03124sl.pdf Workman 200 Sprayer (Rev A) Nov, 2005

PART NO. 03124SL (Rev. A)

Service Manual

Workman� 200 Spray SystemPrefaceThe purpose of this publication is to provide the servicetechnician with information for troubleshooting, testing,and repair of major systems and components on theWorkman 200 Spray System.

REFER TO THE OPERATOR�S MANUAL FOR OPER-ATING, MAINTENANCE, AND ADJUSTMENTINSTRUCTIONS. Keep the Operator�s Manual, Instal-lation Instructions and Parts Catalog for your machinewith this Service Manual. Replacement Operator�sManuals and Parts Catalogs are available on the inter-net at www.Toro.com or by sending complete Model andSerial Number to:

The Toro CompanyAttn. Technical Publications8111 Lyndale Avenue SouthBloomington, MN 55420�1196

The Toro Company reserves the right to change productspecifications or this publication without notice.

This safety symbol means DANGER, WARNING,or CAUTION, PERSONAL SAFETY INSTRUC-TION. When you see this symbol, carefully readthe instructions that follow. Failure to obey theinstructions may result in personal injury.

NOTE: A NOTE will give general information about thecorrect operation, maintenance, service, testing, or re-pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-portant instructions which must be followed to pre-vent damage to systems or components on themachine.

� The Toro Company � 2003, 2005

Workman 200 Spray System

This page is intentionally blank.

Rev. AWorkman 200 Spray System

Table Of Contents

Chapter 1 � Safety and Product Records

Safety Instructions 1 � 2. . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 � 3. . . . . . . . . . . . . . . . Product Records 1 � 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 � Electrical System

Electrical Schematic and Electrical Harness and Con-nector Drawings 2 � 2. . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 2 � 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Testing 2 � 4. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 � Spray System

Specifications 3 � 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 3 � 3. . . . . . . . . . . . . . . . . . . . . . . . Spray System Flow Diagram 3 � 4. . . . . . . . . . . . . . . . . Spray System Operation 3 � 5. . . . . . . . . . . . . . . . . . . . Troubleshooting 3 � 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 3 � 8. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 � Electrical Diagrams

Electrical Schematic 4 � 3. . . . . . . . . . . . . . . . . . . . . . . . Wire Harness Drawings 4 � 5. . . . . . . . . . . . . . . . . . . . .

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Workman 200 Spray System


Workman 200 Spray System Page 1 – 1 Safety and Product Records

Chapter 1

Safety and Product RecordsTable of ContentsSAFETY INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . .

Before Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .

SAFETY AND INSTRUCTION DECALS 3. . . . . . . . . . PRODUCT RECORDS 3. . . . . . . . . . . . . . . . . . . . . . . . .

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Workman 200 Spray SystemPage 1 – 2Safety and Product Records

Safety InstructionsThe Workman 200 Spray System is designed andtested to offer safe service when operated and main-tained properly. Although hazard control and accidentprevention are partially dependent upon the design andconfiguration of the machine, these factors are also de-pendent upon the awareness, concern, and propertraining of the personnel involved in the operation, trans-port, maintenance, and storage of the machine. Improp-er use or maintenance of the machine can result in injuryor death. To reduce the potential for injury or death,comply with the following safety instructions.

WARNINGTo reduce the potential for injury or death,comply with the following safety instructions.

Before Operating

1. Read and understand the contents of the Operator’sManual before starting and operating the machine. Be-come familiar with the controls and know how to stop themachine and engine quickly. A replacement Operator’sManual is available on the Internet at www.Toro.com orby sending the complete model and serial number to:

The Toro CompanyAttn. Technical Publications8111 Lyndale Avenue SouthBloomington, Minnesota 55420–1196

2. Keep all shields, safety devices, and decals in place.If a shield, safety device, or decal is defective, illegibleor damaged, repair or replace it before operating themachine. Also tighten any loose nuts, bolts or screws toensure machine is in safe operating condition.

While Operating

1. Sit on the seat when starting and operating the ma-chine.

2. Before starting the engine:

A. Engage the parking brake.

B. Make sure drive system is in the NEUTRAL posi-tion and the pump switch is OFF.

3. Do not run engine in a confined area without ade-quate ventilation. Exhaust fumes are hazardous andcould possibly be deadly.

4. Do not touch engine, radiator, muffler or exhaustpipe while engine is running or soon after it is stopped.These areas could be hot enough to cause burns.

5. Before getting off the seat:

A. Ensure that drive system is in the NEUTRALposition.

B. Set parking brake.

C. Turn pump switch OFF.

D. Stop engine and remove key from ignition switch.

E. Do not park on slopes unless wheels are chockedor blocked.

6. Follow spray chemical manufacturer’s recommen-dations for handling precautions, protective equipment,and mixing proportions.

Workman 200 Spray System Page 1 – 3 Safety and Product Records

Maintenance and Service

1. Before servicing or making adjustments, turn PTOoff, put shift lever in neutral, stop engine, set parkingbrake, and remove key from the switch.

2. Prior to servicing sprayer components, determinewhat chemical(s) have been used in the sprayer. Followprecautions and recommendations printed on chemicalcontainer labels or Material Safety Data Sheets whenservicing sprayer components. Use appropriate protec-tive equipment: protective clothing, chemical resistantgloves, and eye protection.

3. Make sure machine is in safe operating condition bykeeping all nuts, bolts and screws tight.

4. Never store the machine or fuel container insidewhere there is an open flame, such as near a water heat-er or furnace.

5. If major repairs are ever needed or assistance is de-sired, contact an Authorized Toro Distributor.

6. If engine must be running to perform maintenance oran adjustment, keep clothing, hands, feet, and otherparts of the body away from moving parts. Keep by-standers away.

7. Disconnect battery before servicing the machine.Disconnect negative (–) battery cable first and positive(+) cable last. If battery voltage is required for trouble-shooting or test procedures, temporarily connect thebattery. Reconnect positive (+) cable first and negative(–) cable last.

8. Battery acid is poisonous and can cause burns.Avoid contact with skin, eyes, and clothing. Protect yourface, eyes, and clothing when working with a battery.

9. Battery gases can explode. Keep cigarettes, sparks,and flames away from the battery.

10.To assure optimum performance and continuedsafety of the machine, use genuine Toro replacementparts and accessories. Replacement parts and acces-sories made by other manufacturers may result in non-conformance with safety standards, and the warrantymay be voided.

Safety and Instruction DecalsNumerous safety and instruction decals are affixed tothe Workman 200 Spray System. If any decal becomesillegible or damaged, install a new decal. Part numbersare listed in your Parts Catalog. Order replacement de-cals from your Authorized Toro Distributor.

Product RecordsInsert Operator’s Manual, Installation Instructions andParts Catalog for your Workman 200 Spray System atthe end of this Chapter. Refer to Operator’s Manual forrecommended maintenance intervals. Additionally, in-sert Installation Instructions, Operator’s Manuals, andParts Catalogs for other accessories (e.g. Foam Mark-ing Kit, Hose Reel Kit) that have been installed on yourWorkman vehicle at the end of this Chapter.

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Workman 200 Spray SystemPage 1 – 4Safety and Product Records


Workman 200 Spray System Page 2 – 1 Electrical System

Chapter 2

Electrical System

Table of ContentsELECTRICAL SCHEMATIC and ELECTRICAL

HARNESS and CONNECTOR DRAWINGS 2. . . . . SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT TESTING 4. . . . . . . . . . . . . . . . . . . . . . .

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

(Optional) Switches 5. . . . . . . . . . . . . . . . . . . . . . . . Supervisor Key Switch 6. . . . . . . . . . . . . . . . . . . . . . . Boom Control and Monitor Power Switches 7. . . . . Hold Relay 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traction Speed Sensor 9. . . . . . . . . . . . . . . . . . . . . .

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Workman 200 Spray SystemPage 2 – 2Electrical System

Electrical Schematic and Electrical Harness andConnector DrawingsThe electrical schematic and other electrical drawingsfor the Workman 200 Spray System are located in Chap-ter 4 – Electrical Diagrams.


Special Tools

Multimeter

The multimeter can test electrical components and cir-cuits for current, resistance, or voltage.

NOTE: Toro recommends the use of a DIGITAL Volt–Ohm–Amp multimeter when testing electrical circuits.The high impedance (internal resistance) of a digital me-ter in the voltage mode will make sure that excess cur-rent is not allowed through the meter. This excesscurrent can cause damage to circuits not designed tocarry it.

Figure 1

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Component Testing

Master Boom Switch

The master boom switch is located on the spray controlenclosure faceplate (Fig. 2).

Testing

1. Remove spray control enclosure faceplate, locatemaster boom switch and unplug wire harness connectorfrom switch.

2. The switch terminals are marked as shown in Figure3. In the ON position, continuity should exist betweenterminals 2 and 3 and also between terminals 5 and 6.In the OFF position, continuity should exist between ter-minals 1 and 2 and also between terminals 4 and 5.

3. Reconnect the harness connectors to the switch af-ter testing. Install console panel to machine.

1. Master boom switch

Figure 2

1

Figure 3

1 2

4

3

5 6

BACK OF SWITCH


Rate Control and Boom Actuator (Optional) Switches

The rate control (increase/decrease) switch is locatedon the spray control enclosure faceplate (Fig. 4).

On machines equipped with the optional electric boomlift kit, this is the same switch that is used to operate theboom actuators.

Testing

1. Remove spray control enclosure faceplate, locateswitch to be tested and unplug wire harness connectorfrom switch.

2. The switch terminals are marked as shown in Figure5. In the INCREASE or boom raise position, continuityshould exist between terminals 2 and 3 and also be-tween terminals 5 and 6. In the neutral, center position,there should be no continuity between any switch termi-nals. In the DECREASE or boom lower position, conti-nuity should exist between terminals 2 and 1 and alsobetween terminals 5 and 4.

3. Reconnect the harness connector to the switch aftertesting. Install console panel to machine.

1. Rate control switch2. Boom actuator switch

Figure 4

1

2

Figure 5

1 2

4

3

5 6

BACK OF SWITCH

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Supervisor Key Switch

The supervisor key switch (rate lockout) is located onthe spray control enclosure faceplate (Fig. 6).

Testing

1. Remove spray control enclosure faceplate, locatekey switch and remove wire harness connectors fromswitch.

2. The switch terminals are shown in Figure 7. Whenthe key is in the ON position, continuity should exist be-tween the two terminals. In the OFF position, thereshould be no continuity between the switch terminals.

3. Reconnect the harness connectors to the switch af-ter testing. Install console panel to machine.

1. Supervisor key switch

Figure 6

1

Figure 7

BACK OF SWITCH

FRONT OF SWITCH

OFF

ON60o


Boom Control and Monitor Power Switches

The three boom control (on/off) and monitor powerswitches are located on the spray control enclosurefaceplate (Fig. 8).

Testing

1. Remove spray control enclosure faceplate, locateboom control switch and unplug wire harness connectorfrom switch.

2. The switch terminals are marked as shown in Figure9. In the ON position, continuity should exist betweenterminals 2 and 3 and also between terminals 5 and 6.In the OFF position, continuity should exist between ter-minals 1 and 2 and also between terminals 4 and 5.

3. Terminals 7 (–) and 8 (+) are used for the indicatorlight in the switch. The light should be illuminated whenthe switch is in the ON position.

4. Reconnect the harness connector to the switch aftertesting. Install console panel to machine.

1. Boom control switch 2. Monitor power switch

Figure 8

2

1

Figure 9

4 6

1

5

8 2

7

3

BACK OF SWITCH

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Hold Relay

The hold relay used on the Workman Spray System islocated in the spray control enclosure.

Testing

1. Remove spray control enclosure faceplate, locatehold relay and unplug wire harness connector fromrelay.

2. Connect multimeter (ohms setting) leads to relay ter-minals 30 and 87 (Fig. 10). Ground terminal 86 and ap-ply +12 VDC to terminal 85. The relay should make andbreak continuity between terminals 30 and 87 as +12VDC is applied and removed from terminal 85.

3. Disconnect voltage from terminal 85 and multimeterlead from terminal 87.

4. Connect multimeter (ohms setting) leads to relay ter-minals 30 and 87A. Apply +12 VDC to terminal 85. Therelay should make and break continuity between termi-nals 30 and 87A as +12 VDC is applied and removedfrom terminal 85.

5. Disconnect voltage and multimeter leads from therelay terminals. Reconnect relay to machine wire har-ness.

Figure 10

86

85

87A 87

30

8687A

30

87

85

TOP VIEW


Traction Speed Sensor

The traction speed sensor is attached to the uppertransaxle cover (Fig. 11). It uses a magnetically based,Hall Effect integrated circuit. As the differential in thetransaxle turns, the sensor accurately senses the move-ment of the differential ring gear teeth passing by thesensor. The red striped connector wire is the positivelead, the black wire is the ground lead, and the graystriped wire is the signal output.

Testing

1. Locate traction speed sensor on the transaxle as-sembly. Disconnect the wire harness connector from thetraction speed sensor.

2. Remove cap screw and lock washer that securespeed sensor to transaxle. Remove speed sensor fromtransaxle.

3. Connect positive multimeter test lead to the sensorconnector gray striped wire terminal and the negativemultimeter lead to the connector black wire terminal(Fig. 12). Set multimeter to ohms setting.

IMPORTANT: Incorrect jumper wire connectionsduring testing can damage the sensor.

4. Using jumper wires, apply +12 VDC to the sensorconnector red striped wire terminal and ground the con-nector black wire terminal (Fig. 12).

5. The sensor should have very low resistance (nearzero) when a metal object is held near the sensor tip.The sensor should have very high resistance (infinite)when the metal object is moved away from the sensortip.

6. After testing is complete, remove jumper wires andmultimeter leads from sensor connector. Reinstallspeed sensor into transaxle and secure with cap screwand lock washer. Reconnect speed sensor to wire har-ness.

1. Transaxle assembly 2. Traction speed sensor

Figure 11

2

1

1. Speed sensor2. Sensor tip3. Sensor connector

4. Red striped wire5. Gray striped wire6. Black wire

Figure 12

B AC

–+

12 VDC

1

2

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Rev. AWorkman 200 Spray System Page 3 � 1 Spray System

Chapter 3

Spray SystemTable of ContentsSPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .

Precautions Concerning Chemicals Used inSpray System 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Removing or Adjusting SpraySystem Components 3. . . . . . . . . . . . . . . . . . . . . . .

O�Ring Seal Kit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRAY SYSTEM FLOW DIAGRAM 4. . . . . . . . . . . . . SPRAY SYSTEM OPERATION 5. . . . . . . . . . . . . . . . . TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 8. . . . . . . . . . . . . . . . . . . . . .

Suction Dampener 8. . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Dampener 9. . . . . . . . . . . . . . . . . . . . . . . . . Spray Pump 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pump Service 12. . . . . . . . . . . . . . . . . . . . . . . . Agitation Control Valve 16. . . . . . . . . . . . . . . . . . . . . . Agitation Nozzles (Tank Mounted) 18. . . . . . . . . . . . Pressure Relief Valve (Tank Mounted) 20. . . . . . . . Spray Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flowmeter 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rate Control Motor 26. . . . . . . . . . . . . . . . . . . . . . . . . Boom Valve Motor 28. . . . . . . . . . . . . . . . . . . . . . . . . . Boom Bypass 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Suction 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Drain 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turret Bodies 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turret Body Service 39. . . . . . . . . . . . . . . . . . . . . . . . Boom Frame Breakaway Pivot Assembly

(Machines with Serial Numbers Below260000000) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Hinge (Machines with Serial NumbersAbove 260000000) 42. . . . . . . . . . . . . . . . . . . . . . .

Boom Actuator (Optional) (Machines withSerial Numbers Below 260000000) 44. . . . . . . . .

Boom Actuator Service (Machines with SerialNumbers Below 260000000) 46. . . . . . . . . . . . . . .

Boom Actuator (Machines with Serial NumbersAbove 260000000) 48. . . . . . . . . . . . . . . . . . . . . . .

Boom Actuator Service (Machines with SerialNumbers Above 260000000) 50. . . . . . . . . . . . . .

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Workman 200 Spray SystemPage 3 � 2Spray System

SpecificationsItem Description

Spray Pump Diaphragm Pump, 29 GPM

Spray Pressure Relief Valve Poppet Style, 220 PSI Maximum

Sprayer Tank 200 Gallon (757 Liter), Polyethylene

Suction Strainer 50 Mesh, Stainless Steel, Tank Mounted(30 Mesh and 90 Mesh Optional)


General Information

Precautions Concerning Chemicals Used in Spray System

Chemicals can injure persons, animals, plants, soil, orother property. To eliminate environmental damage andpersonal injury:

1. Select the proper chemical for the job.

2. Carefully read the directions printed on the chemicalmanufacturer�s labels before handling chemicals. In-structions on chemical manufacturer�s container labelsregarding mixing proportions should be read and strictlyfollowed.

3. Keep spray material away from skin. If spray materialcomes in contact with a person, wash it off immediatelyin accordance with manufacturer�s recommendations(container labels and Material Safety Data Sheets).

4. Always wear protective clothing, chemical resistantgloves, eye protection, and other personal protectiveequipment as recommended by the chemical manufac-turer.

5. Properly dispose of chemical containers, unusedchemicals, and chemical solution.

Precautions for Removing or Adjusting Spray System Components

1. Stop the vehicle and set the parking brake.

2. Shut off the vehicle�s engine and remove the keyfrom the ignition switch.

3. Disengage all power and wait until all moving partshave stopped.

4. Remove chemicals from pump, hoses, and otherspray components. Thoroughly neutralize and rinsespray system before loosening or removing any spraysystem component(s).

5. Make sure line pressure is relieved before looseningany system component.

O�Ring Seal Kit

Part Number: 106�4846

The O�Ring Seal Kit includes an assortment of o�ringsused for sealing hose couplings on the spray tank. It isrecommended that o�rings be replaced every two (2)years or whenever a fitting is loosened.

Figure 1

SPRAYERO�RING SEAL KIT

PART NO. 106�4846S

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Spray System Flow Diagram

Spray System Flow DiagramWorkman 200 Spray System

SUCTIONPRESSUREAGITATIONBOOM SUPPLYFLOW DIRECTION

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Workman 200 Spray System Page 3 � 5 Spray System

Spray System OperationThe Workman 200 Spray System uses a positive dis-placement diaphragm pump to move spray solutionfrom the spray tank to the boom nozzles. The spraypump is self�priming and has a dry crankcase. Thepump is driven by the transaxle PTO kit output shaft ata speed that is proportional to the ground speed of thevehicle. It should be noted that pump rotation will stopwhenever the vehicle clutch pedal is depressed.

The downward stroke of the pumps� connecting rodsand diaphragms create suction to allow fluid to be drawnfrom the spray tank to the pump through the suctiontube, suction strainer, hoses, and connectors. A suctiondampener placed in the suction line dampens suctionpulses to smooth suction flow. Suction valves positionedin the pump valve chamber prevent fluid from beingpumped back into the suction line when the connectingrods change direction. Leaks in the suction line willcause system problems and often will be indicated by er-ratic suction line jumping and pump noise.

Once to the pump, the fluid is pushed by the upwardstroke of the pumps� connecting rods and diaphragmsto the pressure side of the spray system through hoses,connectors, control valves, and spray nozzles. A pres-sure dampener at the pump outlet smooths systempressure pulsation. Pressure valves positioned in thepump head prevent fluid from being drawn back into thepump. Maximum pressure in the system is limited by apressure relief valve located in the tank. A pressuregauge indicates system pressure.

The spray system is controlled electrically and consistsof a rate control valve and three boom control valves. Amanually adjustable boom bypass valve exists in eachof the boom control valves to prevent system pressurechanges when a boom section is shut off. Flow in excessof control valve settings is directed back to the spraytank.

An inline flowmeter in the pressure side of the system di-rectly before the boom control valves measures flow tothe spray booms. The Spray Pro Monitor displays infor-mation regarding application rate based on input fromthe flowmeter and the ground speed sensor in the trans-axle.

Flow for tank agitation comes from flow that is bypassedby the rate control valve. A manual agitation controlvalve directs flow to four agitation nozzles in the spraytank.

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Troubleshooting

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Possible CauseÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Spray system leaks fluid. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

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.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fluid leaking from bottom of spraypump.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Faulty diaphragm(s) in spray pump.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Excessive suction hose vibration.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

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.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Spray pressure is low.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Suction line is restricted.

Suction screen in tank is plugged.

Spray nozzles worn or damaged.

Pressure line or component is loose or leaking.

Engine speed is low.

Pressure relief valve in tank is stuck.

Spray pump is damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Single spray boom nozzle leakswhen boom is turned off.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Diaphragm in turret body is leaking or damaged.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Nozzles on one spray boom leakwhen boom is switched off.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Diaphragm in turret body is leaking or damaged.

Boom valve motor for affected boom not seating.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Spray pump doesn�t rotate. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Vehicle clutch pedal is depressed.

Key on spray pump shaft is sheared.

Auxiliary PTO not engaged or faulty.

Auxiliary PTO output shaft damaged.

PTO drive shaft damaged or missing.


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Erratic spray operation from booms.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

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.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No spray output from one sprayboom.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hoses on boom are pinched or kinked.

Boom valve motor for affected boom not opening.

Console boom switch dirty, corroded, or damaged.

Check for 12 volts at affected boom valve motor in both directions(on and off).

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Low spray rate from one nozzle.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clogged or damaged spray nozzle(s).

Spray nozzles are different sizes.

Boom valve motor for affected boom not seating.

Sp

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Sys

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Service and Repairs

Suction Dampener

The suction dampener is mounted to the suction line atthe spray pump (Fig. 2) and is used to dampen suctionpulses and smooth suction flow. During pump operation,the suction dampener diaphragm will move.

IMPORTANT: Make sure to neutralize and removechemicals from pump and hoses before looseningand removing spray system components.

A damaged suction dampener diaphragm will allow asuction leak and will cause improper pump operation. Ifthe diaphragm is damaged, remove diaphragm fromdampener housing and replace it (Fig. 3).

1. Spray pump2. Suction dampener

3. Suction hoseFigure 2

3

1

2

1. Spray pump2. O�ring

3. Dampener housing4. Diaphragm

Figure 3

2

4

3

1


Pressure Dampener

The pressure dampener is mounted to the pressure lineat the spray pump (Fig. 4) and is used to smooth systempressure pulsation. Adjust air pressure on the pressuredampener from 12 to 15 PSI (.82 to 1.03 bar).

IMPORTANT: Any fluid in the pressure dampenerwill include spray system chemicals so take neces-sary precautions when working with the dampener.Use appropriate protective equipment: protectiveclothing, chemical resistant gloves, and eye protec-tion.

If fluid is present when pressure in the dampener ischecked, the diaphragm in the pressure dampener isdamaged and should be replaced.

Dampener Service (Fig. 5)


1. Loosen and remove cap screws and nuts that securediaphragm between housings.

2. Remove diaphragm from dampener.

3. Replace diaphragm and reassemble dampener.

1. Spray pump 2. Pressure dampenerFigure 4

2

1

1. Spray pump2. O�ring3. Hex nut (12 used)4. Rear housing

5. Diaphragm6. Front housing7. Cap screw (12 used)8. Air valve

Figure 5

1 23

45

6

7

8

Sp

ray

Sys

tem


Spray Pump

1. Spray pump assembly2. Elbow (pressure)3. Gasket4. Pressure tee fitting5. O�ring6. Pressure dampener7. O�ring8. Hosebarb9. Nut10. Hose clamp

11. Pressure hose12. Flange head screw (4 used)13. Pump drive shroud14. Shroud bracket15. Square key16. Set screw17. PTO driveshaft18. Flange nut (4 used)19. Flange nut (4 used)

20. Pump mount bracket21. Flange head screw (4 used)22. Suction tee fitting23. Suction dampener24. Gasket25. Hosebarb26. Nut27. Hose clamp28. Suction hose

Figure 6

1

23

4

5

6

78 9

18

19

20

21

22 23

24

25

26

27

28

1011

12

13

14

1516

Loctite #242

Apply thread sealantAnti�seizeLubricant

Apply thread sealant

Loctite #242

FRONT

RIGHT

5

13

16

17


Removal (Fig. 6)


1. Park machine on a level surface, stop engine, en-gage parking brake, and remove key from the ignitionswitch.

2. Loosen hose clamp that secures suction hose (item28) to hosebarb (item 25). Pull suction hose from hose-barb.

3. Loosen hose clamp that secures pressure hose(item 11) to hosebarb (item 8). Pull pressure hose fromhosebarb.

4. Remove PTO driveshaft (item 17) from output shaftof transaxle PTO assembly.

5. Remove four (4) flange head screws and flange nutsthat secure pump assembly to pump mount bracket.

6. Remove pump assembly (with PTO driveshaft anddrive shrouds attached) from machine.

7. Remove four (4) flange head screws and flange nutsthat secure pump drive shrouds (item 13) to shroudbracket (item 14). Remove pump drive shrouds.

8. Loosen two (2) set screws (item 16) that secure PTOdrive shaft to pump shaft. Separate PTO drive shaft frompump. Locate and remove key from pump shaft.

9. As needed, remove pressure and suction compo-nents from pump using Figure 6 as a guide. Discard anyremoved o�rings and gaskets.

Installation (Fig. 6)

NOTE: Coat all o�rings with vegetable oil before instal-lation to reduce the chance of damage during assembly.

1. Apply thread sealant to threads of pressure tee fit-ting, elbow (pressure), and suction tee fitting. Positionnew o�rings and gaskets on suction and pressure fit-tings that were removed during disassembly.

2. Install suction tee fitting and suction dampener topump inlet. Orientate tee toward right side of machine(Fig. 7).

3. Install elbow (pressure), pressure tee fitting, andpressure dampener to pump outlet. Orientate elbow to-ward right side of machine (Fig. 7).

4. Remove set screws (item 16) from PTO driveshaft.Clean threads of set screws and set screw threads in dri-veshaft.

5. Apply anti�seize lubricant to pump shaft. Positionsquare key in pump shaft and slide PTO driveshaft fullyonto pump shaft.

6. Apply Loctite #242 (or equivalent) to threads of setscrews. Install set screws into PTO drive shaft to securePTO shaft to pump shaft.

7. Position pump drive shrouds (item 13) to shroudbracket (item 14). Install four (4) flange head screws andflange nuts to secure shrouds to bracket.

8. Position pump on pump mount bracket. Install flangehead screws and flange nuts to pump and mount brack-et. Secure pump to mount bracket.

9. Attach PTO driveshaft to output shaft of transaxlePTO assembly.

10.Install pressure and suction hoses to correct barb fit-tings. Secure hoses with hose clamps.

1. Elbow (pressure) 2. Suction hose

Figure 7

2

1

Sp

ray

Sys

tem


Spray Pump Service

1. Valve chamber2. Valve (inlet position)3. O�ring4. Diaphragm cover5. Hex bolt6. Washer7. Diaphragm8. Diaphragm back disc9. Nylon washer10. Lock washer

11. Hex bolt12. Ball bearing (crankshaft)13. Dust plate14. Pump casing15. Hex bolt (30 mm long) (3 used)16. Hex bolt (4 used per cover)17. Hex bolt (55 mm long) (2 used)18. Felt seal19. Hex nut

20. Connecting rod21. Ball bearing (connecting rod)22. Grease fitting23. Crankshaft24. Hex nut (5 used)25. Valve (outlet position)26. Hex bolt (2 used)27. Washer (2 used)28. Poly o�ring

Figure 8

9

1011

12

13

14

7

8

15

1718

1

2

3

4

5

6

5

68

7

9

12

13

14

10

18

19

20 21

22

23

24

16

26

2120

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


Disassembly (Fig. 8)

IMPORTANT: Make sure to remove and neutralizechemicals from pump before disassembly. Wearprotective clothing, chemical resistant gloves, andeye protection during pump repair.

NOTE: Many pump components can be easily re-versed. During disassembly, make note of componentposition (e.g. crankshaft, valve chamber) to assure cor-rect assembly.

1. Remove two (2) hex bolts that retain valve chamberto pump. Separate valve chamber from pump.

2. Remove inlet and outlet valves and o�rings fromeach diaphragm cover. Note orientation of valves. Dis-card valves and o�rings. Clean valve and o�ring seatsin the valve chambers and diaphragm covers.

3. Remove hex bolts that secure diaphragm covers topump. Remove diaphragm covers.

4. Remove hex bolt, washer, nylon washer, diaphragm,and diaphragm back disc from each connecting rod.Discard diaphragms.

5. Remove five (5) hex bolts and nuts that secure pumpcasing halves together. Note location of two (2) longerhex bolts with washers. Carefully separate pump casinghalves.

6. Clean grease from bottom of housing and check con-dition of bearings on crankshaft. If bearings require re-placement, remove and disassemble crankshaft:

A. Remove crankshaft assembly from pump casing.

B. Slide felt seal and dust plate from both ends ofcrankshaft.

C. Loosen hex bolt and hex nut that secure connect-ing rods to crankshaft. Slide connecting rods fromcrankshaft. Press ball bearings from crankshaft.

Assembly (Fig. 8)

1. If disassembled, reassemble crankshaft.

A. Hand pack new bearings with #2 general purposelithium base grease.

B. Pressing on bearing inner race, install two con-necting rod and two crankshaft ball bearings ontocrankshaft.

C. Slide connecting rods onto connecting rod bear-ings. Offsets of the connecting rods should face eachother. Install hex bolt, flat washers, and hex nut toeach connecting rod. Torque hex nuts to 25 ft�lb (34N�m) to secure connecting rods to crankshaft.

D. Position dust plate and felt seal on both ends ofcrankshaft.

IMPORTANT: If connecting rod position is incor-rect, pump will not operate properly.

E. Slide crankshaft assembly into pump casing. Therear connecting rod should be positioned to the leftside and the connecting rod closest to you to the rightside (Fig. 9).

2. Place second pump casing onto assembly. Pumpcasing surfaces should mate together.

3. Install three (3) shorter (30 mm) bolts and two (2) lon-ger (55 mm) bolts with washers into pump casing as-sembly (Fig. 10). Thread hex nuts onto bolts but do notfully tighten. Check that crankshaft turns freely.

1. Closest connecting rod (to right side)2. Rear connecting rod (to left side)

Figure 9

12

1. Hex bolt (30 mm long) 2. Hex bolt (55 mm long)Figure 10

1

22

1

1

Sp

ray

Sys

tem


4. Place diaphragm back disc and new diaphragm ontoeach connecting rod. The connecting rods should ex-tend above the diaphragms when correctly installed(Fig. 11). Position nylon washer and washer on eachconnecting rod and then thread hex bolt into connectingrod. Torque bolt to 60 ft�lb (81 N�m).

5. Make sure that pump casings align and then securepump casing assembly by torquing five (5) bolts to 32 ft�lb (43 N�m).

6. Secure diaphragm covers to pump using hex bolts (4per cover). Torque bolts to 55 ft�lb (75 N�m).

7. Place new o�rings and valves into diaphragm coveropenings (Fig. 12). Inlet valves should be installed withthe spring down into the cover and should be on thesame side of the pump as the crankshaft grease fitting.Outlet valves should be installed with the spring up andaway from cover and should be on the same side of thepump as the crankshaft extension.

8. Place valve chamber over valves noting orientationof chamber inlet and outlet. Secure valve chamber withtwo (2) hex bolts. Torque bolts 60 ft�lb (81 N�m).

1. Diaphragm 2. Connecting rodFigure 11

2 1

1. Inlet (suction)2. Inlet valve

3. Outlet valveFigure 12

2 2

1

3



Sp

ray

Sys

tem


Agitation Control Valve

1. Agitation control valve2. Fork3. Hosebarb/hose (to agitation nozzles)

4. O�ring5. O�ring6. Hosebarb/hose (from spray control)

7. Connector8. Pump suction hose

Figure 13

A

A

1

2

3

4

5

4

7

8

6

8

FRONT

RIGHT

NOTE: ARROWS SHOW FLUIDFLOW DIRECTION


Removal (Fig. 13)

IMPORTANT: Make sure to remove and neutralizechemicals from spray components before disas-sembly. Wear protective clothing, chemical resist-ant gloves, and eye protection during repair.


2. Label disconnected hoses for proper installation af-ter repairs are completed.

3. Remove agitation control valve using Figures 13 and14 as guides.

4. Disassemble agitation valve as required (Fig 15).



1. Assemble agitation control valve (Fig 15). Align ar-row on valve handle with large hole in valve ball duringassembly (Fig. 16).

2. Install agitation valve using Figures 13 and 14 asguides.

3. Check spray system for leaks.

1. Agitation control valve2. Control bypass hose

3. Suction hose (from tank)4. Suction hose (to pump)

Figure 14

1

2

3

4

1. Valve housing2. Ball seat3. O�ring4. O�ring5. Washer (8 used)6. Cap screw (4 used)7. End cover8. Screw (4 used)

9. Screw10. Button11. Valve handle12. Disc13. O�ring14. Spindle15. Valve ball16. Lock nut (4 used)

Figure 15

1

2

5

34

23

15

16

5

9

13

10

12

11

14

6

78

4

7

1. Valve handle arrow 2. Valve ball large hole

Figure 16

2

1

Sp

ray

Sys

tem


Agitation Nozzles (Tank mounted)

1. Agitation supply2. Tee fitting3. Hosebarb/hose4. O�ring5. Connector6. Bulkhead nut7. Gasket8. Bulkhead fitting

9. Hosebarb10. Agitation nozzle11. Nut12. Fork (12 used)13. Hosebarb/hose14. Hosebarb/hose15. Hosebarb/hose16. Agitation nozzle

17. Hosebarb/hose18. Tee fitting19. Nipple20. Adapter21. O�ring22. Elbow23. Hosebarb/hose

Figure 17

A

B

C

A

B

C

FRONT

RIGHT

1

2

35

6

7

8

9

18

1920

21

22

23

2

4

6

67

7

8

8

910

11

1212

14

15

16

10

11

11

11

17

16

13 4

4

4




IMPORTANT: Make sure to remove and neutralizechemicals from tank and other components beforedisassembly. Wear protective clothing, chemical re-sistant gloves, and eye protection during repair.


2. Drain spray tank (see Operator�s Manual).

3. Label hoses for proper installation after repairs arecompleted.

4. Remove agitation nozzles as required using Figure17 as a guide. Discard all removed o�rings and gaskets.

Assembly (Fig. 17)


1. Install agitation nozzles using Figure 17 as a guide.Replace all removed o�rings and gaskets.


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Pressure Relief Valve (Tank Mounted)

1. Hosebarb/hose2. Ringnut3. Pressure relief valve

4. Gasket5. Hosebarb/hose6. O�ring

7. Fork8. Hosebarb/hose (from spray pump)

Figure 18

FRONT

RIGHT

1

3 4

5

A

2

A

6

7

8



Removal (Fig. 18)

IMPORTANT: Make sure to remove and neutralizechemicals from tank and other components beforedisassembly. Wear protective clothing, chemical re-sistant gloves, and eye protection during repair.



3. Label disconnected hoses for proper installation af-ter repairs are completed.

4. Remove pressure relief valve from spray tank usingFigure 18 and 19 as guides. Discard all removed o�ringsand gaskets.

5. Disassemble pressure relief valve using Figure 20as a guide.

Assembly (Fig. 18)


1. Assemble and install pressure relief valve using Fig-ure 18, 19 and 20 as guides. Replace all removed o�rings and gaskets.


1. Hose to pressure relief2. Hose from spray pump

3. Control supply hose

Figure 19

1

2

3

1. Nut2. Seat3. Spring

4. Cone5. Relief valve housing

Figure 20

5

3

2

4

1

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Rev. A Workman 200 Spray SystemPage 3 � 22Spray System

Spray Control

1. Nut2. Threaded rod3. Washer4. Bushing5. O�ring6. Cap7. O�ring8. Tee piece9. Hose: control supply (1�)10. Hose clamp11. Fork12. Screw13. Control valve bracket14. Rate control valve housing

15. Rate control motor16. Screw (4 used)17. Screw18. O�ring19. Lock washer20. Handgrip21. Flowmeter assembly22. Flowmeter housing23. Hose: control bypass (1�)24. Hosebarb25. O�ring26. End cap27. Hose: boom bypass (1�)28. Hosebarb

29. Fork30. Joiner31. LH boom valve motor/manifold32. O�ring33. End cap34. Joiner35. Boom valve bracket36. O�ring (3 used)37. Hosebarb: boom supply (3 used)38. Nut (3 used)39. Coupler (pressure gauge)40. Center boom valve motor/manifold41. RH boom valve motor/manifold

Figure 21

3

7

4

8

1

5

2

6

11

15

12

16

9

13

10

14

19

23

20

24

21

18

22

13

5

7

10

10

7

7

17

25

26

27

FRONT

RIGHT

28

41

2930

32

35

3334

2929

29

29 30

7

7

7

40

31

3232

3232

34

35

32

3637

3812

12

39


71 in�lb(8 N�m)

71 in�lb(8 N�m)

IMPORTANT: Rate control and boom valve motorsmay have a fuse for circuit protection. Make surethat correct fuse is installed in the in�line fuse hold-er located in the motor harness.



Removal (Fig. 21)


2. Label hoses for proper installation after repairs arecompleted. Loosen hose clamps and disconnect hosesfrom spray control.

3. Unplug electrical connectors from rate control motor,flowmeter, and three (3) boom valve motors from ma-chine electrical harness.

4. Remove pressure gauge tube from coupler on backof flowmeter housing (Fig. 23).

5. Remove three (3) flange head screws that securespray control assembly to valve mounting bar. Removespray control assembly from machine.

6. Remove spray control components as required us-ing Figure 21 as a guide. Discard all removed o�ringsand gaskets.

Assembly (Fig. 21)


1. Install spray control components using Figure 21 asa guide. Replace all removed o�rings and gaskets.

2. Before installing rod (Item 2) into assembly, threadnut (item 1) fully onto rod end that has fewer threads.Make sure that o�ring (Item 3) is not damaged duringinstallation over rod. To secure assembly, torque nut 71in�lb (8 N�m).

3. Position spray control assembly to valve mountingbar and secure with three (3) flange head screws.

4. Install hoses to correct locations on spray control as-sembly. Secure hoses with hose clamps.

5. Install pressure gauge tube to coupler on back offlowmeter housing (Fig. 23).

6. Plug electrical connectors from rate control motor,flowmeter, and three (3) boom valve motors to machineelectrical harness.

7. Operate spray system and check for leaks.

1. Rate control motor2. Flowmeter3. LH boom valve motor

4. Center boom valve motor5. RH boom valve motor6. Valve mounting bar

Figure 22

1

2

53

6

4

1. Flowmeter2. Pressure gauge tube

3. CouplerFigure 23

1

2

3

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Flowmeter

1. Nut2. Threaded rod3. Washer4. Bushing5. O�ring6. Cover7. O�ring8. Tee piece9. Hose: control supply (1�)10. Hose clamp

11. Fork12. Screw13. Control valve bracket14. Rate control motor/housing15. O�ring16. Hosebarb17. Hose: control bypass (1�)18. Coupler (pressure gauge)19. Flowmeter housing

20. O�ring21. Flowmeter rotor shaft22. Flowmeter rotor23. Flow sensor24. Nut25. End cap26. LH boom control motor27. Center boom control motor28. RH boom control motor

Figure 24

3

7

4

8

1

5

2

6

11

15

1216

9

1310

14

19

23

20

24

17

21

1822

27

28

25

261

357

7

7

10

FRONT

RIGHT


71 in�lb(8 N�m)

71 in�lb(8 N�m)


Removal and Inspection (Fig. 24)



2. Loosen and remove nut that secures flow sensor toflowmeter housing. Carefully remove flow sensor fromhousing.

3. Inspect for worn rotor shaft and/or bushings. Makesure that rotor magnets are not missing or damaged.

4. Clean rotor, rotor shaft, and flowmeter sensor if re-quired (see Operator�s Manual).

5. With the flow sensor harness connected to the ma-chine and the ignition key in the ON position, slowly spinthe flowmeter rotor. The flowmeter LED should illumi-nate as a rotor magnet passes the flow sensor andshould go out as the next magnet passes the sensor.

NOTE: When using a magnet to check the flowmeter,make sure to alternately use both north and south polesof the magnet.

6. If the flowmeter LED does not flash, remove rotorand rotor shaft from sensor. With the flowmeter harnessconnected to the machine and the ignition key in the ONposition, slowly pass alternate poles of a magnet pastthe flow sensor. If the flowmeter LED flashes as themagnet poles pass the sensor, replace the rotor and ro-tor shaft. If the flowmeter LED does not flash as the mag-net poles pass the sensor, replace the flow sensor.

7. If necessary, remove flowmeter housing using Fig-ures 24 and 26 as guides (also see Spray Control) in thissection). Discard all removed o�rings and gaskets.

Assembly (Fig. 24)


NOTE: When installing flow sensor into housing, makesure to align locating pin on sensor flange with hole inhousing.

1. Reassemble flowmeter using Figures 24 and 26 asguides. Replace all removed o�rings and gaskets.


1. Rotor shaft 2. Rotor

Figure 25

1

2


4. Center boom valve motor5. RH boom valve motor

Figure 26

1

2

53 4

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Rate Control Motor

1. Phillips head screw (5 used)2. Lock washer3. Hand grip4. O�ring5. Phillips head screw (4 used)

6. Rate control motor assembly7. Gasket8. Phillips head screw (4 used)9. Rate valve spindle section10. Rate control valve housing

11. O�ring12. Cone13. Control valve14. Seal

Figure 27

3

7

4

8

11

12

14

10

13

9

6

5

2

1

1

The rate control motor allows the operator to vary thespray application rate. The pressure increase/decreaseswitch on the spray console energizes the rate controlmotor which adjusts the valve opening and allows someflow to bypass the spray booms.

NOTE: The rate control motor affects flow to all spraybooms. Therefore, a problem with the rate control motorwill affect all booms and nozzles.

Disassembly and Inspection (Fig. 27)


1. To remove the rate control motor:

A. Adjust the rate control to maximum to allow therate control motor spring to relax. This can be donewith either the increase/decrease switch on thespray console or by rotating the hand grip on the mo-tor fully in a clockwise direction.

B. Unplug rate control motor electrical connectorfrom machine electrical harness.

C. Loosen four (4) phillips head screws (item 5)evenly to allow removal of the rate control motor.

D. The inside of motor housing should be free of ex-cessive moisture, corrosion, and dirt.


2. Remove four (4) phillips head screws (item 8) thatsecure spindle section to housing. Remove spindle sec-tion.

3. Locate, remove, and discard o�ring (item 11) andseal (item 14).

4. Remove valve (item 13) and inspect for wear and/ordamage. Replace if needed.

5. If needed, the spindle shaft can be removed by re-moving lock nut that secures cone (item 12) to shaft.

NOTE: Many individual components for the rate controlmotor and spindle section are not available separately.If individual components are worn or damaged, assem-blies must be replaced. Refer to Parts Catalog.

6. If necessary, remove rate control valve housing frommachine (see Spray Control in this section).

Assembly (Fig. 27)


1. If removed, install rate control valve housing to ma-chine (see Spray Control in this section).

2. If spindle shaft was removed, assemble by reversingdisassembly process. Make sure that spindle shaft sup-port aligns with notches in housing during assembly. Se-cure spindle assembly with lock nut.

3. Align control valve with tabs in spindle section andinstall control valve. Rotate spindle to fully retract controlvalve.

4. Install new o�ring (item 11) and seal (item 14) tospindle section.

5. Position spindle section to rate control valve hous-ing. Secure spindle section with four (4) phillips headscrews (item 8).

6. To ease assembly of the motor, rotate spindle shaftso the post is about 1/2� (13 mm) from the spindle sec-tion housing. Align slot in motor with post in spindle andinstall motor.

7. Secure motor to assembly by evenly tightening four(4) phillips head screws (item 5).



Figure 28

1

2

534

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Boom Valve Motor

1. Housing cover2. Cover seal3. Boom valve motor4. Phillips head screw (5 used)5. O�ring6. Lock washer7. Hand grip8. Roller9. Roller pin10. Spindle11. Spring

12. Spring seat13. O�ring14. Spindle housing15. Phillips head screw (4 used)16. O�ring17. O�ring18. Flat washer19. Seat outer o�ring20. Seat21. Seat inner o�ring22. Seat base

23. Flat washer24. Spring25. Flat washer26. Cone27. Screw28. Boom valve manifold housing29. Fork30. O�ring31. Balancing valve32. Roll pin33. Balancing valve knob

Figure 29

9

10

11

12

1314

15

16

1

3

2

4

5

6

7

8

4

17

1819

23

2021

2232 31

2524

26

30

2829

27

33

70 in�lb(8 N�m)

The Workman 200 Sprayer uses three boom valve mo-tor assemblies to control the spray booms. Each boomvalve motor assembly includes a motor section (Fig. 29,Items 1 through 7), a spindle section (Fig. 29, Items 8through 27), and a manifold assembly (Fig. 29, Items 28through 33).

Disassembly and Inspection (Fig. 29)


1. Remove spray control from machine. Separatespray control components to allow boom valve motordisassembly (see Spray Control in this section).

2. To remove the motor and spindle section assemblyfrom the manifold assembly:

A. Remove the fork (item 29) that secures the motorand spindle sections to the manifold assembly.

B. Lift the motor and spindle section assembly fromthe manifold.

3. To allow easier separation of the motor and spindlesections, make sure that boom valve motor is in theclosed position (green indicator is recessed into thespindle housing). Remove four phillips head screws(item 15) and separate spindle section from motor sec-tion.


4. Remove rear housing cover from boom valve motorto inspect motor components.

A. Cam should be tight on shaft. Cam surfaceshould 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 covershould be inspected for excessive wear.

5. Inspect and disassemble spindle section (Fig. 31).

A. Inspect spindle roller surface for wear or scoring.Check that spindle roller rotates freely on roller pin.Replace roller and/or pin as required.

B. The spindle can be disassembled by removingthe screw at the bottom of the spindle shaft. Takenote of washer, spring, seat, and o�ring locations asspindle is removed.

C. Inspect the cone located at the bottom of thespindle. The cone should be free of nicks or wornspots. A damaged cone will allow flow to the boombypass rather than to the spray boom.

D. The seat o�rings allow the spindle to shut off flowto the spray boom. If boom nozzles leak when theboom is shut off, the seat and seat o�rings should beinspected carefully.

6. If leakage occurs from balancing valve knob at bot-tom of boom valve manifold (Fig. 32):

A. Carefully remove roll pin that secures balancingvalve to knob.

B. Remove knob from manifold. Remove and dis-card o�ring.

C. Inspect seating surfaces of manifold and balanc-ing valve. Clean or replace components as needed.

Assembly (Fig. 29)


1. Replace all removed o�rings.

2. If boom valve manifold was disassembled (Fig. 32):

A. Install o�ring, balancing valve, and knob to man-ifold.

B. Secure balancing valve to knob by carefullyinstalling roll pin.



Figure 30

1

2

534

1. Spindle roller2. Cone

3. Seat

Figure 31

1

2

3

1. Boom valve manifold2. Balancing valve

3. Balancing valve knob4. Roll pin

Figure 32

4

3

1

2

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3. Assemble spindle section by reversing disassemblyprocess. Align green indicator tab on spindle to slot inspindle housing. Install screw into bottom of spindle tosecure assembly. Torque screw 70 in�lb (8 N�m).

4. Position spindle section on motor section so thatgreen indicator on spindle section is opposite the motorhand grip. Secure spindle section to motor section withfour phillips head screws (item 15).

5. Replace rear housing to boom valve motor.

6. Position the motor and spindle section assembly tothe manifold assembly. The motor hand grip and boomsupply hosebarb on manifold should be on the sameside of the assembly. Install the fork (item 29) to securethe motor and spindle sections to the manifold.

7. Assemble spray control assembly. Install spray con-trol to machine (see Spray Control in this section).




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Boom Bypass

1. Boom bypass elbow2. O�ring3. Bulkhead fitting

4. Gasket5. Fork6. Bulkhead nut

7. Hosebarb/hose8. Hosebarb/hose

Figure 33

FRONT

RIGHT

A

A

1

2

3

4

5

6

7

8

5

NOTE: ARROW SHOWS FLUIDFLOW DIRECTION



IMPORTANT: Make sure to remove and neutralizechemicals from tank and spray components beforedisassembly. Wear protective clothing, chemical re-sistant gloves, and eye protection during repair.



3. Disassemble boom bypass using Figures 33 and 34as guides. Discard all removed o�rings and gaskets.

Assembly (Fig. 33)


1. Assemble boom bypass using Figures 33 and 34asguides. Replace all removed o�rings and gaskets.

2. Check spray tank for leaks.

1. Boom bypass elbow 2. Tank suction tube

Figure 34

1

2

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Tank Suction

1. Suction hosebarb2. O�ring3. Screen vane4. Suction screen5. Fork6. Filter housing

7. Expansion pin8. Bulkhead gasket9. Bulkhead nut10. O�ring11. Hosebarb12. Hose clamp

13. Suction hose14. Suction tube15. Suction tube foot16. Spray tank17. Hose clamp18. Suction hose (1 1/2�)

Figure 35

13

8

10

3

1

6

9

7

2

4

5

11

12

14

15

16

17 18

FRONT

RIGHT

NOTE: ARROW SHOWS FLUIDFLOW DIRECTION


NOTE: If suction tube in tank develops an air leak, sprayperformance will diminish when tank level reaches theleak.

Removal (Fig. 35)



2. Remove suction strainer from spray tank (see Oper-ator�s Manual).

3. Raise tank lid and remove strainer basket to gain ac-cess to suction tube inside spray tank (Fig. 36).

4. Remove suction tube assembly from spray tank anddisassemble tube using Figure 35 as a guide. Discardall removed o�rings and gaskets.

Assembly (Fig. 35)


1. Assemble and install suction tube assembly usingFigure 35 as a guide. Replace all removed o�rings andgaskets.


1. Suction strainer2. Tank drain

3. Tank lid

Figure 36

2

1

3

1. Tank suction tube 2. Tank drain

Figure 37

2

1

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Tank Drain

1. Drain handle2. Nut3. O�ring4. Bulkhead

5. Gasket6. Ringnut7. Chain8. Drain assembly

9. Hose clamp10. Drain hose11. Spray tank

Figure 38

3

1

2

4

6

9

7

8

10

11

5

FRONT

RIGHT






3. Raise tank lid and remove strainer basket to gain ac-cess to chain (item 7) that connects drain handle (item1) to plunger in drain assembly (item 8). Disconnectchain from drain handle.

4. If necessary, remove drain handle and bulkhead us-ing Figure 38 as a guide.

5. If necessary, remove drain assembly from tank:

A. Loosen hose clamp and slide drain hose fromdrain assembly hosebarb.

B. Remove fork from drain assembly to allow hose-barb to be removed from drain assembly.

C. Remove bulkhead nut that secures drain assem-bly to spray tank.

D. Lift drain assembly from bottom of tank.

6. Disassemble drain assembly using Figure 40 as aguide.

7. Discard all removed o�rings and gaskets.

Assembly (Fig. 38)


1. Assemble drain tube using Figures 38 and 40 asguides. Replace all removed o�rings and gaskets.

2. Hosebarb of drain assembly should be orientated to-ward the rear of the spray tank. Make sure that clear-ance exists between drain assembly and sprayer frame.


1. Tank drain2. Suction strainer

3. Tank lid

Figure 39

1

2

3

1. Adapter2. Plunger holder3. Spring4. Drain plunger5. O�ring6. Drain seat7. O�ring

8. Drain bulkhead9. Fork10. Gasket11. Bulkhead nut12. O�ring13. Hosebarb

Figure 40

9

7

8

10

3

1

2

4

6

5

11

12

13

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Turret Bodies

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 clamp9. Hose barb (for 90o elbow)

Figure 41

7

2

8 3

9

45

RIGHT

6

1

BOOMSUPPLY

CENTERBOOM

SUPPLYLEFT

BOOMSUPPLY

54445

5 4 4

4

41

3

3

Removal (Fig. 41)



2. Loosen hose clamp(s) and remove supply hose(s)from turret body.

3. Remove screw that secures turret body clamp tospray boom. Separate clamp halves and remove turretbody from machine.


NOTE: The type of hose barb on turret body deter-mines turret location on spray boom. Refer to Figure 41for turret position on booms.

1. Position turret body clamp halves to spray boom andturret body. Slide clamp halves together. Position turretso that spray nozzle and nozzle fan slot are parallel toground. Tighten clamp screw to secure turret body.

2. Install supply hose(s) to turret body. Tighten hoseclamp(s).


Turret Body Service


1. Pull e�clip from body and slide plug with o�ring frombody.

2. Disassemble turret body using Figure 42 as a guide.

3. Discard all removed seals, gaskets, o�rings, and di-aphragms.

Assembly (Fig. 42)


1. Replace all removed seals, gaskets, o�rings, and di-aphragms.

2. Assemble turret body using Figure 42 as a guide.

A. The turret (item 8) end with slightly larger boreand detent grooves needs to be orientated towarddetent posts on body (item 4) (Fig. 43).

B. Make sure to align notch on plug (item 10) withgroove in body (item 4) as plug is installed.

C. Install e�clip (item 5) into body to secure assem-bly.

1. Upper clamp2. O�ring3. Pivot pin4. Body5. E�clip6. Gasket (3 used)7. Dust cap (2 used)8. Turret9. O�ring

10. Plug11. Nozzle12. Nozzle cap13. O�ring14. Seal15. Screw16. End cap17. Diaphragm18. Hose barb

Figure 42

2

1

3 6

4

5

11

10

12

1413

15

8

7

9

17

16

18

6

1. Body2. Detent post

3. Detent groove

Figure 43

2

13

2

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Boom Frame Breakaway Pivot Assembly (Machines with Serial Numbers Below260000000)

1. Hinge2. Breakaway pivot3. Spring4. Washer5. Roll pin6. Hex nut7. Support bracket

8. Carriage screw9. Flat washer10. Cotter pin11. Clevis pin12. Clevis pin13. Main boom frame14. Breakaway pivot assembly

15. Cap screw16. Boom support17. Boom extension pipe18. Lock nut (4 used per side)19. Flat washer (4 used per side)20. Cap screw (4 used per side)

Figure 44

1

2

3

47

6

8

5

9

11 12

10

10

1314

11

12

1516

6

17

18

19

20



1. Park machine on a level surface, lower booms, stopengine, engage parking brake, and remove key from theignition switch.

2. Support boom to prevent it from falling. Remove capscrew and hex nut that secure boom support to break-away assembly.

3. Remove hex nut, flat washer, and carriage screwthat secure support bracket to breakaway pivot. Slidesupport bracket from breakaway assembly.

CAUTION

Spring in breakaway pivot is under tension. Toprevent possible personal injury, compressspring before removing roll pin. Wear eyeprotection when removing roll pin.

4. Compress spring in breakaway assembly slightly.Drive roll pin from hinge (Fig. 46). Remove flat washerand spring from assembly.

5. Complete disassembly as required using Figures 44and 45 as guides.

Assembly (Fig. 44)

1. Assemble breakaway pivot using Figures 44 and 45as guides.

2. Lubricate grease fitting on breakaway pivot after as-sembly is complete (see Operator�s Manual).

1. Breakaway pivot2. Support bracket

3. Boom support4. Boom extension pipe

Figure 45

1

2

3

4

1. Roll pin 2. Spring

Figure 46

1

2

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Boom Hinge (Machines with 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. Tee fitting7. Flange hd screw (4 used per hinge)

8. Lock nut9. Cap screw10. Flat washer11. Pivot bracket12. Bushing (2 used per pivot bracket)13. Flange head screw14. Pivot pin

15. Flange nut16. Boom frame17. Tube (2 used per boom)18. Spring retainer (2 used per boom)19. Breakaway spring (2 used per boom)20. Grease fitting (2 used per hinge)

Figure 47

5

41

9

10

2

3

7

8

6

11

12

1516

13

14 17

18

19

FRONT

RIGHT

8

9

10

20



1. Park machine on a level surface, lower spray booms,stop engine, engage parking brake and remove keyfrom the ignition switch.

2. Loosen hose clamp and remove supply hose fromtee fitting (item 6) on spray boom.

3. Support spray boom to prevent it from falling.

4. Loosen two (2) cap screws (item 9) and lock nuts(item 8) to allow breakaway springs (item 18) to fully ex-tend.

5. Complete disassembly as required using Figure 47as a guide. If pivot bracket (item 11) is to be removedfrom machine, disconnect boom actuator (not shown)from pivot bracket (see Boom Actuator Removal (Ma-chines with Serial Numbers Above 260000000) in thissection).

6. Clean all removed components. If pivot bracket wasremoved, inspect bushings and pivot pin for damage orwear.


Assembly (Fig. 47)

1. If pivot bracket (item 11) was removed from machine,lightly lubricate bushings (item 12) with motor oil beforeassembly. Connect boom actuator (not shown) to pivotbracket (see Boom Actuator Installation (Machines withSerial Numbers Above 260000000) in this section).

2. Make sure that hinges (item 1) are securely fastenedto pivot bracket (item 11) and boom (item 5). The boomhinge uses four (4) backing plates between the boomand flange nuts.

3. Position boom hinge to pivot bracket hinge. Makesure that rubber boots (item 2) are placed at hinge junc-tions and that rib on boots are toward the top of the boom(Fig. 48).

4. Insert two (2) cap screws (item 9) through flat wash-ers (item 10) and hinges. Place tube (item 17), break-away spring (item 19), spring retainer (item 18) and locknut (item 8) on each cap screw. Make sure that shoulderon spring retainer fits into breakaway spring.

5. Tighten lock nuts so there is 1.560� (39.6 mm) be-tween the face of the spring retainer and the hinge cast-ing (Fig. 49).

6. Connect supply hose to tee fitting on spray boom andsecure with hose clamp.

7. Lubricate grease fittings on boom hinge (see Opera-tor�s Manual).

1. Rubber boot 2. Rib

Figure 48

1

2

UP

Figure 49

1.560�(39.6 mm)

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Boom Actuator (Optional) (Machines with Serial Numbers Below 260000000)

1. Cotter pin2. Clevis pin

3. Boom actuator4. Wire harness

5. Adjustable clevis

Figure 50

2

3

1

41

23

FRONT

RIGHT

5

5

Removal (Fig. 50)

1. Park machine on a level surface, lower booms, stopengine, engage parking brake, and remove key from theignition switch.

2. Label actuator electrical leads to ease reassembly.Unplug boom actuator connector wires from machineharness.

3. Support boom to prevent it from falling. Remove cot-ter pins and clevis pins that attach boom actuator to cen-ter and side boom.

4. Pull boom actuator from machine.


1. Position boom actuator to clevis attachment pointson center and side booms.

2. Install clevis pins and cotter pins to secure actuatorto boom assembly.

3. Plug actuator connector wires into machine harness.Make sure that operator switches engage correct actua-tor.

A. Left side actuator connector has orange and bluewires.

B. Right side actuator connector has yellow andgreen wires.


Adjustment

1. Loosen end nut that secures adjustable clevis toboom frame (Fig. 51). Position jam nut as close as pos-sible to adjustable clevis. Tighten end nut to secure cle-vis.

2. Fully raise side boom with the boom actuator. Theboom actuator should fully extend and ratchet.

3. With the boom actuator at full extension, the break-away pivot gusset should just touch the center boomframe slot (Fig. 52).

4. If needed, loosen end nut that secures adjustableclevis and readjust jam nut on clevis to allow correctboom actuator extension. Tighten end nut to secure cle-vis adjustment.

1. Boom actuator2. Adjustable clevis

3. Jam nut4. End nut

Figure 51

432

1

1. Breakaway pivot gusset2. Boom frame slot

3. Boom actuator

Figure 52

32

1

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Boom Actuator Service (Machines with Serial Numbers Below 260000000)

1. Screw2. Rear housing3. Washer4. Woodruff key5. Clutch6. Thin washer7. Intermediate gear

8. Thick washer9. Hex nut (2 used)10. Motor gear11. Housing gasket12. Front housing13. Cover tube gasket14. Motor seal

15. Motor assembly16. Ball screw and brake assembly17. Washer head screw (4 used)18. Cover tube19. O�ring20. O�ring

Figure 53

5

41

9 10

2

3

6

7

8

14

17

11

12

13

1815 16

19

20

3

70 in�lb(7.9 N�m)

70 in�lb(7.9 N�m)

20 in�lb(2.3 N�m)



1. Remove four (4) washer head screws that securecover tube. Remove one (1) screw (item 1) that retainsrear housing. Slide rear housing and housing gasketfrom assembly.

2. Slide thin washer, intermediate gear, and thick wash-er from front housing support pin.

3. In order, remove washer, clutch, woodruff key, andsecond washer from ball screw shaft.

4. Pull cover tube from front housing. Remove covertube gasket.

5. Loosen and remove two (2) hex nuts that secure mo-tor to front housing. Slide motor, motor gear, and motorseal from front housing.

6. Remove ball screw and brake assembly from fronthousing.

7. Clean actuator components. Replace worn or dam-aged parts.

8. Discard and replace all removed gaskets and o�rings.

Assembly (Fig. 53)

1. Position ball screw and brake assembly to fronthousing. Take care to not disturb brake components.

2. Slide motor, motor gear, and motor seal to fronthousing. Secure motor with two (2) hex nuts. Torquenuts to 70 in�lb (7.9 N�m).

3. Install new o�rings into rear of cover tube. Slide cov-er tube gasket and cover tube over ball screw.

4. Place washer on ball screw shaft. Position woodruffkey and then slide clutch and second washer onto shaft.

5. Place thick washer, intermediate gear, and thinwasher onto front housing support pin. Make sure thatintermediate gear engages both motor gear and clutch.

6. Position housing gasket to front housing. Slide rearhousing over gears.

7. Secure rear housing:

A. Thread one (1) screw (item 1) through rear hous-ing and into front housing.

B. Install four (4) washer head screws through covertube.

C. Torque screw (item 1) to 20 in�lb (2.3 N�m).Torque four washer head screws to 70 in�lb (7.9N�m).

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Boom Actuator (Machines with Serial Numbers Above 260000000)

1. Boom actuator (2 used)2. Carriage screw (4 used)3. Boom frame4. Washer 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 bracket11. Clevis pin (2 used)12. Cotter pin (2 used)

Figure 54

5

4

1

910

2

3

7

8

6

11

12


Removal (Fig. 54)

1. Park machine on a level surface, place spray boomsin the transport (raised) position, stop engine, engageparking 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 toclevis strap (item 9) on boom frame.

4. Remove cotter pin (item 11) from clevis pin (item 12).Support boom actuator and slide clevis pin from boompivot bracket. Remove actuator from machine.


1. Position boom actuator to boom frame and boompivot bracket.

2. Secure actuator to boom pivot bracket with clevis pinand cotter pin.

3. Secure actuator to clevis strap on boom frame withpivot pin.

4. Connect boom actuator to machine wire harness.

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Boom Actuator Service (Machines with Serial Numbers Above 260000000)

IMPORTANT: Do not dismantle, repair or modify theboom actuator. Internal components are not avail-able for the actuator. If an actuator is damaged orworn, replace actuator.

CAUTIONDuring and after operation, the actuator may bevery hot. To avoid possible burns, allow the ac-tuator to cool before working on it.

Actuator Circuit Protection

Each boom actuator is protected internally by a thermalcircuit breaker. In case of actuator overheating, the ther-mal breaker will trip, causing the actuator to cease func-tioning. Once the actuator cools to appropriateoperating temperature, the actuator thermal breaker willreset to allow actuator operation to resume.

A separate 30 amp thermal breaker also protects eachboom actuator circuit. These thermal breakers are lo-cated at the machine fuse panel and will prevent circuitoperation if overloaded. The thermal breakers reset au-tomatically.

Actuator Freeplay Inspection

Over time, actuator operation may be affected by aircaptured in the reservoir oil. An excessive amount of airin the actuator oil will allow excessive actuator freeplay.Excessive freeplay will allow spray boom bouncingwhen driving over severe terrain.

Measure actuator freeplay using the following proce-dure:

1. Move the vehicle to an open area and lower the spraybooms to the spray position.

2. Lift up on the boom at the last triangular gusset witha 25 pound (11.4 kg) force. Support boom in that posi-tion.

3. Using a non�permanent felt tipped marker, mark thecylinder rod at the outside of the cylinder seal.

4. Release the spray boom and allow it to return to thespray (fully lowered) position.

5. Determine the actuator freeplay by measuring thedistance from the mark on the cylinder rod to the cylinderseal. The freeplay should be less than 0.100� (2.5 mm).If excessive freeplay is found, bleed air from actuator.

Actuator Air Bleeding

If actuator freeplay is excessive, air bleeding of the ac-tuator should be performed using the following proce-dure:

1. Thoroughly clean the exterior of the actuator to pre-vent contaminates from entering the actuator.

2. Make sure that the actuator cylinder is fully retracted.

IMPORTANT: To prevent actuator damage, use visewith protective jaws when clamping actuator.

3. Place the actuator in a vise making sure that actuatoris clamped in the area identified in Figure 55. Use justenough clamping force to hold the housing securely.Make sure that the reservoir plug is orientated up.

CAUTIONThe actuator reservoir is pressurized. If the res-ervoir plug is removed too quickly, oil underpressure can be ejected from the actuator.

4. Slowly loosen and remove the reservoir plug at thetop of the reservoir.

5. Using a light through the plug hole, confirm that thereservoir oil is clear. If the oil appears milky, air is en-trained in the reservoir oil. Keep the actuator verticalwith the plug removed for approximately 15 minutes toallow the air to separate from the oil.

6. When oil appears clear, use a 12 volt DC power sup-ply to power the actuator and extend the cylinder com-pletely.

IMPORTANT: To ensure proper reservoir pressure,make sure that cylinder is extended before instal-ling reservoir plug.

7. Install the reservoir plug and torque from 45 to 60 in�lb (5.1 to 6.8 N�m).

8. If reservoir oil was milky, use power supply to con-tract and extend the actuator cylinder 3 times. Repeatsteps 2 through 7 until oil is clear.

9. When actuator oil is clear and plug has beeninstalled, use power supply to fully contract the actuatorcylinder. Remove actuator from vise and install on ma-chine.


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 bechecked and adjusted.

1. Thoroughly clean the exterior of the actuator to pre-vent contaminates from entering the actuator.

2. Make sure that the actuator cylinder is fully retracted.

IMPORTANT: To prevent actuator damage, use visewith protective jaws when clamping actuator.

3. Place the actuator in a vise making sure that actuatoris clamped in the area identified in Figure 55. Use justenough clamping force to hold the housing securely.Make sure that the reservoir plug is orientated up.

CAUTIONThe actuator reservoir is pressurized. If the res-ervoir plug is removed too quickly, oil underpressure can be ejected from the actuator.

4. Slowly loosen and remove the reservoir plug at thetop of the reservoir.

5. Using a light through the plug hole, confirm that thereservoir oil is clear. If the oil appears milky, perform ac-tuator air bleeding procedure.

6. Use a clean rod to identify the level of oil in reservoir.Distance from plug fitting to oil level should be .984� (25mm). If necessary, add ISO VG 32 mineral oil to actuatorreservoir to adjust oil level.

7. When oil level is correct, use a 12 volt DC power sup-ply to power the actuator and extend the cylinder com-pletely.

IMPORTANT: To ensure proper reservoir pressure,make sure that cylinder is extended before instal-ling reservoir plug.

8. Install the reservoir plug and torque from 45 to 60 in�lb (5.1 to 6.8 N�m).

Actuator Disposal

If actuator disposal is necessary, remove hydraulic oilfrom actuator before disposal.

1. Open actuator reservoir (see Steps 1 through 4 inActuator Air Bleeding).

2. Drain oil from actuator.

Figure 55

CYLINDER

VISE

MOTOR

CLAMPING

RESERVOIR

ELECTRIC

PLUG UP

DOWN

RESERVOIR

AREA

Figure 56

0.984�(25 mm)

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Rev. AWorkman 200 Spray System Electrical DiagramsPage 4 � 1

Chapter 4

Electrical Diagrams

Table of ContentsELECTRICAL SCHEMATIC 3. . . . . . . . . . . . . . . . . . . .

Serial Numbers Below 260000000 3. . . . . . . . . . . . . Serial Numbers Above 260000000 4. . . . . . . . . . . . .

WIRE HARNESS DRAWINGS 5. . . . . . . . . . . . . . . . . . Spray System Wire Harness (Serial Numbers

Below 260000000) 5. . . . . . . . . . . . . . . . . . . . . . . . . Spray System Wire Harness (Serial Numbers

Above 260000000) 7. . . . . . . . . . . . . . . . . . . . . . . . . Spray Console Wire Harness (Serial Numbers

Below 260000000) 9. . . . . . . . . . . . . . . . . . . . . . . . . Spray Console Wire Harness (Serial Numbers

Above 260000000) 11. . . . . . . . . . . . . . . . . . . . . . . . . Sprayer Power Harness (Serial Numbers

Below 260000000) 13. . . . . . . . . . . . . . . . . . . . . . . . Sprayer Power Harness (Serial Numbers

Above 260000000) 14. . . . . . . . . . . . . . . . . . . . . . . .

Ele

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Dia

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ms

Workman 200 Spray SystemElectrical Diagrams Page 4 � 2


Page 4 � 3Rev. A

Electrical SchematicWorkman 200 Spray System

7 7 7 8

BK

8 7 8 8 7

BU Y

BK

Y

BK

ABCDEFGHJK

PK/W

PK/W

VIO/W

VIO/R

R/W

GN/W

GN/BK

PK

8

BU/GN

8

BKW/BK

HOLDRELAY

(+) (�)

FOAM

PK/BU

ABC

GY GY/OR

BU/BK

LEFT SPRAYVALVE

BU/W

R/BK

CENTER SPRAYVALVE

R/W

R/BK

7

GN/W

PKBK

BU/R

BU/R BK

OR

R/WH

BK

OR

BOOM LIFTLH SWITCH

GN

R/WH

LH FOAMSOLENOID

BK

BOOM LIFTRH SWITCH

RH FOAMSOLENOID

R/BKBOOM FOAMLH SWITCH

BK

W/BK

1 2

W/BK

6

8

5

7

43

21

FUSE BLOCK 4 WAY

21

21

BOOMLS LIFT FOAM

COMPRESSOR

PK/BK

BU/BK GN/BKBN/W

FLOWMETER

SPEEDSENSOR

GY/BKPK/BK

PK/BU

MONITORVIO/R

SPRAY SYSTEM

BOOM LIFT

BU/BK

BU/W

SPRAY VALVELS BOOM SWITCH

SPRAY VALVECTR. BOOM SWITCH

RIGHT SPRAYVALVE

RATE CONTROLVALVE

GN/BK BN/W

GN/W

SPRAY VALVERT BOOM SWITCH

MASTER BOOMSWITCH

SUPERVISORSWITCH

BU/R

BN/W

SYSTEM PRESSURESWITCH

MONITOR POWERSWITCH

1 21 2

Y/BU

MASTERFOAM

SOLENOID

GNY/BU

BOOM FOAMRH SWITCH

BU/GN

3085

8786

87a

21

5

23

64

1

5

23

64

1

21

5

23

64

1

5

23

64

1

5

23

64

1

BOOMRS LIFT

5

23

64

1

5

23

64

1

5

23

64

1

(OPTIONAL FOOTMASTER BOOM

SWITCH)

5

23

64

1

5

23

64

1

5

23

64

1(OPTIONAL)(OPTIONAL)(OPTIONAL)(OPTIONAL)

BK

BKBK

BK

R

BU

R

R

R

RRR

BK

BKBN

PK

BNPK

R R R

BN

PK

PK

BK

BN

VIO/W

BNBKR/W

R/BK

R

R/BKR/W

R

BK

R/BKGN/W

BU/W

(OPTIONAL)

(OPTIONAL)(OPTIONAL)(OPTIONAL)

(OPTIONAL)(OPTIONAL)

(Serial Numbers Below 260000000)

Page 4 � 4Rev. A

Electrical SchematicWorkman 200 Spray System

(Serial Numbers Above 260000000)

Page 4 � 5Rev. A

Workman 200 Spray SystemSpray System Wire Harness(Serial Numbers Below 260000000)

Page 4 � 6Rev. A

Workman 200 Spray SystemSpray System Wire Harness

BLU

E/R

ED

BLU

E/B

LAC

K

BLU

E/W

HIT

E

OR

AN

GE

/BLA

CK

OR

AN

GE

/WH

ITE

GR

EE

N/W

HIT

E

GR

EE

N/B

LAC

K

GR

AY

OR

AN

GE

GR

EE

N

YE

LLO

W

GR

AY/O

RA

NG

E

BLU

E

GR

AY/B

LAC

K

BR

OW

N/W

HIT

EB

RO

WN

/WH

ITE

GR

EE

N/B

LAC

K

OR

AN

GE

/WH

ITE

BLU

E/B

LAC

K

BLUE/GREEN

WHITE/BLACK

YELLOW/BLUE

BLACK

BLACK

BLACK

BLACK

WHITE/BLACK


Page 4 � 7Rev. A

Workman 200 Spray SystemSpray System Wire Harness(Serial Numbers Above 260000000)

Page 4 � 8Rev. A

Workman 200 Spray SystemSpray System Wire Harness(Serial Numbers Above 260000000)

RE

D

BLU

E/B

LAC

K

YE

LLO

W

OR

AN

GE

/WH

ITE

OR

AN

GE

/BLA

CK

GR

EE

N/B

LAC

K

GR

EE

N/W

HIT

E

BR

OW

N/W

HIT

E

BLU

E/R

ED

VIO

LET

GR

AY

BLU

E

BLU

E

GR

EE

N

RE

D YE

LLO

W

BLU

E

YE

LLO

W

RE

D

GR

EE

N

GR

EE

N

BLU

E

BLACK

BR

OW

N/W

HIT

E

BLACK

YELLOW/BLUE

BLUE/GREEN

BLU

E/W

HIT

E

BLACK

BLACK

GR

EE

N/B

LAC

K

WHITE/BLACK

WHITE/BLACK

BLU

E/B

LAC

K

OR

AN

GE

/WH

ITE

Page 4 � 9Rev. A

Workman 200 Spray SystemSpray Console Wire Harness(Serial Numbers Below 260000000)

Page 4 � 10Rev. A

Workman 200 Spray SystemSpray Console Wire Harness

BLUE/RED

RED

BLACK

RED

RED

BLUE/RED

BROWN

BLACK BLACK

RED

RE

D

PIN

K

BLA

CK

BLU

E/W

HIT

E

BLU

E/W

HIT

E

BLA

CK

BR

OW

N

RE

D

PIN

K

BLA

CK

BLA

CK

BR

OW

N

OR

AN

GE

/BLA

CK

OR

AN

GE

/BLA

CK

RE

D

PIN

K

BLA

CK

BR

OW

N

BLA

CK

GR

EE

N/W

HIT

E

GR

EE

N/W

HIT

E

PIN

K

BR

OW

N

BLA

CK

BR

OW

N/W

HIT

E

BLU

E/R

ED

BLA

CK

BR

OW

N/W

HIT

E

BLU

E

OR

AN

GE

BLA

CK

BLACK

GR

EE

N

RE

D/B

LAC

K

YE

LLO

W

BLA

CK

BLA

CK

RE

D/W

HIT

E

YE

LLO

W/B

LUE

BLA

CK

YE

LLO

W/B

LUE

WHITE/BLACK

RED/WHITE

RED/WHITE

BLUE/GREEN

VIOLET/RED

VIOLET/WHITE

GRAY/ORANGE

GRAY/BLACK

GRAY

PINK/BLUE

PINK/BLACK

PINK/WHITE

BLACK

RED/WHITE

RED/BLACK

BLA

CK

WH

ITE

/BLA

CK

BLU

E/G

RE

EN

BROWN

RED

BLACK

PINK

YE

LLO

W

GR

EE

N

OR

AN

GE

BLU

E

GR

EE

N/W

HIT

E

GR

EE

N/B

LAC

K

OR

AN

GE

/WH

ITE

OR

AN

GE

/BLA

CK

BLU

E/W

HIT

E

BLU

E/B

LAC

K

RED


Page 4 � 11Rev. A

Workman 200 Spray SystemSpray Console Wire Harness(Serial Numbers Above 260000000)

Page 4 � 12Rev. A

Workman 200 Spray SystemSpray Console Wire Harness(Serial Numbers Above 260000000)

BLACK

RED

PIN

K

BLA

CK

BLU

E/W

HIT

E

BR

OW

N

OR

AN

GE

/BLA

CK

OR

AN

GE

/BLA

CK

PIN

K/B

LAC

K

BR

OW

N

BLA

CK

BLU

E/W

HIT

E

PIN

K

PIN

K

BLA

CK

BLA

CK

PIN

K/B

LAC

K

RED

PINK

BLUE/RED

BLUE/RED

BLACK

VIOLET/RED

PINK

BLACK

PINK/BLACK

BROWN

WH

ITE

/BLA

CK

OR

AN

GE

/WH

ITE

OR

AN

GE

/BLA

CK

BLU

E/B

LAC

K

BLU

E/W

HIT

E

GR

EE

N/B

LAC

K

GR

EE

N/W

HIT

E

GRAY

BLACK

GREEN

BLUE

YELLOW

RED

BROWN

VIOLET

BLUE

VIOLET/WHITE

BLACK

BLACK

BLA

CK

OR

AN

GE

BLA

CK

BLA

CK

OR

AN

GE

BLA

CK

BLA

CK

BLA

CK

BLACK

RED

BLACK

ORANGE

RED

RED

ORANGE

YELLOW

GREEN

YELLOW

BLA

CK

BLACK

BLACK

WHITE/BLACK

BLUE/GREEN

BLU

E

RE

D

BLA

CK

OR

AN

GE

YELLOW

YELLOW

YE

LLO

W

YE

LLO

W/B

LUE

YE

LLO

W

TAN

OR

AN

GE

PINK

PINK

BR

OW

N/W

HIT

E

BLU

E/R

ED

BR

OW

N/W

HIT

E

BLA

CK

BR

OW

N

PIN

K/B

LAC

K

BLA

CK

BLA

CK

GR

EE

N/W

HIT

E

GR

EE

N/W

HIT

E

BR

OW

N

PIN

K/B

LAC

K

Page 4 � 13Rev. A

Workman 200 Spray SystemSprayer Power Harness(Serial Numbers Below 260000000)

PINK/BLUE

PINK/BLACK

PINK/WHITE

RED

BLACK

RED/WHITE

RED/BLACK

Page 4 � 14Rev. A

Workman 200 Spray SystemSprayer Power Harness(Serial Numbers Above 260000000)

PINK

BLACK

RED

ORANGE

GREEN

YELLOW

ORANGE

YELLOW

Documents

03124sl.pdf Workman 200 Sprayer (Rev A) Nov, 2005