Form No. 3351-863 Multi-Pro) 1200 Turf Sprayer Model No. 41164—Serial No. 240000401 and Up Operator’s Manual Register your product at www.Toro.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . . Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . Driving the Sprayer . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Improper use or maintenance by the operator or owner can result in injury.
Chemical Safety • Never allow other adults to operate the sprayer without first reading and understanding the Operator’s Manual. Only trained and authorized persons should operate this sprayer. Make sure that all operators are physically and mentally capable of operating the sprayer. Warning Chemicals are hazardous and can injure you, bystanders, animals, plants, soils, or other property. • This sprayer is designed to carry only you, the operator. Never carry any passengers on the sprayer.
– The electrical and exhaust systems of the sprayer can produce sparks capable of igniting explosive materials. Never operate the sprayer in or near an area where there is dust or fumes in the air which are explosive. – Fill the fuel tank outdoors, and fill it to about 1 inch (25 mm) below the top of the tank (the bottom of the filler neck). Do not overfill it. – Wipe up any spilled gasoline. – If you are ever unsure about safe operation, stop work and ask your supervisor.
• Be aware that heavy loads increase your stopping distance and reduce your ability to turn quickly without tipping over. • Never drive across a steep hill; always drive straight up or down or go around the hill. • If the engine stalls or you begin to lose headway while climbing a hill, gradually apply the brakes and slowly back straight down the hill. Maintenance • Turning while traveling up or down hills can be dangerous. If you have to turn while on a hill, do it slowly and cautiously.
Sound Pressure Vibration This unit has a maximum sound pressure level at the operator’s ear of 82 dBA, based on measurements of identical machines per Directive 98/37/EC. This unit does not exceed a hand/arm vibration level of 2.5 m/s2, based on measurements of identical machines per Directive 98/37/EC. This unit does not exceed a whole body vibration level of 0.5 m/s2, based on measurements of identical machines per Directive 98/37/EC.
100-8882 1. Spray on 2. Spray off 3. Spray pressure 4. Increase 5. Decrease 100-8386 1. Fuel 2. Empty 3. Half-full 4. Full 100-8470 1. 2. 3. 4. Engine—stop Engine—run Engine—start Headlights 5. Neutral engine speed control 6. Engage 7. On 8. Off 100-8621 1. Warning—read the Operator’s Manual. 2. Tipping Hazard—drive slowly over rough terrain and when turning. 3.
104-8939 1. Engine oil level (dipstick) 2. Engine oil filter 3. Transaxle/hydraulic fluid level (dipstick) 4. Transaxle hydraulic filter 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hydraulic strainer Gear box fluid level Brake fluid Belts, steering and drive Fuel, unleaded only Fuel filter Battery Air cleaner Grease Tire pressure 15. Read the instructions before servicing or performing maintenance. 16. Pump 106-5016 1. Warning—read the Operator’s Manual. 2.
6-5050 1. Warning—read the Operator’s Manual; use fresh, clean water for rinsing the tank. 104-8990 1. LCD screen 2. Selection dial 3. Reset 4. Calibrate 5. Decrease 6. Increase 106-5051 1. Warning—read the Operator’s Manual; use fresh, clean water for first-aid washing. 108-3306 106-5065 1. On 2. Tank drain 3.
Specifications Note: Specifications and design are subject to change without notice. 108-3308 1. 2. 3. 4. 5. Speed Calibration distance Speed calibration Units of measure Select units 6. 7. 8. 9.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify that all parts have been shipped. Description Qty.
Installing the Anti-siphon Fill Receptacle 1 4 1. Place the fill receptacle bracket over the threaded hole in the tank and secure it with a flange-head bolt (5/16 x 3/4 inch) (Fig. 2). 4 2 7 4 1 3 6 3 5 Figure 3 1. Spray Pro monitor 2. Bracket 2 3. Flange-head bolts, 1/4 x 3/4 inch 4. Knob m-7368 2. Loosely install the 2 carriage bolts, rubber washers, and knobs on the bracket as shown in Figure 3 and 4. Figure 2 1. Fill receptacle bracket 2. Threaded hole in the tank 3.
Before Operating Adding Fuel Checking the Engine Oil Danger The engine is shipped with oil in the crankcase; however, the level of oil must be checked before you first start the engine and after you have run it. In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 1. Position the machine on a level surface. 2. Remove the dipstick and wipe it with a clean rag (Fig. 5).
Checking the Brake Fluid Note: The fuel tank cap contains a gauge which shows the fuel level; check it frequently. The brake fluid reservoir is shipped from the factory filled with DOT 3 brake fluid. Check the level before starting the engine each day. 1. Shut the engine off and set the parking brake. 2. Clean the area around the fuel tank cap (Fig. 6). 1 1 Figure 7 1. Brake fluid reservoir Figure 6 1.
Checking the Transaxle/Hydraulic Fluid Filling the Fresh Water Tank The sprayer is equipped with a fresh water tank (Fig. 10) for you to wash chemicals off of your skin, eyes, or other surfaces in the case of accidental exposure. Always fill the fresh water tank with clean water before handling or mixing any chemicals. 1. Position the sprayer on a level surface, set the parking brake, stop the pump, stop the engine, and remove the ignition key. 2.
Operation Brake Pedal Use the brake pedal to stop or slow the sprayer (Fig. 11). Note: Determine the left and right sides of the machine from the normal operating position. Caution Think Safety First Brakes can become worn or can be misadjusted resulting in personal injury. Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you or bystanders avoid injury. If brake pedal travels to within 1 inch (2.
Range Selector Headlight Switch The range selector, located to the left of the seat, has 5 positions: 3 forward speeds, Neutral, and Reverse (Fig. 13). The engine will start only when the range selector is in the Neutral position. You must also fully press the brake with the sprayer stopped to change gears. Toggle the switch to operate the headlights (Fig. 13). Push it forward to turn the lights on and rearward to turn them off.
New Sprayer Break-In If any of the above items are not correct, notify your mechanic or check with your supervisor before taking the sprayer out for the day. Your supervisor may want you to check other items on a daily basis, so ask what your responsibilities are. To provide proper performance and long sprayer life, follow these guidelines for the first 100 operating hours: • Check the fluid and engine oil levels regularly and be alert for indications of overheating in any component of the sprayer.
Boom Levers Warning The boom levers are located at the rear of the control panel to the right of the seat (Fig. 16). Push each lever down to turn the corresponding boom section on and up to turn them off. These levers will only affect the spray system when the master spray lever is on. Towing at excessive speeds could cause a loss of steering control, resulting in personal injury. Never tow the sprayer faster than 5 mph (8 kph). Pump Switch Towing the sprayer is a two person job.
Flowmeter Pressure Gauge The flowmeter measures the flow rate of the fluid for use by the Spray Prot system (Fig. 17). The pressure gauge is located to the right of the tank (Fig. 18). This gauge shows the pressure of the fluid in the system in psi and kPa. Boom Valves Pump These valves turn the three booms on or off (Fig. 17). The pump is located near the front of the tank on the right side (Fig. 19).
Tank Cover 1 The tank cover is located in the center of the top of the tank (Fig. 21). To open it, turn off the engine, then turn the front half of the cover to the left and swing it open. You can remove the strainer inside for cleaning. To seal the tank, close the cover and rotate the front half toward the right. 1 2 3 2 Figure 22 1. Filler cap 2. Fresh water tank 3. Spigot Figure 21 1. Tank cover 2.
Spray Prot Monitor The Spray Pro monitor displays and monitors various system performance data such as vehicle speed and application rates. It does not control the application rate. The monitor has an LCD screen that displays the data you select, a selection dial, and 4 buttons for calibrating the monitor (Fig. 24). 11 11 16 US English 16 CE Symbol m–XXXX Figure 24 1. 2. 3. 4. LCD screen Selection dial Reset, calibration button Calibrate, calibration button 5. 6. 7. 8.
• Width 5. Use the Increase or Decrease calibration buttons to change the boom width as needed. Sets and displays the boom width. The default setting is 220 inches (460 cm). This is based on 4 nozzles on the right and left booms and 3 on the center boom all spaced 20 inches (50.8 cm) apart. 6. Press Calibrate button until the red light turns off. You can also exit calibration mode by driving the sprayer.
6. Press and hold the Reset calibration button until the display reads “0.” 9. Turn the selection dial to the Calibration Distance position. 7. Set the master spray lever to the On position and run the booms until all the water is out of the tank, then stop them using the master spray lever. 10. Press and hold the Reset calibration button until the display reads “0.” 11.
4. Set the dial on the Spray Pro monitor to Application Rate. night and then spray in the morning. This would lead to separation of the chemicals and possible damage to the sprayer components. 5. Place the range selector in the Neutral position. 6. Press the accelerator to the floor and set the neutral engine speed control switch to the On position. Caution 7. Set the pump switch to the On position to start the pump. Chemicals are hazardous and can cause personal injury. 8.
Cleaning the Sprayer 9. Add the remaining water to the tank. Important You must always empty and clean the sprayer immediately after each use. Failure to do so may cause the chemicals to dry or thicken in the lines, clogging the pump and other components. Applying Chemicals Important In order to ensure that your solution remains well mixed, use the agitation feature whenever you have solution in the tank. For agitation to work, the pump must be on and the engine must be running above an idle.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Important Refer to your engine operator’s manual for additional maintenance procedures. Maintenance Service Interval After first 8 hours Maintenance Procedure • • • • Torque the wheel lug nuts. Replace the hydraulic filter. Check the drive belt tension. Check the steering pump belt. 8 hours • Check the engine oil. • Check the tire pressure.
Maintenance Service Interval Maintenance Procedure • • • • 400 hours or yearly • • • • • 800 hours or yearly Change the pump drive gearbox fluid. Clean and lubricate the primary drive clutch Inspect the fuel lines. Have an Authorized Toro Service Distributor check the diaphragms and check valves in the pump and replace them if necessary. Complete all yearly maintenance procedures specified in the engine operator’s manual. Inspect the pump diaphragm and replace it if necessary.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check the brake and parking brake operation. Check the gear shift/neutral operation. Check the fuel level. Check the engine oil level. Check the transaxle oil level. Inspect the air filter. Inspect the engine cooling fins. Check any unusual engine noises. Check any unusual operating noises. Check the tire pressure. Check for fluid leaks. Check the instrument operation.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark plug(s).
Removing the Foam and Paper Elements 2 1. Set the parking brake, stop the pump, stop the engine, and remove the ignition key. 1 2. Release the latch on the back of the seat and lift the seat forward. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage (Fig. 28). m–3247 Figure 29 1. Foam element 2 2. Oil 5. Squeeze the element to distribute the oil.
4. Install the air cleaner cover and knob (Fig. 28). 5. Close and latch the seat. 1 Servicing the Engine Oil Change the engine oil and oil filter after every 100 operating hours. Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity: w/filter, 2.1 qts. (2.0 l) Viscosity: Refer to the following table. Figure 31 USE THESE SAE VISCOSITY OILS 1. Oil drain plug 6. When the oil has drained completely, replace the drain plug and torque it to 10 ft-lb (13.6 N⋅m). 7.
Changing the Engine Oil Filter Greasing the Sprayer 1. Drain the oil from the engine; refer to Changing Oil, page 33, steps 1 through 7. Lubricate all bearings and bushings after every 100 hours or once a year, whichever occurs first. 2. Remove the old filter (Fig. 33). Grease Type: No. 2 General Purpose Lithium Base Grease 1. Wipe the grease fitting clean so that foreign matter cannot be forced into the bearing or bushing. 1 2. Pump grease into the bearing or bushing. 3. Wipe off excess grease.
Figure 38 Figure 36 Three on each side Figure 37 Five on each side Figure 39 Figure 40 35
Greasing the Boom Pivot Arms Replacing the Fuel Filter The boom pivot arms are not greased at the time of factory assembly and must be greased before use. Replace the fuel filter after every 100 operating hours. Grease Type: No. 2 general-purpose lithium base grease. 1. Set the parking brake, stop the pump, stop the engine, and remove the ignition key. 1. Manually place grease on the support shaft and within the ball seat of the hinge plate as shown in Figure 41. 2.
Changing Transaxle/Hydraulic Fluid 8. Install the strainer. Change Transaxle hydraulic fluid, filter and clean strainer every 800 hours. 10. Install and tighten the drain plug. 9. Install the hydraulic hose and 90_ fitting to the strainer. 11. Fill the reservoir with approximately 7.5 qt. of Dexron IIl ATF. 1. Position the sprayer on a level surface, set the parking brake, stop the pump, stop the engine, and remove the ignition key. Important Use only the hydraulic fluids specified.
Changing the Pump Drive Gearbox Fluid • Inspect the backing plate and other components for signs of excessive wear or deformation. If any deformation is found, replace the appropriate components. Change the pump drive gearbox after the first 50 hours and then after every 400 hours thereafter. Adjusting the Parking Brake 1. Position the sprayer on a level surface, set the parking brake, stop the pump, stop the engine, and remove the ignition key. Check the parking brake adjustment every 200 hours. 1.
4. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Fig. 48). A fixture or alignment gauge is needed for the rear measurement of the front tires at axle height. Use the same fixture or alignment gauge to accurately measure the front of the front tires at axle height (Fig. 48). 8. Ensure that there is full travel of the steering wheel in both directions.
Adjusting the Steering Pump Belt Danger A sprayer on a jack may be unstable and slip off of the jack, injuring anyone beneath it. Check the tension of the steering pump belt after the first day of operation and every 100 operating hours thereafter. The belt should flex 1/4 inch (5 mm) when 5 lb of force (22 N) is applied midway on the top span. • Do not start the engine while the sprayer is on a jack. • Always remove the key from the ignition before getting off of the sprayer.
5. Remove the spark plugs and metal washers. Caution 2 The dust in the clutch will become airborne and could damage your eyes or you could inhale it causing breathing difficulties. Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure. 1 6. Lubricate the moving parts in the areas circled in Figure 54 using Toro Dry Lubricant Spray, available through your Authorized Toro Dealer or Distributor. m–3246 Figure 55 1. Spark plug wire 2.
3. Push the wires onto the spark plugs (Fig. 55). Important 4. Close and latch the seat. Do not jump start the sprayer. Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Replacing the Fuses There are 2 fuses and 2 empty slots in the electrical system.
Warning Danger Battery terminals or metal tools could short against metal sprayer components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte or allow it to contact your skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.
Storing the Battery If the machine will be stored for more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if it is stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent the battery from freezing, make sure it is fully charged. 1 3 2 Cleaning the Suction Strainer Clean the suction strainer daily.
6. Loosen the jam nut and rotate the adjustment nut to bring the ball support into contact with the 12-gauge sheet stock shim and the cutout on the center boom. 4. Release the knob allowing the hook to catch the boom extension frame and secure it to the boom holder. 5. Repeat steps 1 through 4 with the right boom extension and left boom holder. 7. Tighten the jam nut. 8. Remove the sheet stock shim. Adjusting the Extension Booms 9. Move the boom throughout its length of travel.
Storage Important Do not store stabilizer/conditioned gasoline over 90 days. 11. Remove the spark plugs and check their condition; refer to Changing Spark Plugs, page 41. 1. Position the sprayer on a level surface, set the parking brake, stop the pump, stop the engine, and remove the ignition key. 12. With the spark plugs removed from the engine, pour two tablespoons of engine oil into the spark plug hole. 2.
Troubleshooting Troubleshooting the Engine and Vehicle Problem The starter does not crank. g The engine cranks, but will not start. The engine g starts, but does not k keep running i Possible Causes Corrective Action 1. The range selector is in a gear other than Neutral. 1. Press the brake pedal and move the range selector to the Neutral position. 2. The electrical connections are corroded or loose. 2. Check the electrical connections for good contact. 3. A fuse is blown or loose. 3.
Problem Possible Causes Corrective Action 1. Dirt, water, or stale fuel is in the fuel system. 1. Drain and flush the fuel system; add fresh fuel. 2. A spark plug lead is loose. 2. Reconnect the spark plug lead. 3. A spark plug is broken. 3. Replace the spark plug. 4. Loose wires or poor connections. 4. Check and tighten wire connections. 5. Engine overheating. 5. See Engine Overheats. 1. The fuel tank vent is restricted. 1. Replace the fuel cap. 2.
Problem The engine loses power. The sprayer will not operate in either direction. Possible Causes Corrective Action 1. The crankcase oil level is incorrect. 1. Fill or drain to the full mark. 2. The air cleaner element is dirty. 2. Clean or replace. 3. Dirt, water, or stale fuel is in the fuel system. 3. Drain and flush the fuel system; add fresh fuel. 4. The engine is overheated. 4. See Engine Overheats. 5. A spark plug is damaged or dirty. 5. Replace the spark plug. 6.
Problem A pressure drop occurs when you turn on a boom. Possible Causes Corrective Action 1. The boom bypass valve is improperly adjusted. 1. Adjust the boom bypass valve. 2. There is an obstruction in the boom valve body. 2. Remove the inlet and outlet connections to the boom valve and remove any obstructions. 3. A nozzle filter is clogged. 3. Remove and clean all nozzles. Troubleshooting the Spray Pro Monitor Problem The monitor does not function. Possible Causes Corrective Action 1.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
