. 2. Loosen hose clamp that secures suction hose (item 28) to hosebarb (item 25). Pull s ...

  • Toro 41235 - page 30

    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. V alve chamber 1 1. Hex bolt 20. Connecting rod 2. V alve (inlet position) 12. Ball bearing (cran ...

  • Toro 41235 - page 31

    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. During disassembly , make note of component position (e.g. crankshaft, valve chamber) to assur ...

  • Toro 41235 - page 32

    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. T orque bolt to 60 ft–lb (81 N–m). 5. Make sure that pump casings align and ...

  • Toro 41235 - page 33

    Spray System This page is intentionally blank. Workman 200 Spray System Page 3 – 15 Spray System ...

  • Toro 41235 - page 34

    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. 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 SHOW FLUID FLOW DIRECTION ...

  • Toro 41235 - page 35

    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. 2. Label disconnected ho ...

  • Toro 41235 - page 36

    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. Fork (12 used) 13. Hosebarb/hose 14. Hosebarb/hose 15. Hosebarb/hose 16. Agitation nozzle 17. ...

  • Toro 41235 - page 37

    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. 2. Drain spr ...

  • Toro 41235 - page 38

    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. Hosebarb/hose 6. O–ring 7. Fork 8. Hosebarb/hose (from spray pump) Figure 18 FRONT RIGHT 1 3 4 5 A 2 A 6 7 8 NOTE: ARROWS SHOW FLUID FLOW DIRECTION ...

  • Toro 41235 - page 39

    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. 2. Drain spray t ...

  • Toro 41235 - page 40

    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. Fork 12. Screw 13. Control valve bracket 14. Rate control valve housing 15. Rate control motor 16 ...

  • Toro 41235 - page 41

    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. 2. Label hoses for prope ...

  • Toro 41235 - page 42

    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. Flowmeter 8. Clamp (2 used) 9. Boom valve manifold 10. Pressure gauge tube 1 1. Coupler (pressur ...

  • Toro 41235 - page 43

    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 . 1. Park machine on a level surface, stop engine, en- gage parkin ...

  • Toro 41235 - page 44

    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. Screw 13. Control valve bracket 14. Rate control motor/housing 15. O - - ring 16. Hosebarb ...

  • Toro 41235 - page 45

    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. 2. Loosen ...

  • Toro 41235 - page 46

    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. Retaining ring (2 used) 6. T urbine stud with bearing 7. Sensor assembly 8. Cable cl ...

  • Toro 41235 - page 47

    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 . 1. Remove spray c ontrol assembly from machine and separate ...

  • Toro 41235 - page 48

    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 spindle section 10. Rate control valve housin ...

  • Toro 41235 - page 49

    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. 5. If needed, the spindle shaft can be removed by re- moving lock nut that secures ...

  • Toro 41235 - page 50

    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. Elbow fitting 7. Mounting bracket (2 used) 8. Fork 9. W asher (4 used) 10. Cap screw (4 used) 1 1 ...

  • Toro 41235 - page 51

    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. B. Carefully rotate cover onto valve motor tak ing care to not da ...

  • Toro 41235 - page 52

    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. Spindle 11 . S p r i n g 12. Spring seat 13. O - - ring 14. Spindle housing 15. Philli ...

  • Toro 41235 - page 53

    4. Remove rear housing cover from boom valve motor to inspect motor components. A. Cam should be tight on shaft. Cam surface should be free of wear and/or scoring. B. The inside of motor housing should be free of ex- cessive moisture, corrosion, and dirt. C. The cam bearing surface in the housing cover should be inspected for excessive wear . 5. In ...

  • Toro 41235 - page 54

    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. Secure s ...

  • Toro 41235 - page 55

    Spray System This page is intentionally blank. Workman 200 Spray System Page 3 – 31 Spray System ...

  • Toro 41235 - page 56

    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. Balancing valve assembly 9. Flange 10. Fork (3 used) 1 1 . F o r k( 6u ...

  • Toro 41235 - page 57

    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. Make sure that cover wire color is the same as the motor wire color ...

  • Toro 41235 - page 58

    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 ...

  • Toro 41235 - page 59

    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. 2. Drain spr ...

  • Toro 41235 - page 60

    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. Suction hose 14. Suction tube 15. Suction tube foot 16. Spray tank 17. Hose clamp 18. Suction h ...

  • Toro 41235 - page 61

    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 . 1. Park mach ...

  • Toro 41235 - page 62

    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. Hose clamp 10. Drain hose 1 1. Spray tank Figure 38 3 1 2 4 6 9 7 8 10 11 5 FRONT RIGHT ...

  • Toro 41235 - page 63

    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 . 1. Park machine on a level surface, stop engine, en- gage parking brake, an ...

  • Toro 41235 - page 64

    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 clamp 9. Hose barb (for 90 o elbow) Figure 41 7 2 8 3 9 4 5 RIGHT 6 1 BO ...

  • Toro 41235 - page 65

    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. 3. Discard all removed seals, gaskets, o–rings, and di- aphragms. Assembly (Fig. 42) NOTE: Coat all o–rings with vegetable oil before instal- lation to reduce the chance of damage ...

  • Toro 41235 - page 66

    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. Cotter pin 1 1. Clevis pin 12. Clevis pin 13. Main boom frame 14. Breakaway pivot assembly 15 ...

  • Toro 41235 - page 67

    Disassembly (Fig. 44) 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch. 2. Support boom to prevent it from falling. Remove cap screw and hex nut that secure boom support to break - away assembly . 3. Remove hex nut, flat washer , and carriage screw that secure support bracke ...

  • Toro 41235 - page 68

    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. T ee fitting 7. Flange hd screw (4 used per hinge) 8. Lock nut 9. Cap screw 10. Flat washer 1 ...

  • Toro 41235 - page 69

    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). 2. Make sure that hinges (item 1) are securely fasten ...

  • Toro 41235 - page 70

    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. 50) 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remo ...

  • Toro 41235 - page 71

    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. 3. With the boom actuator at full extension, the break- away piv ...

  • Toro 41235 - page 72

    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. Motor gear 1 1. Housing gasket 12. Front housing 13. Cover tube gasket 14. Motor seal 15. Motor a ...

  • Toro 41235 - page 73

    Disassembly (Fig. 53) 1. Remove four (4) washer head screws that secure cover tube. Remove one (1) screw (item 1) that retains rear housing. Slide rear housing and housing gasket from assembly . 2. Slide thin washer , intermediate gear , and thick wash- er from front housing support pin. 3. In order , remove washer , clutch, woodruf f key , and sec ...

  • Toro 41235 - page 74

    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. Pivot pin (2 used) 9. Clevis strap (2 used) 10. Boom pivot bracket 1 1. Clevis pin ...

  • Toro 41235 - page 75

    Removal (Fig. 54) 1. Park machine on a level surface, place spray booms in the transport (raised) position, stop engine, engage parking brake and remove key from the ignition switch. 2. Disconnect boom actuator from machine wire har- ness. 3. Remove pivot pin (item 8) that secures actuator to clevis strap (item 9) on boom frame. 4. Remove cotter pi ...

  • Toro 41235 - page 76

    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 . CAUTION During and after operation, the actuator may b ...

  • Toro 41235 - page 77

    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 . 2. Make sure that the actuator ...

  • Toro 41235 - page 78

    This page is intentionally blank. Spray System Page 3 – 52 Workman 200 Spray System ...

  • Toro 41235 - page 79

    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 ............................. Precautions for Removing o r Adjust ...

  • Toro 41235 - page 80

    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. Refer to that publication for additional information when serv ...

  • Toro 41235 - page 81

    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. Electronic control unit (ECU) inputs and outputs for the Sonic B ...

  • Toro 41235 - page 82

    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 BOOM ACTUA TOR ...

  • Toro 41235 - page 83

    Rev . B Workman 200 Spray System Page 3.1 - - 5 Sonic Boom System (Optional Kit) This page is intentionally blank. ...

  • Toro 41235 - page 84

    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) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (ST A TIONARY) (ST A TIONARY) Sprayer Operation on Level T urf Sonic Mode Switch in Au ...

  • Toro 41235 - page 85

    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 boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the sig- nals bounce off the ...

  • Toro 41235 - page 86

    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) (NOT ENERGIZED) (NOT ENERGIZED) (EXTENDING) (ST A TIONARY) Downward Slope in T urf Encountered (Left Boom Shown) Sonic Mode Switch in Automatic RIGHT ...

  • Toro 41235 - page 87

    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 (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the sig- nals bounce off ...

  • Toro 41235 - page 88

    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) (ENERGIZED) (NOT ENERGIZED) (ST A TIONARY) Rise in T urf Encountered (Right Boom Shown) Sonic Mode Switch in Automatic (RETRACTING) RIGHT BOOM ACTUA ...

  • Toro 41235 - page 89

    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 light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the sig- nals bounce off the turf ...

  • Toro 41235 - page 90

    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) (NOT ENERGIZED) (ENERGIZED) (RETRACTING) (ST A TIONARY) Boom Level Changed by Operator (Raise Left Boom Shown) Sonic Mode Switch in Automatic (PRESSE ...

  • Toro 41235 - page 91

    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 send impulse signals and then receive echos as th ...

  • Toro 41235 - page 92

    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) (ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (ST A TIONARY) (EXTENDING) Manual Boom Operation (Lower Right Boom Shown) Sonic Mode Switch in Manual (PRESSED TO L ...

  • Toro 41235 - page 93

    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 is in the manual position, the sonic boom light s ...

  • Toro 41235 - page 94

    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). NOTE: When troubleshooting an electrical problem ...

  • Toro 41235 - page 95

    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.g. boom actuator switches, sonic boom sen- sors) and energizes outputs to actu ...

  • Toro 41235 - page 96

    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 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: ...

  • Toro 41235 - page 97

    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). This is a quick way to de- termine which electrical component is malfunctioning. NOTE ...

  • Toro 41235 - page 98

    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. Also, consider that there may be more than one cause for a machine problem. ...

  • Toro 41235 - page 99

    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 . Boom actuator switch or circuit w iring for af fected boom a ...

  • Toro 41235 - page 100

    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 located on the console. If the sonic mode switch is ...

  • Toro 41235 - page 101

    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 . The electronic control unit (ECU) con ...

  • Toro 41235 - page 102

    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. 12). Power is provided to the ECU when the vehicle ignition swi ...

  • Toro 41235 - page 103

    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. 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 electron ...

  • Toro 41235 - page 104

    Rev . B Workman 200 Spray System Page 3.1 - - 26 Sonic Boom System (Optional Kit) This page is intentionally blank. ...

  • Toro 41235 - page 105

    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 ............................. Precautions for Removing o r Adjus ...

  • Toro 41235 - page 106

    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. Refer to that publ ication for additional info rma- tion when serv ...

  • Toro 41235 - page 107

    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. T oro electronic controller (TEC) inputs and output s for the Ultra ...

  • Toro 41235 - page 108

    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 7.5A A B AB ...

  • Toro 41235 - page 109

    Workma n 200 Ultra Sonic Boom System (Rev . C) Page 3.2 - - 5 This page is intentionally blank. Ultra Sonic Boom System ...

  • Toro 41235 - page 110

    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 O perat ion o n Le vel Turf Sonic Boom Switch in Automatic Position LEFT BOOM LIFT SWIT CH SONIC BO OM RIGHT BOOM SWITCH LIFT SWITCH INTERF ACE T O VE ...

  • Toro 41235 - page 111

    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. The T o ...

  • Toro 41235 - page 112

    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 7.5A 2A 7.5A 7.5A ...

  • Toro 41235 - page 113

    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. The ...

  • Toro 41235 - page 114

    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 7.5A 2A 7.5A 7.5A RIGHT A ...

  • Toro 41235 - page 115

    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. The T oro el ...

  • Toro 41235 - page 116

    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 7.5A 2A 7.5A 7.5 ...

  • Toro 41235 - page 117

    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 position (sonic boom switch light is illumi- nated), the bo om mounted sonic boo m sensors continu- ally send impulse signals and then receive echoes as the ...

  • Toro 41235 - page 118

    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 7.5A 2A 7.5A 7.5A A B AB ( ...

  • Toro 41235 - page 119

    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. The sonic boom light should not be illuminated when in the manual position. The opera tor will c ...

  • Toro 41235 - page 120

    Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 16 This page is intentionally blank. ...

  • Toro 41235 - page 121

    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). NOTE: When troubleshooting an electrical problem ...

  • Toro 41235 - page 122

    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. 8). When the ignition switch is moved to the ON position and the Ultra Sonic Boom System elec ...

  • Toro 41235 - page 123

    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. T o retrieve these fault co ...

  • Toro 41235 - page 124

    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.g. sonic b oom switch, boom lift switches, sonic boom sensors) and energiz ...

  • Toro 41235 - page 125

    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 . 6. T he Diagnostic Display will illuminate the ...

  • Toro 41235 - page 126

    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). This is a quic k way to deter mine whic h electri- cal comp ...

  • Toro 41235 - page 127

    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 lamp is not ON or FLASHING: LED OFF SONIC SENSOR TEC output exists to sonic sensors: LED ON No TEC output to soni c sensors: LED OFF RIGHT RAISE TEC out ...

  • Toro 41235 - page 128

    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. Also, consider that there may be more than one cause for a machine proble m. NOT ...

  • Toro 41235 - page 129

    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 . On affected boo m, calibration of the son ic boom sensors is incor- ...

  • Toro 41235 - page 130

    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. The upper , extreme l ...

  • Toro 41235 - page 131

    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. The so nic boom switch is l ocated on the spray control panel (F ig. 15). If the ...

  • Toro 41235 - page 132

    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 . The sensors are m ounted to the spray booms (Figs. 1 7, 18 and 19). During sprayer op- eration with the son ic boom switch in the a utomatic posi- tion, the so nic sensors will p rovide inp uts ...

  • Toro 41235 - page 133

    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 . The LED window includes four (4) LED? ...

  • Toro 41235 - page 134

    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 . The T oro electronic control ...

  • Toro 41235 - page 135

    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. 24). Power is pr ovided to the T EC when the v ehicle ignition switch is ...

  • Toro 41235 - page 136

    Wor k ma n 2 0 0 Ultra Sonic Boom Sys tem (Rev . C) Page 3.2 - - 32 This page is intentionally blank. ...

  • Toro 41235 - page 137

    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 ......................... S ...

  • Toro 41235 - page 138

    This page is intentionally blank. Electrical Diagrams Page 4 – 2 Workman 200 Spray System ...

  • Toro 41235 - page 139

    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 BK OR R/WH BK OR BOOM LIFT LH SWITCH GN R/WH LH FOAM SOLENOID BK BOOM LIFT RH SWITCH RH FOAM SOLENOID R/BK BOOM FOAM LH SWITCH BK W/BK 1 2 W/BK 6 8 5 ...

  • Toro 41235 - page 140

    Page 4 – 4 Rev . A Electrical Schematic W orkman 200 Spray System (Serial Numbers Above 260000000) ...

  • Toro 41235 - page 141

    Rev . B Page 4 - - 5 This page is intent ional ly blank . ...

  • Toro 41235 - page 142

    Rev . B Page 4 - - 6 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial N umbers Below 260000000) ...

  • Toro 41235 - page 143

    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/ORANGE BLUE GRA Y/BLA CK BROWN/WH ITE BROWN/WH ITE GREEN/BLACK ORANGE/W HIT E BLUE/ BLACK BLUE/GREEN WHITE/BLACK YELLOW/BLUE BLACK BLACK BLACK BLACK WHIT ...

  • Toro 41235 - page 144

    Rev . B Page 4 - - 8 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial Numbers From 260000001 to 280000200) ...

  • Toro 41235 - page 145

    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 BLACK BROWN/WH ITE BLACK YELLOW/BLUE BLUE/GREEN BLUE/ WHIT E BLACK BLACK GREEN/BLACK WHITE/BLACK WHITE/BLACK BLUE/ BLACK ORANGE/W HIT E W orkman 200 S pra ...

  • Toro 41235 - page 146

    Rev . B Page 4 - - 10 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial Numbers From 280000201 to 290999999) ...

  • Toro 41235 - page 147

    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 ITE BLUE/RED VIOLET GRA Y BLUE BLUE GREEN BLUE/ WHIT E BLUE/ BLACK YELLOW/BLUE BLUE/GREEN WHITE/BLACK BLACK RED YELLO W BLUE GREEN GREEN YELLO W BLUE ...

  • Toro 41235 - page 148

    Rev . B Page 4 - - 12 W orkman 200 S pray Sy stem Spray S ystem Wire Har ness (Serial Numbers Above 310000000) ...

  • Toro 41235 - page 149

    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/RED BLACK SHIELD CLEAR BLUE GREEN BLUE/ WHIT E BLUE/ BLACK BROWN/WH ITE GREEN/BLACK ORANGE/W HIT E BLUE/ BLACK BLUE RED GREEN YELLO W YELLO W GREEN RED ...

  • Toro 41235 - page 150

    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) ...

  • Toro 41235 - page 151

    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 BLACK BLACK BROWN ORANGE/ BL ACK ORANGE/ BL ACK RED PINK BLACK BROWN BLACK GREEN/WHITE GREEN/WHITE PINK BROWN BLACK BROWN/WHITE BLUE/RED BLACK BROWN/ ...

  • Toro 41235 - page 152

    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) ...

  • Toro 41235 - page 153

    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 VIOLET/RED PINK BLACK PINK/B LACK BROWN WHITE/BLACK ORANGE/ WH ITE ORANGE/ BL ACK BLUE/ BLACK BLUE/ WHIT E GREEN/BLACK GREEN/WHITE GRA Y BLACK GREEN BLUE ...

  • Toro 41235 - page 154

    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) ...

  • Toro 41235 - page 155

    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 RED RED PINK PIN K PINK PINK PINK BRO WN ORA NGE /B LA CK ORA NGE /B LA CK BLACK BLACK PINK/B LACK BLUE/W HITE BLUE/W HITE BRO WN BLACK PINK/B LACK BLA ...

  • Toro 41235 - page 156

    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) ...

  • Toro 41235 - page 157

    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 BLACK BLUE/B LACK BLUE/W HITE ORA NGE /W HI TE ORA NGE /B LA CK GR EEN/BLAC K GR EEN/WH ITE RED RED PINK VIO LET/ WHIT E PINK BRO WN PINK PINK/B LACK B ...

  • Toro 41235 - page 158

    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 ...

  • Toro 41235 - page 159

    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 ...

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A complete manual for the device Toro 41235, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Toro 41235 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Toro 41235.

A complete Toro manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Toro 41235 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Toro 41235, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Toro 41235, that we can find in the current document
3. Tips how to use the basic functions of the device Toro 41235 - which should help us in our first steps of using Toro 41235
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Toro 41235
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Toro 41235 in a specific country, if it was not possible to solve the problem on our own.

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