Service Manual

ManualsBrandsToro ManualsSprayersMulti-Pro 1200 Turf Sprayer

(Serial Number Below 290999999)

PART NO. 03112SL (Rev. C)

Service Manual

Multi Pro

1200/1250

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing,

and repair of major systems and components on the

Multi Pro 1200 and Multi Pro 1250 sprayers with a serial

number below 290999999.

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE, AND ADJUSTMENT

INSTRUCTIONS. Space is provided in Chapter 2 of this

book to insert the Operator’s Manual and Parts Catalog

for your machine. Replacement Operator’s Manuals

and Parts Catalogs are available on the internet at

www.Toro.com.

The ToroCompany reservesthe right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing, or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im -

portant instructions which mustbefollowed to pre-

vent damage to systems or components on the

machine.

E The Toro Company -- 2003, 2005, 2007, 2011

Summary of content (302 pages)

PAGE 1
PART NO. 03112SL (Rev. C) Service Manual (Serial Number Below 290999999) Multi ProR 1200/1250 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Multi Pro 1200 and Multi Pro 1250 sprayers with a serial number below 290999999. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS.
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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Spray System Operation . . . . . . . . . . . . . . . . . . . . Spray System Flow Diagrams . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 -- Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . .
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General Information . . . . . . . . . . . . . . . . . . . . . . 8.1 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 -- 3 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 8.1 -- 4 Sonic Boom System Operation . . . . . . . . . . . . . 8.1 -- 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 -- 16 Service and Repairs . . . . . . . . . . . . . . . . . . . . . 8.1 -- 22 Chapter 9 -- Electrical Diagrams Electrical Schematics . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Multi Pro 1200/1250 2 2 2 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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Safety Instructions The Multi Pro 1200 and Multi Pro 1250 Turf Sprayers are designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
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1. Before servicing or making adjustments, turn spray pump off, put range selector in neutral, stop engine, set parking brake, and remove key from the switch. 2. Prior to servicing sprayer components, determine what chemical(s) have been used in the sprayer. Follow precautions and recommendations printed on chemical container labels or Material Safety Data Sheets when servicing sprayer components. Use appropriate protective equipment: protective clothing, chemical resistant gloves, and eye protection. 3.
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Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or solid wood blocks to support the raised machine.
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Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series Fasteners) . . . . .
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Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
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Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series Fasteners) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 170 + 20 23 +
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Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m M12 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
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Maintenance Multi Pro 1200/1250 Page 2 – 7 Product Records and Maintenance Maintenance procedures and recommended service intervals for the Multi Pro 1200 and Multi Pro 1250 are covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Several maintenance procedures have break–in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
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Chapter 3 Kohler Gasoline Engine 1 2 3 3 4 5 5 6 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine Mounting Plate Assembly . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Installation .
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Specifications Item Description Make / Designation Kohler, CH20S, 4–stroke, V–Twin Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 77 mm x 67 mm (3.03” x 2.64”) Total Displacement 624 cc (38 cu. in.) Compression Ratio 8.5:1 Dry Weight (approximate) 41 kg (90 lb.) Fuel Unleaded, Regular Gasoline (Minimum 87 Octane) Fuel Tank Capacity 18.9 liters (5 U.S. gal.
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Adjustments Adjust Engine Speed 1. Allow engine to reach operating temperature before checking or adjusting engine speed. Park machine on a level surface, shift range selector to neutral, and engage parking brake. 1 2. Tip seat to gain access to engine speed control (Fig. 1). Kohler Gasoline Engine 2 3. With engine running, move accelerator pedal to FAST position. 4. Using a tachometer, check that engine is operating at 3375 + 25 RPM. 5.
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Adjust Choke Cable 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Remove air cleaner cover and air filter from engine (see Operator’s Manual). 3. Move choke control on control panel while watching choke plate in carburetor. A. Choke plate should be fully open when choke control is pushed in. B. Choke plate should be fully closed when choke control is pulled out. 2 3 Figure 3 1. Choke cable 2. Cable clamp 3. Choke lever 4.
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Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual. Kohler Gasoline Engine IMPORTANT: The engine that powers the Multi Pro is air–cooled.
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Fuel System 11 12 10 1 6 9 6 8 2 6 RIGHT FRONT 6 5 7 4 3 Figure 5 1. 2. 3. 4. Fuel tank Foam strip Nut (4 used) Flat washer Kohler Gasoline Engine 5. 6. 7. 8. R–clamp Hose clamp Fuel hose Fuel filter Page 3 – 6 9. 10. 11. 12.
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Fuel Tank Removal Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting the engine. Store fuel in a clean, safety–approved container and keep cap in place. Use gasoline for the engine only; not for any other purpose. 1.
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Exhaust System 18 18 14 18 7 18 16 19 18 10 8 17 4 11 7 15 11 2 11 13 5 10 3 1 6 12 FRONT 9 20 LEFT 10 11 Figure 6 1. 2. 3. 4. 5. 6. 7. Engine Exhaust gasket Flange nut Header pipe Header support Flange head screw Exhaust stud Kohler Gasoline Engine 8. 9. 10. 11. 12. 13. 14. Muffler hanger Muffler/tailpipe Muffler clamp Flange nut Cap screw Flat washer Flange head screw Page 3 – 8 15. 16. 17. 18. 19. 20.
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Removal (Fig. 6) Installation (Fig. 6) NOTE: Make sure engine and exhaust header sealing surfaces are free of debris or damage that may prevent a tight seal. The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2.
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Engine Mounting Plate Assembly 1 8 9 10 2 11 12 3 28 4 5 27 13 6 7 8 26 9 10 14 15 16 25 25 17 FRONT 24 18 LEFT 24 22 23 21 20 19 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engine Pump pulley Key Drive clutch Flat washer Lock washer Cap screw CVT belt guide Lock washer Cap screw 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Removal (Fig. 7) 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. Chock wheels to keep the machine from moving. 4 2 1 2. Disconnect negative (–) and then positive (+) battery cables at the battery. 3. Remove muffler/tailpipe section of the exhaust system (see Exhaust System Removal). A. Slide the sleeve back on the cable ball joint and lift accelerator cable from the ball stud. Figure 8 1. Accelerator cable 2. Cable ball joint 3. Cable jam nut 4. Choke cable 5.
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CAUTION 1 Rotate steering wheel to relieve hydraulic system pressure and avoid injury from pressurized hydraulic oil. 3 2 4 11. If the mounting plate assembly is being removed from machine, label all hydraulic connections for reassembly purposes. Clean hydraulic hose ends prior to disconnecting the hoses. Remove hydraulic hoses from steering pump. 12.Remove engine mounting plate assembly from machine (Fig. 7 and 11): Figure 11 1. Frame 2. Engine support strap 3. Engine mount 4.
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7. Reconnect accelerator cable to engine (Fig. 8 and 9). A. Position accelerator cable to the engine speed control bracket. B. Slide the sleeve back on the cable ball joint and place cable ball joint on ball stud. Release the sleeve so it slides over the stud to secure cable. C. Tighten cable jam nuts that secure accelerator cable to control bracket. 8. If fuel line was removed, route fuel line through R– clamps on mounting plate. Connect fuel line to the fuel pump. Multi Pro 1200/1250 9.
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Engine 1 8 9 10 2 11 12 3 27 4 5 13 6 26 7 8 25 9 10 14 15 16 Anti–seize Lubricant 17 FRONT 24 18 LEFT 24 22 23 21 20 19 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine Pump pulley Key Drive clutch Flat washer Lock washer Cap screw CVT belt guide Lock washer Kohler Gasoline Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Engine Installation (Fig. 13) 1. Remove engine mounting plate assembly from machine (see Engine Mounting Plate Removal in this section). 1. Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled to the engine. 2. Loosen CVT drive belt guides. Rotate driven clutch and route drive belt over the driven clutch. Remove belt from the drive clutch (see Drive Belt Service in Service and Repairs Section of Chapter 7 – Drive Train). 2.
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Chapter 4 Hydraulic System Table of Contents Multi Pro 1200/1250 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . General Precautions for Removing and Installing Hydraulic System Components . . . . . . . . . . . . . Check Hydraulic Lines and Hoses . . . . . . . . . . . . Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . Steering Pump Drive Belt . . . . . . . . . . . . . . . . . . . Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Pump Service .
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Specifications Item Description Gear Pump Steering Relief Pressure Positive displacement, gear type pump 1000 PSI (69.
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General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, or mishandling during operation and maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
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SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fitting shows signs of leakage. O–Ring 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 3 5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.). 4 (1/4 in.
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Hydraulic Schematic P: PRESSURE FROM PUMP T: RETURN TO TRANSAXLE R: WORKING PRESSURE (RIGHT TURN) L: WORKING PRESSURE (LEFT TURN) STEERING CONTROL UNIT P T R L STEERING CYLINDER RELIEF VALVE GEAR PUMP RETURN FILTER TRANSAXLE HOUSING SUCTION STRAINER IN TRANSAXLE Multi Pro 1200/1250 Hydraulic Schematic Hydraulic System Page 4 – 6 Multi Pro 1200/1250
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Hydraulic Flow Diagrams Steering Circuit inder is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinder flows back through the steering control spool valve, then to the oil filter, and returns to the transaxle. A single section, belt driven gear pump supplies hydraulic flow to the steering control valve and steering cylinder. The gear pump takes its suction from the transaxle. Steering circuit pressure is limited by a relief valve located in the gear pump.
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Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges.
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Hydraulic Test Fitting Kit Toro Part Number: TOR4079 TORO TEST FITTING KIT (NO. TOR4079) This kit includes a variety of O–ring Face Seal fittings to enable connection of test gauges to the hydraulic system. The kit includes: tee’s, unions, reducers, plugs, caps, and test fittings.
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Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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Testing CAUTION Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to gauge and possible personal injury from leaking hot oil. Before Performing Hydraulic Tests All obvious areas such as oil supply, filter, binding linkage, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced. Precautions For Hydraulic Testing 3.
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TEST NO.
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1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the spray system off. Apply parking brake and make sure range selector is in the neutral position. 3. Read Precautions For Hydraulic Testing. 4. Make sure that steering pump drive belt is adjusted properly. (see Operator’s Manual). CAUTION Rotate steering wheel with engine off to relieve system pressure and avoid injury from pressurized hydraulic oil.
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TEST NO.
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Procedure for Steering Control Valve and Steering Cylinder Test: C. Turn engine off and engage the parking brake. D. Read Precautions for Hydraulic Testing. E. Remove hydraulic hose from the fitting on the rod end of the steering cylinder. Plug the end of the hose. 2. Perform the Steering Pump Relief Pressure and Steering Pump Flow tests to make sure that pump and relief valve are functioning correctly.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, and stop engine. Remove key from the ignition switch. 1. Check oil level in the transaxle and add correct oil if necessary.
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Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil appears milky, black, or contains metal particles. 1 1. Park machine on a level surface. Stop engine, apply parking brake, and remove key from ignition switch. 2. Clean area around filter mounting area (Fig. 13). Remove filter and drain filter into a suitable container. Discard filter. 3. Remove drain plug from transaxle (Fig.
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Steering Pump Drive Belt 11 10 12 13 14 15 2 1 11 12 4 9 5 3 13 6 7 16 17 8 FRONT LEFT Figure 15 1. 2. 3. 4. 5. 6. Drive clutch Pump drive pulley Pump pulley Flange head screw (4 used) Steering pump bracket Steering pump 7. 8. 9. 10. 11. 12. Flange nut (4 used) Flange head screw (2 used) Steering pump drive belt Engine CVT belt guide Lock washer 13. 14. 15. 16. 17. Cap screw CVT drive belt Driven clutch Pump drive gearbox Engine mounting plate Steering Pump Drive Belt Removal (Fig.
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Steering Pump 10 16 11 2 12 13 14 1 10 11 4 5 9 19 12 8 3 6 4 18 15 Anti–seize Lubricant FRONT 17 7 LEFT Figure 16 1. 2. 3. 4. 5. 6. 7. Drive clutch Pump drive pulley Pump pulley Flange head screw (4 used) Steering pump bracket Steering pump Flange head screw (2 used) 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Flange nut (4 used) Steering pump belt CVT belt guide Lock washer Cap screw Drive belt Removal (Fig. 16 and 17) 1.
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8. Loosen and remove four (4) flange head screws and flange nuts that secure pump to pump bracket. Remove pump from bracket. Loctite #242 5 5 6 Installation (Fig. 16 and 17) 7 12 1. Position steering pump to pump bracket. Install four (4) flange head screws and flange nuts to secure pump to bracket. 13 2. Make sure the pulley bore and pump shaft are clean. Apply anti–seize lubricant to both the pump shaft and the bore of the pulley. Position key to pump shaft. 4 8 Anti–seize Lubricant 3 3.
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Steering Pump Service 8 1 6 2 7 10 5 3 144 to 180 in–lb (16 to 20 N–m) 9 4 11 12 13 12 14 15 114 to 150 in–lb (13 to 17 N–m) 12 24 23 20 22 16 19 17 21 15 18 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. Snap ring Seal Spacer Ball bearing Check ball Spring Spring Adjusting screw 9. 10. 11. 12. 13. 14. 15. 16. Gasket Cap Key Crescent ring (4 used) Woodruff key Drive shaft Needle bearing (4 used) Plug Relief Valve Service (Fig.
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Disassembly (Fig. 18) 2. Check all parts for burrs, scoring, nicks, etc. 1. Remove shaft seal (see Shaft Seal Replacement). 3. Clean seal bore and drive shaft of pump so they are free of any foreign material. 2. Remove relief valve (see Relief Valve Service). IMPORTANT: Use caution when using a vise to avoid distorting any pump components. 4. Secure flange end of pump in a vise with drive shaft facing down. 5. Remove eight (8) screws. 6.
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Steering Control Valve Removal (Fig. 19) 5. Check fluid level in transaxle and adjust as required (see Operator’s Manual). 1. Park the machine on a level surface, engage parking brake, and stop engine. Remove key from the ignition switch. 6. After assembly is completed, operate steering cylinder to verify that hydraulic hoses and fittings are not contacted by anything. CAUTION 6 Rotate steering wheel to relieve system pressure and avoid injury from pressurized hydraulic oil. 2.
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Steering Control Valve Service 8 1 3 24 2 6 7 4 5 20 19 19 23 22 21 150 in–lb (17 N–m) 9 10 13 12 11 14 140 to 160 in–lb (16 to 18 N–m) 15 18 17 16 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. Steering valve housing Dust seal O–ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers 9. 10. 11. 12. 13. 14. 15. 16. Cap screw (7 used) End cap O–ring Seal ring O–ring Geroter O–ring Spacer Geroter drive Wear plate Bearing race Thrust bearing Plug O–ring Check ball Quad seal 4.
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8. Put the thrust bearing and bearing races into the housing. The thrust bearing goes between the two bearing races (Fig. 22). The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean Dexron III ATF to the spool and sleeve assembly. Carefully slide the assembly into the housing.
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Steering Cylinder Anti–seize Lubricant 3 2 1 3 11 5 6 10 4 9 7 1 8 9 1 8 7 10 12 13 14 4 3 5 15 16 1 10 17 3 FRONT RIGHT Figure 23 1. 2. 3. 4. 5. 6. Cotter pin Slotted hex nut Grease fitting Jam nut Tie rod end Retaining ring Hydraulic System 7. 8. 9. 10. 11. 12. Thrust washer Bearing Slotted hex nut Flat washer Steering cylinder Grease fitting Page 4 – 28 13. 14. 15. 16. 17.
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Removal (Fig. 23) 1. Park the machine on a level surface, engage the parking brake, and stop the engine. Remove the key from the ignition switch. 2. Lower the engine mounting plate assembly from machine (see Engine Mounting Plate Assembly Removal in Service and Repairs Section of Chapter 3 – Kohler Gasoline Engine). 3. Label all hydraulic connections for reassembly. Clean hydraulic hose ends prior to disconnecting the hoses. 2. Position shaft end of cylinder to the steering pivot.
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Steering Cylinder Service 11 2 7 6 14 12 3 10 75 ft–lb (102 N–m) 9 8 5 4 1 13 Figure 25 1. 2. 3. 4. 5. Retaining ring O–ring Head Backup ring O–ring Hydraulic System 6. 7. 8. 9. 10. Shaft Rod seal Piston Uni–ring Lock nut Page 4 – 30 11. 12. 13. 14.
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Disassembly (Fig. 25) Reassembly (Fig. 25) 1. Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. 2. Mount end of steering cylinder in a vise. Remove retaining ring. 3. Remove plugs from ports. Extract shaft, head, and piston by carefully twisting and pulling on the shaft. IMPORTANT: Do not clamp vise jaws against the shaft surface.
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Chapter 5 Electrical System ELECTRICAL SCHEMATICS and ELECTRICAL HARNESS and CONNECTOR DRAWINGS . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Run Problems . . . . . . . . . . . . . . . . . . . . . . 5 ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 6 Battery Test (Open Circuit Test) . . . . . . . . . . . . . . .
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Electrical Schematics and Electrical Harness and Connector Drawings The electrical schematics and other electrical drawings for the Multi Pro 1200 and Multi Pro 1250 are located in Chapter 9 – Electrical Diagrams.
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Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits 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 meter in the voltage mode will make sure that excess current is not allowed through the meter.
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Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Chapter 9 – Electrical Diagrams). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
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Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Ignition switch is faulty. Circuit wiring to engine magneto is grounded (see Chapter 9 – Electrical Diagrams). Circuit wiring to carburetor solenoid is loose, corroded, or damaged (see Chapter 9 – Electrical Diagrams). Engine or fuel system is malfunctioning (see Chapter 3 – Kohler Gasoline Engine). Engine may be too cold. Engine cranks (but should not) with the range selector lever out of the neutral position.
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Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition key should be in the OFF position and all accessories turned off.
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Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the ignition switch). NOTE: See the Kohler Engine Repair Manual for more component testing information. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
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Start, Neutral Engine Speed Control, Spray Pump and Spray Valve Relays The start and neutral engine speed control relays are used on both the Multi Pro 1200 and Multi Pro 1250. The Multi Pro 1250 uses an additional three (3) relays for the spray valve system. All relays are located under the operator seat (Fig. 6). 2 During the 2003 model year, an additional relay was added to both the Multi Pro 1200 and Multi Pro 1250. This additional relay is used to energize the spray pump clutch.
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Neutral Interlock Switch The neutral interlock switch is attached to the shift lever assembly (Fig. 8). The switch is closed when the shift lever is in the neutral position and allows engine cranking/ starting only when the machine is in neutral. 2 Two types of neutral interlock switches have been used on Multi Pro 1200 and 1250 sprayers: 1 On machines with serial numbers below 250000000, the neutral interlock switch is a ball type switch (Fig. 9).
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Hour Meter The hour meter is located on the control console next to the operator seat. Testing 1. Remove console panel. Disconnect the harness electrical connectors from the terminals on the hour meter. 2. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. Figure 11 3. Connect the negative (–) terminal of the voltage source to the other terminal of the hour meter. 4. The hour meter should move a 1/10 of an hour in six minutes. 5.
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Pump Control and Neutral Engine Speed Control Switches The pump control and neutral engine speed control switches are identical switches. The pump control switch is located on the sprayer (right side) console (Fig. 14). The neutral engine speed control switch is positioned on the control console (Fig. 15). MULTI PRO 1200 MULTI PRO 1250 Testing L R 1. Locate switch, remove console panel, and unplug machine wire harness connector from switch. SONIC BOOM TM 2.
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Traction Speed Sensor The traction speed sensor is attached to the upper transaxle cover (Fig. 17). It uses a magnetically based, Hall Effect integrated circuit. As the differential in the transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the sensor. The red striped connector wire is the positive lead, the black wire is the ground lead, and the gray striped wire is the signal output. 1 3 Testing 2 1.
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Shifter Solenoid (Machines With Serial Number Below 250000000) The shifter solenoid is attached to the shift lever assembly (Fig. 19). The solenoid is energized when the brake pedal is depressed. When the solenoid is energized, the solenoid plunger retracts to allow shifting. 2 Testing 1 1. Park machine, stop engine, and engage parking brake. Make sure that range selector is in neutral. 2. Locate shifter solenoid on the shift lever assembly. Remove air cleaner cover to ease access to solenoid. 3.
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Pump Drive Electric Clutch An electric clutch is used to engage and drive the sprayer pump on the Multi Pro. Clutch operation is controlled by the pump control switch located on the spray console. The electric clutch is mounted on the pump drive gearbox output shaft and is coupled to the spray pump. The clutch engages when current is applied to the clutch. 2 1 Testing 1. Locate clutch on pump drive gearbox shaft. Unplug clutch connector from machine wire harness (Fig. 21).
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Neutral Engine Speed Control Coil The neutral engine speed control coil is energized by the speed control switch and cruise module. The energized coil becomes a magnet to hold the accelerator lever in position and maintains engine speed for sprayer operation when the machine is stationary. 2 Testing 1. Locate control coil next to accelerator lever under the floorboard. Unplug coil connector from machine wire harness (Fig. 22).
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Accessory Solenoid The accessory solenoid provides a current supply to the spray system and optional accessories (electric boom lifts and foam markers). The solenoid is energized when the ignition key switch is in the RUN position. The accessory solenoid is located under the operator seat (Fig. 23). 2 Testing 1. Make sure engine is off. Disconnect battery. 2. Raise operator seat and locate accessory solenoid. Put labels on wires for proper installation after repairs are completed.
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Brake Pedal Switch (Machines With Serial Number Below 250000000) The brake pedal switch is located on the brake lever under the floorboard (Fig. 25). The brake pedal switch allows the shifter solenoid to be energized when the brake pedal is pushed. Testing 1. Locate switch and unplug wire harness connector from switch. 2. When the switch plunger is pressed (brake pedal depressed), there should be continuity (closed) between the switch terminals.
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Spray Pro Monitor The Multi Pro 1200 and 1250 are equipped with a spray monitor to provide the machine operator with spray system information. Operation, calibration, and troubleshooting information for the Spray Pro Monitor is included in the Operator’s Manual.
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Rate Lockout Key Switch (Multi Pro 1250 only) The rate lockout key switch is located on the spray control console (Fig. 30). Testing 1 1. Locate switch, remove console panel, and remove wire harness connectors from switch. 2. The switch terminals are shown in Figure 31. When the key is in the ON position, continuity should exist between the two terminals. In the OFF position, there should be no continuity between the switch terminals. 2 3. Reconnect the harness connectors to the switch after testing.
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Master Boom (Foot) Switch (Multi Pro 1250 only) The master boom switch is located on the floorboard of the machine (Fig. 32). 2 Testing 1 1. Locate switch and unplug wire harness connectors from switch. Note wire connector location on switch. 2. The switch terminals are shown in Figure 33. Continuity should exist between the common terminal and only one of the side terminals. When the switch is depressed, continuity should exist between the common terminal and the other side terminal.
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Service and Repairs NOTE: See the Kohler Engine Repair Manual for more component repair information. Headlights Removal and Installation (Fig. 36) 1. Set parking brake, turn ignition off, and remove key. 2. Reach beneath dash and push headlight out of the hood. 3. Remove screws attaching the wire harness to the headlight. 4. Remove rubber seal from around the headlight. Discard headlight. 2 5. Align notch on the inside of the seal with the notch on the new headlight.
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Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service). 3. Leave cables disconnected if the battery is stored on the machine. Battery Care 1.
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Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 1 2 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. Electrolyte Specific Gravity Fully charged: 1.
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B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100oF Cell Gravity 1.245 100oF minus 80oF equals 20oF (37.7oC minus 26.7oC equals 11.0oC) 20oF multiply by 0.004/10oF equals 0.008 (11oC multiply by 0.004/5.5oC equals 0.008) ADD (conversion above) 0.008 Correction to 80oF (26.7oC) 1.253 G.
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2. Determine the charging time and rate using the manufacturer’s battery charger instructions or the following table. Battery Reserve Capacity (Minutes) 3. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good connection is made. 4. Charge the battery following the manufacturer’s instructions. Battery Charge Level (Percent of Fully Charged) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.
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Chapter 6 Spray System Table of Contents Multi Pro 1200/1250 Pressure Control Valve (Multi Pro 1200) . . . . . . . Boom Distribution Valves (Multi Pro 1200) . . . . . Spray Control (Multi Pro 1250) . . . . . . . . . . . . . . . Flowmeter (Multi Pro 1250) . . . . . . . . . . . . . . . . . . Rate Control Motor (Multi Pro 1250) . . . . . . . . . . Boom Valve Motor (Multi Pro 1250) . . . . . . . . . . . Boom Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Suction . . . . . . . . . . . .
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Specifications Item Description Spray Pump Diaphragm Pump, 30 GPM @ 220 PSI Spray Pressure Relief Valve Poppet Style, 220 PSI Maximum Sprayer Tank 160 Gallon, Polyethylene Suction Strainer 50 Mesh, Stainless Steel, Tank Mounted (30 Mesh and 80 Mesh Optional) General Information Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons, animals, plants, soil, or other property. To eliminate environmental damage and personal injury: 1. Select the proper chemical for the job.
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Spray System Operation The Multi Pro 1200 and 1250 spray systems use a positive displacement diaphragm pump to move spray solution from the spray tank to the boom nozzles. The spray pump is self–priming and has a dry crankcase. The pump is driven by the pump drive gearbox output shaft at a speed that is proportional to the ground speed of the vehicle. The pump is engaged with an electric clutch.
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Spray System Flow Diagrams SUCTION PRESSURE AGITATION BOOM SUPPLY FLOW DIRECTION Spray System Multi Pro 1200 Spray System Flow Diagram Page 6 – 4 Multi Pro 1200/1250
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Spray System SUCTION PRESSURE AGITATION BOOM SUPPLY FLOW DIRECTION Multi Pro 1200/1250 Multi Pro 1250 Spray System Flow Diagram Page 6 – 5 Spray System
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Troubleshooting Problem Possible Cause Spray system leaks fluid. Fitting(s), hose(s), or tube(s) are loose or damaged. O--ring(s) or seal(s) are missing or damaged. Fluid leaking from bottom of spray pump. Faulty diaphragm(s) in spray pump. Excessive suction hose vibration. Suction screen in tank is plugged. Spray pump suction line has an air leak. Suction tube in spray tank has air leak. Suction line is restricted. Suction dampener diaphragm is damaged. Spray pressure is low.
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Spray pump doesn’t rotate. Spray pump switch off or damaged. Foot switch off or damaged (Multi Pro 1250). Key on spray pump shaft or gearbox shaft is sheared. Spray pump coupler is damaged. Pump drive electric clutch not engaged or is damaged (see Chapter 5 -- Electrical System). Erratic spray operation from booms. Clogged strainer. Damaged suction dampener. Damaged pressure dampener. Boom bypass valve on distribution valve is damaged (Multi Pro 1200). Master boom valve damaged (Multi Pro 1200).
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Service and Repairs Pump Drive Electric Clutch 1 4 27 ft–lb (36.6 N–m) 5 8 7 6 9 10 11 17 7 10 RIGHT 12 11 7 22 Anti–seize Lubricant 13 14 15 21 7 FRONT 6 5 19 4 2 18 16 7 3 20 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. Spray pump Shoulder bolt Key Cap screw (4 used) Coupling spacer (4 used) Rubber coupling Lock nut Drive coupler Spray System 9. 10. 11. 12. 13. 14. 15.
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Removal (Fig. 1) Installation (Fig. 1) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1. Apply anti–seize lubricant to pump drive gearbox shaft. Place key and spacer onto shaft. 2. Remove cap screws, flat washers, lock nuts, and spacers that secure rubber coupling to pump hub (item 23). 3. Remove lock nuts that secure clutch adapter (item 17) to electric clutch. 4.
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Suction Dampener The suction dampener is mounted to the suction line at the spray pump (Fig. 2) and is used to dampen suction pulses and smooth suction flow. During pump operation, the suction dampener diaphragm will move. IMPORTANT: Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components. 2 A damaged suction dampener diaphragm will allow a suction leak and will cause improper pump operation.
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Pressure Dampener The pressure dampener is mounted to the pressure line at the spray pump (Fig. 4) and is used to smooth system pressure pulsation. Adjust air pressure on the pressure dampener to approximately 14 PSI (.97 bar). If fluid is present when pressure in the dampener is checked, the diaphragm in the pressure dampener is damaged and should be replaced. 3 2 Dampener Service (Fig.
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Spray Pump 8 7 6 5 Apply PTFE tape 3 4 3 2 10 1 9 23 Loctite #271 24 14 15 32 31 26 25 30 27 28 31 23 11 12 29 13 21 9 26 17 22 16 27 23 24 20 Apply PTFE tape Anti–seize Lubricant 19 28 23 25 FRONT RIGHT 18 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Spray pump assembly Elbow (pressure) O–ring Tee (pressure) Hose barb Nut Hose clamp Pressure hose (1”) O–ring Pressure dampener Suction hose (1 1/2”) Spray System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 6) IMPORTANT: Make sure to neutralize and remove chemicals from pump and hoses before loosening and removing spray system components. 4. Remove set screws from pump hub. Clean threads of set screws and hub. 5. Apply anti–seize lubricant to pump shaft. Install key in shaft and slide pump hub onto shaft. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 6. Position pump on pump mounting bracket.
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Spray Pump Service 26 1 60 ft–lb (81 N–m) 2 30 27 3 2 30 25 4 9 3 5 60 ft–lb (81 N–m) 4 6 28 7 29 8 7 5 6 8 18 24 9 32 ft–lb (43 N–m) 11 10 13 12 14 12 13 21 14 20 23 15 22 10 20 21 16 18 55 ft–lb (75 N–m) 19 25 ft–lb (34 N–m) 32 ft–lb (43 N–m) 17 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Valve chamber Valve (inlet position) O–ring Diaphragm cover Hex bolt Washer Diaphragm Diaphragm back disc Nylon washer Lock washer 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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D. Position dust plate and felt seal on both ends of crankshaft. Disassembly (Fig. 8) IMPORTANT: Make sure to remove and neutralize chemicals from pump before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during pump repair. IMPORTANT: If connecting rod position is incorrect, pump will not operate properly. E. Slide crankshaft assembly into pump casing.
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4. Place diaphragm back disc and new diaphragm onto each connecting rod. The connecting rods should extend above the diaphragms when correctly installed (Fig. 11). Position nylon washer and washer on each connecting rod and then thread hex bolt into connecting rod. Torque bolt to 60 ft–lb (81 N–m). 2 1 5. Make sure that pump casings align and then secure pump casing assembly by torquing five (5) bolts to 32 ft– lb (43 N–m). 6. Install diaphragm covers to pump using hex bolts and nuts (4 per cover).
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Agitation Control Valve 3 5 7 4 8 9 3 2 10 11 12 4 2 13 11 14 2 6 1 2 19 2 15 3 18 17 16 FRONT 21 RIGHT 20 Figure 13 1. 2. 3. 4. 5. 6. 7. Agitation control valve O–ring Fork Hose clamp Hosebarb Hose: agitation supply(1”) Hosebarb Spray System 8. 9. 10. 11. 12. 13. 14. Nut Hose: control bypass (1”) Hosebarb Hose clamp Hose: tank suction (1 1/2”) Hosebarb Suction hose (1 1/2”) Page 6 – 18 15. 16. 17. 18. 19. 20. 21.
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Removal (Fig. 13) 1 IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 3 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Label disconnected hoses for proper installation after repairs are completed. 2 3. Remove agitation control valve using Figures 13 and 14 as guides. 4.
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Agitation Nozzles (Tank mounted) 18 17 19 23 20 19 20 24 6 25 4 18 19 6 17 16 20 15 6 15 14 14 26 14 6 12 15 13 8 6 4 19 6 4 22 13 4 12 21 21 4 13 19 4 8 1 8 9 27 12 11 2 3 4 5 6 3 2 4 10 6 7 6 8 9 2 3 8 4 26 7 FRONT 4 5 6 RIGHT 4 7 8 11 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. Hose: agitation supply (1”) Hose clamp Hosebarb O–ring Tee Fork Hosebarb Hose clamp Hose (3/4”) Spray System 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Disassembly (Fig. 17) Assembly (Fig. 17) IMPORTANT: Make sure to remove and neutralize chemicals from tank and other components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. NOTE: Coat all o–rings with vegetable oil before installation to reduce the chance of damage during assembly. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1.
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Pressure Relief Valve (Tank Mounted) 1 2 3 4 5 6 7 8 24 9 21 1 10 11 15 12 17 20 22 18 23 19 13 14 10 15 12 16 10 17 13 FRONT RIGHT Figure 18 1. 2. 3. 4. 5. 6. 7. 8. Nut Valve seat Spring Valve cone Relief valve housing Gasket Ringnut O–ring Spray System 9. 10. 11. 12. 13. 14. 15. 16. Hosebarb Hose clamp Hose: pressure relief valve (1”) Hosebarb Fork Hose: control supply (1”) O–ring Hosebarb Page 6 – 22 17. 18. 19. 20. 21. 22. 23. 24.
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Removal (Fig. 18) IMPORTANT: Make sure to remove and neutralize chemicals from tank and other components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2 1 2. Drain spray tank (see Operator’s Manual). 3. Label disconnected hoses for proper installation after repairs are completed. 4.
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Spray Control (Multi Pro 1200) 6 2 1 4 10 6 5 3 3 4 11 4 7 12 8 9 8 2 4 FRONT 3 RIGHT 6 13 Figure 20 1. 2. 3. 4. 5. Boom distribution valves Screw Hex nut Washer Bracket Spray System 6. 7. 8. 9. Flange head screw Flowmeter Hex nut Hex bolt Page 6 – 24 10. 11. 12. 13.
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Removal (Fig. 20) 3 IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove master boom valve handle, spray console panel, and spray console from machine (Fig. 21). 1 2 3. Label hoses for proper installation after repairs are completed. 4.
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Flowmeter (Multi Pro 1200) 1 2 10 3 11 4 8 5 7 6 8 9 Figure 23 1. 2. 3. 4. Flow sensor with nut Flowmeter rotor shaft Flowmeter rotor Fork Spray System 5. 6. 7. 8. Flowmeter housing O–ring Hosebarb Hose clamp Page 6 – 26 9. Hose: from master boom valve (1”) 10. O–ring 11.
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Removal and Inspection (Fig. 23) IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 3 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Remove master boom valve handle, spray control panel, and spray console from machine (Fig. 24). 3. Loosen and remove nut that secures flow sensor to housing (Fig. 25).
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Master Boom Valve (Multi Pro 1200) 31 32 33 34 29 27 1 2 30 28 26 3 16 25 4 24 23 5 15 14 10 20 11 7 22 6 35 7 21 20 8 19 9 18 17 12 16 15 14 7 13 Figure 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Housing Ball Seat O–ring Hosebarb Nut Hose clamp Hose: to flowmeter (1”) Nut (2 used) Flange head screw (2 used) Plate Screw (4 used) Spray System 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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Disassembly (Fig. 27) IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1 1. Remove master boom valve from machine (see Spray Control (Multi Pro 1200) in this section). 2. Disassemble master boom valve using Figure 27 as a guide. Discard all removed o–rings. Assembly (Fig.
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Pressure Control Valve (Multi Pro 1200) 8 1 7 17 2 6 16 3 4 5 3 3 5 15 6 7 14 8 13 9 12 10 9 11 Figure 29 1. 2. 3. 4. 5. 6. Pressure control valve O--ring O--ring Tee piece Cap O--ring Spray System 7. 8. 9. 10. 11. 12. Washer Hex nut Hose clamp Hose: pressure supply (1”) Hose: control bypass (1”) Nut Page 6 -- 30 13. 14. 15. 16. 17.
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Disassembly (Fig. 29) IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1 1. Remove pressure control valve from machine (see Spray Control (Multi Pro 1200) in this section). 2. Disassemble pressure control valve using Figure 29 as a guide. Discard all removed o–rings. Assembly (Fig.
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Boom Distribution Valves (Multi Pro 1200) 6 7 1 4 4 5 1 3 4 25 3 14 12 3 2 15 9 11 9 8 3 17 9 18 8 10 11 13 9 8 19 17 9 18 20 19 21 12 14 24 20 15 21 6 23 RIGHT 22 16 FRONT Figure 31 1. 2. 3. 4. 5. 6. 7. 8. 9. Distribution valve (center/LH boom) Distribution valve (RH boom) O--ring Fork Elbow Hose clamp Hose: boom bypass (1”) Fork O--ring 10. 11. 12. 13. 14. 15. 16. 17. Tee fitting Cover Washer Threaded rod Hex nut O--ring Hose: from flowmeter (1”) Housing 18. 19.
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Disassembly (Fig. 31) 1. Remove boom distribution valve assembly (see Spray Control (Multi Pro 1200) in this section). 2 2. Separate boom distribution valves: 1 A. Remove forks (item 4) that secure distribution valves together. B. Remove hex nut from one end of threaded rod. C. Pull threaded rod from assembly and separate components. 3. Remove fork (item 8) to separate individual distribution valves from housings. 4. Remove and discard o–rings and seals. 3 Distribution Valve Service (Fig.
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Spray Control (Multi Pro 1250) 19 17 18 FRONT 20 16 39 15 RIGHT 21 14 8 7 11 22 7 2 7 1 3 4 5 23 12 25 10 6 24 10 9 13 41 40 31 29 29 29 30 29 5 26 3 1 7 30 7 29 7 28 10 12 32 32 34 7 32 32 33 12 32 34 36 32 27 38 37 35 35 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Nut Threaded rod Washer Bushing O–ring Cap O–ring Tee piece Hose: control supply (1”) Hose clamp Fork Screw Control valve bracket Rate control valve housing 15. 16. 17. 18. 19.
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IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 4 3 1 5 2 Removal 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Label hoses for proper installation after repairs are completed. Loosen hose clamps and disconnect hoses from spray control. 3.
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Flowmeter (Multi Pro 1250) 24 21 23 18 FRONT RIGHT 22 20 14 6 8 7 11 19 7 2 1 7 3 5 4 17 12 13 10 15 16 10 28 9 7 25 5 27 3 1 26 Figure 38 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Nut Threaded rod Washer Bushing O–ring Cover O–ring Tee piece Hose: control supply (1”) Hose clamp Spray System 11. 12. 13. 14. 15. 16. 17. 18. 19. Fork Screw Control valve bracket Rate control motor/housing O–ring Hosebarb Hose: control bypass (1”) Coupler (pressure gauge) Flowmeter housing Page 6 – 36 20.
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Removal and Inspection (Fig. 38) IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 1 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen and remove nut that secures flow sensor to flowmeter housing. Carefully remove flow sensor from housing. 3.
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Rate Control Motor (Multi Pro 1250) 1 2 3 1 4 5 6 8 7 11 9 12 13 14 10 Figure 41 1. 2. 3. 4. 5. Phillips head screw (5 used) Lock washer Hand grip O–ring Phillips head screw (4 used) 6. 7. 8. 9. 10. Rate control motor assembly Gasket Phillips head screw (4 used) Rate valve spindle section Rate control valve housing The rate control motor allows the operator to vary the spray application rate.
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2. Remove four (4) phillips head screws (item 8) that secure spindle section to housing. Remove spindle section. 4 3 1 5 2 3. Locate, remove, and discard o–ring (item 11) and seal (item 14). 4. Remove valve (item 13) and inspect for wear and/or damage. Replace if needed. 5. If needed, the spindle shaft can be removed by removing lock nut that secures cone (item 12) to shaft. NOTE: Many individual components for the rate control motor and spindle section are not available separately.
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Boom Valve Motor (Multi Pro 1250) 9 8 1 10 4 11 12 5 13 14 7 6 2 15 16 17 19 3 4 28 29 18 30 20 21 22 23 32 31 24 25 26 27 33 70 in–lb (8 N–m) Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Housing cover Cover seal Boom valve motor Phillips head screw (5 used) O–ring Lock washer Hand grip Roller Roller pin Spindle Spring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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4. Remove rear housing cover from boom valve motor to inspect motor components. 4 3 1 5 2 A. Cam should be tight on shaft. Cam surface should be free of wear and/or scoring. B. The inside of motor housing should be free of excessive moisture, corrosion, and dirt. C. The cam bearing surface in the housing cover should be inspected for excessive wear. 5. Inspect and disassemble spindle section (Fig. 45). A. Inspect spindle roller surface for wear or scoring.
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3. Assemble spindle section by reversing disassembly process. Align green indicator tab on spindle to slot in spindle housing. Install screw into bottom of spindle to secure assembly. Torque screw 70 in–lb (8 N–m). 6. Position the motor and spindle section assembly to the manifold assembly. The motor hand grip and boom supply hosebarb on manifold should be on the same side of the assembly. Install the fork (item 29) to secure the motor and spindle sections to the manifold. 4.
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Boom Bypass 9 5 3 4 8 7 5 6 4 3 1 FRONT RIGHT 2 Figure 47 1. Hose: boom bypass (1”) 2. Hose clamp 3. Hosebarb Spray System 4. O–ring/gasket 5. Fork 6. Nut Page 6 – 44 7. Bulkhead gasket 8. Bulkhead 9.
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Disassembly (Fig. 47) Assembly (Fig. 47) IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. NOTE: Coat all o–rings with vegetable oil before installation to reduce the chance of damage during assembly. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1.
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Tank Suction 1 15 16 2 3 4 14 5 6 2 8 7 17 9 10 10 11 12 13 FRONT RIGHT Figure 48 1. 2. 3. 4. 5. 6. Suction hosebarb O–ring Screen vane Suction screen Filter housing Expansion pin Spray System 7. 8. 9. 10. 11. 12. Bulkhead gasket Hosebarb Nut Hose clamp Suction hose (2”) Suction tube Page 6 – 46 13. 14. 15. 16. 17.
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NOTE: If suction tube in tank develops an air leak, spray performance will diminish when tank level reaches the leak. 3 Removal (Fig. 48) 1 IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2.
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Tank Drain Valve 1 2 4 3 6 5 9 7 8 10 11 13 12 15 14 6 16 17 FRONT RIGHT 19 18 Figure 50 1. 2. 3. 4. 5. 6. 7. Tank drain knob Bolt Lock nut O–ring Bulkhead O–ring Ringnut Spray System 8. 9. 10. 11. 12. 13. Drain tube Pin Connector Pin Flex tube Pin Page 6 – 48 14. 15. 16. 17. 18. 19.
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Disassembly (Fig. 50) 3 IMPORTANT: Make sure to remove and neutralize chemicals from tank and spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Drain spray tank (see Operator’s Manual). 3. Remove bolt and locknut that secure tank drain knob to drain tube. Slide knob from tube. 4.
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Turret Bodies 6 7 3 8 3 4 5 2 9 3 CENTER BOOM SUPPLY LEFT BOOM SUPPLY RIGHT BOOM SUPPLY 1 5 4 4 4 1 4 5 4 4 4 5 Figure 52 1. Turret body (w/90o elbow) 2. 90o elbow (1 used) 3. Screw 4. Turret body (w/double hose barb) 5. Turret body (w/single hose barb) 6. Single hose barb (3 used) 7. Double hose barb (7 used) 8. Turret body clamp 9. Hose barb (for 90o elbow) Removal (Fig. 52) Installation (Fig.
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Turret Body Service Disassembly (Fig. 53) 1 1. Pull e–clip from body and slide plug with o–ring from body. 18 2. Disassemble turret body using Figure 53 as a guide. 3 3. Discard all removed seals, gaskets, o–rings, and diaphragms. 7 5 2 6 4 17 8 9 Assembly (Fig. 53) NOTE: Coat all o–rings with vegetable oil before installation to reduce the chance of damage during assembly. 16 1. Replace all removed seals, gaskets, o–rings, and diaphragms. B.
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Boom Frame Breakaway Pivot Assembly (Machines with Serial Numbers Below 260000000) 6 5 7 4 3 8 9 2 1 10 10 16 15 6 14 18 17 12 11 13 11 19 20 12 Figure 55 1. 2. 3. 4. 5. 6. 7. Hinge Breakaway pivot Spring Washer Roll pin Hex nut Support bracket Spray System 8. 9. 10. 11. 12. 13. 14. Carriage screw Flat washer Cotter pin Clevis pin Clevis pin Main boom frame Breakaway pivot assembly Page 6 – 52 15. 16. 17. 18. 19. 20. Rev.
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Disassembly (Fig. 55) 2 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Support boom to prevent it from falling. Remove cap screw and hex nut that secure boom support to breakaway assembly. 3. Remove hex nut, flat washer, and carriage screw that secure support bracket to breakaway pivot. Slide support bracket from breakaway assembly. 1 4 CAUTION Spring in breakaway pivot is under tension.
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Boom Hinge (Machines with Serial Numbers Above 260000000) 16 15 8 19 18 17 14 9 FRONT 10 RIGHT 20 1 12 3 4 2 13 11 7 10 9 5 8 6 Figure 58 1. 2. 3. 4. 5. 6. 7. Hinge (2 used per boom) Rubber boot (2 used per hinge) Backing plate (4 used per hinge) Flange nut (4 used per hinge) Boom (RH shown) Tee fitting Flange hd screw (4 used per hinge) 8. 9. 10. 11. 12. 13. 14. Lock nut Cap screw Flat washer Pivot bracket Bushing (2 used per pivot bracket) Flange head screw Pivot pin Disassembly (Fig.
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Assembly (Fig. 58) 1. If pivot bracket (item 11) was removed from machine, lightly lubricate bushings (item 12) with motor oil before assembly. Connect boom actuator (not shown) to pivot bracket (see Boom Actuator Installation (Machines with Serial Numbers Above 260000000) in this section). 2. Make sure that hinges (item 1) are securely fastened to pivot bracket (item 11) and boom (item 5). The boom hinge uses four (4) backing plates between the boom and flange nuts. 2 UP 1 Figure 59 1. Rubber boot 2.
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Boom Actuator (Optional) (Machines with Serial Numbers Below 260000000) 5 FRONT RIGHT 5 1 2 3 4 1 3 2 Figure 61 1. Cotter pin 2. Clevis pin 3. Boom actuator 4. Wire harness 5. Adjustable clevis Removal (Fig. 61) Installation (Fig. 61) 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position boom actuator to clevis attachment points on center and side booms. 2.
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Adjustment 1. Loosen end nut that secures adjustable clevis to boom frame (Fig. 62). Position jam nut as close as possible to adjustable clevis. Tighten end nut to secure clevis. 2. Fully raise side boom with the boom actuator. The boom actuator should fully extend and ratchet. 2 3. With the boom actuator at full extension, the breakaway pivot gusset should just touch the center boom frame slot (Fig. 63). 4.
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Boom Actuator Service (Machines with Serial Numbers Below 260000000) 20 18 70 in–lb (7.9 N–m) 15 16 14 12 11 9 20 in–lb (2.3 N–m) 19 10 7 6 1 4 17 70 in–lb (7.9 N–m) 13 8 3 3 5 2 1. 2. 3. 4. 5. 6. 7. Screw Rear housing Washer Woodruff key Clutch Thin washer Intermediate gear Spray System 8. 9. 10. 11. 12. 13. 14. Figure 64 Thick washer Hex nut (2 used) Motor gear Housing gasket Front housing Cover tube gasket Motor seal Page 6 – 58 15. 16. 17. 18. 19. 20. Rev.
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Disassembly (Fig. 64) Assembly (Fig. 64) 1. Remove four (4) washer head screws that secure cover tube. Remove one (1) screw (item 1) that retains rear housing. Slide rear housing and housing gasket from assembly. 1. Position ball screw and brake assembly to front housing. Take care to not disturb brake components. 2. Slide thin washer, intermediate gear, and thick washer from front housing support pin. 3. In order, remove washer, clutch, woodruff key, and second washer from ball screw shaft. 4.
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Boom Actuator (Machines with Serial Numbers Above 260000000) 1 2 12 11 9 10 8 7 6 4 3 5 Figure 65 1. 2. 3. 4. Boom actuator (2 used) Carriage screw (4 used) Boom frame Washer plate Spray System 5. 6. 7. 8. Lock nut (4 used) Flange nut (2 used) Flange head screw (2 used) Pivot pin (2 used) Page 6 – 60 Rev. A 9. 10. 11. 12.
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Removal (Fig. 65) Installation (Fig. 65) 1. Park machine on a level surface, place spray booms in the transport (raised) position, stop engine, engage parking brake and remove key from the ignition switch. 1. Position boom actuator to boom frame and boom pivot bracket. 2. Disconnect boom actuator from machine wire harness. 3. Remove pivot pin (item 8) that secures actuator to clevis strap (item 9) on boom frame. 3. Secure actuator to clevis strap on boom frame with pivot pin. 4.
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Boom Actuator Service (Machines with Serial Numbers Above 260000000) IMPORTANT: Do not dismantle, repair or modify the boom actuator. Internal components are not available for the actuator. If an actuator is damaged or worn, replace actuator. CAUTION During and after operation, the actuator may be very hot. To avoid possible burns, allow the actuator to cool before working on it.
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Actuator Oil Level RESERVOIR PLUG Under normal conditions, actuator oil level should remain constant. If any oil is spilled from the reservoir during air bleeding, the oil level in the actuator should be checked and adjusted. 1. Make sure that the exterior of actuator is thoroughly clean to prevent contaminates from entering the actuator. 2. Make sure that the actuator cylinder is fully retracted.
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Chapter 7 Drive Train Table of Contents Drive Train SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Clutch Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . 2 Clutch Service Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Clutch System Operation . . . . . . . . . . . . . . . . . . . . . 3 Drive Clutch . . . . . . . . . . . .
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Specifications Item Description Transmission Fluid Capacity Fluid Type Integrated Transaxle with 3 Forward Speed Ranges and Reverse 7.5 quarts (7.1 liters) Dexron III ATF Clutch System Drive Clutch Driven Clutch Centrifugally Engaged Variable Belt Drive Speed Sensing With Mechanical Fly--Weights Torque Sensing With Spring Loaded Cam Pump Drive Gearbox Fluid Capacity Fluid Type Reducing Worm Gear for Pump Drive (through shaft for Transaxle) .5 quarts (.
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General Information Clutch System Operation FULL ENGINE SPEED DECREASING LOAD 1 LOW ENGINE SPEED LIGHT LOAD 3 FULL ENGINE SPEED INCREASING LOAD 4 6 7 9 5 v 8 2 Figure 3 4. Fixed sheave (drive clutch) 5. Moveable sheave (driven clutch) 6. Button 7. Ramp (fixed cam) 8. Spring 9. Fixed sheave (driven clutch) Drive Train 1. Drive clutch 2. Driven clutch 3. Moveable sheave (drive clutch) Two Clutch System (Fig.
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Drive Clutch 2 1 3 4 5 6 v 7 8 9 Figure 4 1. Fixed sheave 2. Moveable sheave 3. Spider assembly 7. Spring 8. Cam weight 9. Roller 4. Cover 5. Washer 6. Plastic cap Principles of Operation (Fig. 4) The operation of the drive clutch is affected by engine shaft speed. With the engine not turning, the drive belt rests low within the drive clutch sheaves as the pressure of the spring holds the sheaves apart.
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Driven Clutch Principles of Operation (Fig. 5) The operation of the driven clutch is affected by load. When the vehicle is stopped, the drive belt is held at the outer diameter of the driven clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam. Three sets of buttons on the moveable sheave provide a low friction surface on which the sheave can slide on the ramp of the fixed cam.
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Troubleshooting Transaxle Symptom Possible Causes Noisy operation. Low oil level in transaxle. Damaged or worn transaxle bearings. Gears worn, scuffed, or broken. Excessive end play in countershaft. Gears loose on transaxle shaft. Excessive wear of differential side gear liners and pinion liners. Excessive wear of splined slider on axle drive joints. Difficult shifting. Shift cable out of adjustment. Shift cable damaged. Shifter capscrew loose (at operator station). Loose shift lever on transaxle.
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Transaxle (continued) Symptom Possible Causes Gears make clashing noise when shifting. Shifting too fast. Excessive wear of synchro rings. Excessive wear of differential side gear thrust washers and/or pinion gear washers. Damaged synchro springs and/or keys. Main gear needle bearings worn or damaged. Excessive wear of driveshaft(s). Transaxle sticks in gear. Shift fork detent ball stuck. Shift linkage damaged, loose, or out of adjustment. Sliding gears tight on shaft splines.
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Adjustments Shift Cable Adjustment (Fig. 6) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. Place the shift lever in the neutral position. 2 2. Remove cotter pins and clevis pins that secure cable clevis to shift levers. 1 3 4 3. Check that the threads of the shift cables are centered in the mounting brackets. If needed, readjust shift cable jam nuts. 4.
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Service and Repairs Drive Belt Service Inspection NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual. 1 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Put vehicle transmission in neutral. 3. Rotate and inspect drive belt for excessive wear or damage. Replace belt as necessary. 2 Replacement (Fig. 7) 1.
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Drive Clutch 8 45 ft–lb (61 N–m) 7 6 5 14 1 13 12 2 3 7 4 9 6 15 Loctite #242 5 10 11 FRONT LEFT Figure 8 1. 2. 3. 4. 5. Drive clutch Flat washer Lock washer Cap screw Cap screw Drive Train 6. 7. 8. 9. 10. Lock washer Belt guide Engine Steering pump belt Steering pump Page 7 – 10 11. 12. 13. 14. 15.
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Removal (Fig. 8) Installation (Fig. 8) 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 1. Slide drive clutch onto engine shaft. 2. To ease drive clutch removal, lower engine mounting plate from machine (see Engine Mounting Plate Assembly Removal in the Service and Repairs section of Chapter 3 – Kohler Gasoline Engine). 3. Remove drive belt from the drive clutch (see Drive Belt Service). 4.
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Drive Clutch Service 11 1 100 ft–lb (136 N–m) 7 4 75 to 100 in–lb (8.5 to 11.3 N–m) 5 2 3 6 10 8 12 9 v Figure 9 1. 2. 3. 4. Fixed sheave Spring Washer Spider assembly 5. 6. 7. 8. 9. 10. 11. 12. Cap screw (3 used) Plastic cap Cover Moveable sheave Roller kit (3 used) Cam weight (3 used) Lock nut (3 used) Pilot bolt (3 used) Disassembly (Fig. 9) IMPORTANT: Do not pry off cover, damage may result. Cover should pop off. 1. Remove cap screws securing the cover to the movable sheave.
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Inspection 2 1. Inspect the tapered ends of the crankshaft and primary fixed sheave for scratches. If either is severely scratched, replace component. If scratches are minor, burnish the component with emery cloth. 2. Check the contact surface of the cam weights. If worn, replace all cam weights as a set (Fig. 11). 3. Check the rollers. If binding or uneven wear is found, replace all rollers as a set (Fig. 12). 1 Figure 11 1. Cam weight 4.
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Driven Clutch 7 9 6 5 4 3 2 1 Anti–seize Lubricant 12 8 7 6 11 5 10 FRONT LEFT Figure 14 1. 2. 3. 4. Driven clutch Drive belt Flat washer Lock nut (LH thread) 5. 6. 7. 8. Cap screw Lock washer Belt guide Drive clutch 9. 10. 11. 12. Engine Pump drive gearbox Pump drive electric clutch Spacer Removal (Fig. 14) Installation (Fig. 14) 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 1.
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4. Measure spring torsion. Ramp Button Replacement (Fig. 15) 1. Remove drive belt from the driven clutch (see Drive Belt Service). A. Pull spring tension scale tangentially to the outer diameter of the moveable sheave. 2. Turn fixed and moveable sheaves in opposite directions so buttons are separated sufficiently enough from the ramp to allow removal. B. When the button on the ramp of the moveable sheave is 0.125” (3.18 mm) from the ramp of the fixed sheave, read the scale. 3.
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Pump Drive Gearbox 14 13 12 11 Anti–seize Lubricant 10 9 15 21 7 6 2 5 20 22 4 8 23 2 1 19 3 Anti–seize Lubricant Loctite #242 16 24 18 FRONT 17 Loctite #242 LEFT Figure 16 1. 2. 3. 4. 5. 6. 7. 8. Pump drive gearbox Key Spacer Pump drive electric clutch Shoulder bolt Coupler/nipple Breather Flange head screw (4 used) Drive Train 9. Spacer 10. Driven clutch 11. Drive belt 12. Flat washer 13. Lock nut (LH thread) 14. Engine 15. Drive clutch 16. Lock nut (4 used) Page 7 – 16 17.
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Removal (Fig. 16) Installation (Fig. 16) 1. Park vehicle on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 1. Position gearbox to engine mounting plate. Secure gearbox to mounting plate with four flange head screws and lock nuts. 2. To ease gearbox removal, lower engine mounting plate assembly from machine (see Engine Mounting Plate Assembly Removal in the Service and Repairs section of Chapter 3 – Kohler Gasoline Engine). 3.
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Pump Drive Gearbox Service 9 8 3 2 1 4 6 5 2 7 8 ft–lb (10.8 N–m) 1 10 11 12 Loctite #242 13 8 ft–lb (10.8 N–m) 14 Thread Sealant 15 21 18 7 19 Loctite #242 Loctite #271 23 20 22 16 15 17 14 26 13 18 25 17 8 ft–lb (10.8 N–m) 5 7 10 11 16 Loctite #242 24 8 ft–lb (10.8 N–m) Loctite #242 7 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. Bearing cup Bearing cone Worm gear Key Red shim (.002”) Open output cap Cap screw (4 per cap) Output shaft seal Retaining ring 10. 11. 12. 13.
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7. Remove seals from open caps taking care not to damage seal bores. Clean seal bore in caps. Remove and discard o–rings from caps. 1 8. If required, press bearings from input shaft (item 26). 3 2 9. If necessary, remove bearing cups from output caps. Make sure to remove bearing cups evenly to prevent damage to output caps. IMPORTANT: Do not attempt to remove both bearing cones and gear from output shaft at the same time. The key (item 4) will cause severe damage to gear, shaft, and bearings. 3 10.
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7. Slide output shaft with worm gear and bearing cones into housing. Align output shaft worm gear with input shaft gear. 8. Adjust output shaft end play. A. Position one red (.002”) and one blue (.005”) shim to both openings of gearbox housing. 11. Install retaining ring to output shaft. 12.If breather assembly was removed from gearbox, apply Loctite #271 (or equivalent) to threads on each end of nipple. Install nipple into gearbox housing and then thread coupling onto nipple.
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Stub Axle and Driveshaft Loctite #242 220 to 250 ft--lb (298 to 339 N--m) 27 75 ft--lb (101 N--m) Loctite #242 28 13 29 23 22 12 21 11 10 9 Loctite #680 8 7 26 25 40 to 60 ft--lb (54 to 81 N--m) 6 5 24 4 45 to 65 ft--lb (61 to 88 N--m) 20 19 200 to 250 in--lb (23 to 28 N--m) 18 1 30 17 16 RIGHT 15 Anti--seize Lubricant 14 FRONT 3 2 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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Bearing Service (Fig. 21) 2. If driveshaft was removed from transaxle: 1. Inspect bearings and replace if necessary. If outer bearing is removed from stub axle, bearing set must be replaced. A. Apply anti--seize lubricant to transaxle shaft. Slide driveshaft clamp end onto splined transaxle shaft. IMPORTANT: Bearings, with bearing cups and thin spacer, are a MATCHED SET. Use one bearing set for each axle housing. Bearing set components are NOT INTERCHANGEABLE. B.
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Driveshaft Universal Joint Service 1. Remove driveshaft from machine: TRANSAXLE DRIVESHAFT A. For transaxle driveshaft (Fig. 22) removal, see Pump Drive Gearbox Removal in this section. 3 2 4 5 1 6 B. For rear axle driveshaft (Fig. 23) removal, see Stub Axle and Driveshaft Removal in this section. 7 8 2. Remove snap rings that secure bearings. 7 IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage. 10 3. Use a press to remove cross and bearings from yokes.
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Transaxle 8 8 9 10 11 12 39 Loctite #242 38 22 21 7 6 37 1 Anti–seize Lubricant 13 20 5 4 3 2 19 24 25 23 14 22 21 20 18 16 19 26 13 32 44 33 42 45 43 30 RIGHT 31 FRONT 34 36 35 34 33 Anti–seize Lubricant 29 15 18 17 Loctite #242 41 40 28 32 27 80 to 90 ft–lb (108 to 122 N–m) Figure 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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Removal (Fig. 24) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain oil from transaxle (see Operator’s Manual). 1 3. Disconnect negative (–) cable from battery first and then positive (+) cable. 2 4. Block front wheels. Jack–up rear of machine and secure machine with jack stands or blocks so transaxle can be removed by sliding out under rear of machine (see Jacking Instructions in Operator’s Manual). 5.
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Installation (Fig. 24) 1. Lubricate new oil strainer o–ring with Dexron III ATF oil and position on strainer. Install strainer into transaxle and torque from 80 to 90 ft–lb (108 to 122 N–m). 2. If removed, install front transaxle mount, shift cable mount, and transaxle strap mounts to transaxle. 1 3. Apply anti–seize lubricant to transaxle shafts. 2 4. Position transaxle to machine. Slide universal joint of transaxle driveshaft onto input shaft of transaxle.
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Transaxle Service Transaxle Disassembly 1. Thoroughly clean outside surface of transaxle. 3 NOTE: Item numbers in figures are shown in order of disassembly; for example, remove Item 1 first, then Item 2, etc. Reassemble in reverse order; for example, install Item 1 last. 2 1 2. Remove three (3) cap screws that secure input shaft cover plate to transaxle. Remove cover plate. 1 3. Loosen four (4) cap screws (Items 1 and 2) and remove fork shaft cap (Item 3) from center plate.
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7. Remove reverse shaft (Item 1) from transaxle case. 1 Figure 32 8. Remove main shaft assembly (Item 1) together with 2nd–3rd fork shaft assembly (Item 2) from transaxle case. 2 1 NOTE: This shaft not used on Multi Pro Figure 33 9.
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10.Loosen five (5) cap screws (Item 1) and remove differential carrier with L.H. axle shaft assembly (Item 2) and shims (Item 3) from side cover (Item 4). 3 2 1 4 Figure 35 11. Loosen cap screws (Item 1) and remove side cover (Item 2) from transaxle case. Note locations of two dowel pins (Item 3) in transaxle case. 3 1 12.Inspect side cover for cracks or damage and replace if necessary. 2 Figure 36 13.Loosen cap screws (Item 1) and remove R.H. axle shaft assembly (Item 2) from transaxle case.
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15.To remove shift arms: 8 4 A. Loosen and remove lock nut (Item 8) that secures 2nd–3rd shift arm (Item 1). Remove flat washer (Item 7), and 2nd–3rd shift arm together with shift arm plate (Item 6), compression spring (Item 2), lock nut (Item 5), flat washer (Item 3) and cap screw (Item 4). 7 3 6 2 5 1 B. Loosen and remove lock nut (Item 8) that secures 1st–reverse shift arm (Item 9). Remove flat washer (Item 7). Remove 1st–reverse shift arm lever. 8 10 11 9 12 13 7 10 13 C.
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21.Disassemble main shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from main shaft. B. Remove snap ring (Item 2) and thrust washer (Item 3). Measure thickness of thrust washer. Replace washer if it is less than .0709” (1.8 mm) thick. C. Remove two (2) needle bearings (Item 5) and 36T gear (Item 4). Inspect needle bearings and replace if necessary. D. Remove synchro ring (Item 6). Figure 42 E. Remove retaining ring (Item 7). F.
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22.Disassemble reduction shaft assembly: 1 A. Use a bearing puller to remove bearing (Item 1) from reduction shaft. 5 3 14 13 15 7 B. Remove 25T gear (Item 2), 23T helical gear (Item 3), collar (Item 4), and 32T gear (Item 5). C. Use a bearing puller to remove bearing (Item 6). D. Remove thrust washer (Item 7), needle bearing (Item 9), and 40T gear (Item 8). 18 E. Remove retaining ring (Item 11). 2 4 17 16 12 11 8 F.
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23.Disassemble reverse shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from reverse shaft. B. Remove 33T gear (Item 2). C. Use a bearing puller to remove bearing (Item 3) from reverse shaft. Figure 46 24.Disassemble countershaft assembly: A. Use a bearing puller to remove bearing (Item 1) from countershaft. B. Remove collar (Item 2) and retaining ring (Item 3). C. Remove thrust washer (Item 4) and 49T gear (Item 5). Measure thickness of thrust washer.
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25.Disassemble fork shaft assemblies: 3 A. Remove spring pin (Item 1) from 2nd–3rd fork shaft assembly. 6 1 4 B. Remove shift fork (Item 2) from fork shaft (Item 3). C. Remove spring pin (Item 4) from 1st–Reverse fork shaft assembly. 5 2 D. Remove fork (Item 5) from fork shaft (Item 5). Figure 49 26.Disassemble differential gear assembly: 1 4 A. Use a bearing puller to remove bearing (Item 1) from differential case. 10 7 2 B. Remove retaining ring (Item 2). C.
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27.Disassemble differential carrier (L.H. axle shaft) assembly: A. Remove O–ring (Item 1) from differential carrier. B. Remove retaining ring (Item 2) from differential carrier. C. Remove L.H. axle shaft assembly (Item 3) from differential carrier. D. Remove retaining ring (Item 4) and washer (Item 5) from axle shaft. L.H. SHAFT E. Use a bearing puller to remove bearing (Item 6) from axle shaft. Figure 52 F. Remove oil seal (Item 7) from differential carrier (Item 8). 28.Disassemble R.H.
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Transaxle Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Inspect synchronizer ring: A. Inspect the chamfer for excessive wear or damage. B. Inspect inner tapered area for excessive wear or damage. C. Measure the clearance between synchronizer ring and synchro gear in three equally spaced points. If clearance is less than .0197” (0.5 mm) replace the synchronizer ring. Figure 54 4. Inspect synchro gears: A.
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5. Inspect hub, shifter, synchro keys, and synchro springs: A. Inspect hub for worn or damaged spline. B. Inspect shifter for chipping or damaged chamfer. C. Inspect synchro keys for wear or damage. D. Inspect synchro springs for wear or damage. E. The shifter should move freely on the hub. F. Measure the clearance between shifter groove and fork. Replace shift fork if the clearance exceeds .039” (1.0 mm). Figure 57 6. Inspect main shaft: A. Inspect main shaft for worn or damaged surfaces. If O.D.
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8. Inspect center plate for cracks and damage. Replace center plate if the retaining ring groove has more than 15% of its edges damaged due to nicks, rounding, cracks, or dents (Fig. 60 and 61). UNDAMAGED GROOVE EDGES Figure 60 DAMAGED GROOVE EDGES Figure 61 9. Inspect reduction shaft: A. Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than .864” (21.95 mm) or .982” (24.95 mm), replace the reduction shaft. STD. O.D. 0.984” (25 mm) Reject O.D. 0.982” (24.95 mm) STD. O.
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10.Inspect countershaft: A. Inspect countershaft for wear or damage. If O.D. of inner portion is less than 1.100” (27.95 mm) or 71T gear portion is less than 1.179” (29.95 mm), replace the countershaft. B. Inspect the gear contact condition of the bevel gear. 71 TOOTH GEAR INNER PORTION Figure 63 11. Inspect differential: A. Inspect pinion shaft for excessive wear or damage. If O.D. is less than .707” (17.95 mm), replace the pinion shaft. B. Measure thickness of pinion shaft washers.
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Transaxle Assembly NOTE: Item numbers in figures are shown in reverse order of assembly; for example, when reassembling, install Item 1 last. IMPORTANT: Be careful not to damage mating surfaces when removing gasket material. 1. Clean gasket material from all transaxle mating surfaces before reassembling. Make sure all parts are clean and free of dirt and dust. 2. Assemble differential carrier (L.H. axle shaft) assembly (Fig. 65): A.
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4. Assemble differential gears: 1 4 A. Apply moly disulfide grease on washers (Item 10), holes of pinion gears (Item 9), side gear thrust washers (Item 13), and hubs of side gears (Item 11 and 12). 10 7 2 B. Install side gear thrust washers (Item 13), side gears (Item 11 and 12), washers (Item 10), and differential pinion gears (Item 9) into differential case. C. Rotate side gears until holes of pinion gears and washers line up with holes of differential case. D.
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5. Assemble 1st–reverse and 2nd–3rd fork shaft: 3 A. Insert 1st–reverse fork shaft (Item 3) into 1st–reverse fork (Item 2). 6 1 4 B. Drive spring pin (Item 1) into fork and fork shaft. Pay attention to direction of slit in spring pin. C. Insert 2nd–3rd fork shaft (Item 6) into 2nd–3rd fork (Item 5). 5 2 Figure 70 D. Drive spring pin (Item 4) into fork and fork shaft. Pay attention to direction of slit in spring pin. 6. Assemble countershaft: A.
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7. Assemble synchro hub: A. Install three (3) keys (Item 1) into grooves of hub (Item 2). 1 2 Figure 73 B. Install shifter (Item 1) onto hub assembly (Item 2). 1 2 Figure 74 C. Insert two (2) springs (Item 1) into hub to secure hub assembly. Pay attention to direction of spring.
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8. Assemble reduction shaft: 1 A. Apply moly disulfide grease to thrust washer (Item 16) and two (2) needle bearings (Item 15). Install washer, needle bearings, and 47T gear (Item 14) onto reduction shaft (Item 17). Oil groove on washer must face the gear. 5 3 14 13 10 15 7 B. Apply Dexron III ATF oil on cone face of gear (Item 14). Install synchro ring (Item 13) onto gear. C. Insert key (Item 12) into reduction shaft slot. 18 D. Install synchro hub sub–assembly (Item 11). 2 4 17 16 12 11 8 E.
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10.Assemble main shaft: A. Install 16T gear (Item 18), 20T gear (Item 17) and retaining ring (Item 16). B. Install 14T gear (Item 15). C. Use a press to install bearing (Item 14) onto shaft. D. Apply moly disulfide grease onto thrust washer (Item 13) and two (2) needle bearings (Item 12). Install washer and needle bearings onto main shaft. Oil groove on washer must face the gear. Figure 80 E. Install 22T gear (Item 11) and retaining ring (Item 10). F.
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11. Assemble shift arms: A. Apply multi–purpose grease on lips of three (3) new oil seals (Item 14). Install oil seals into transaxle case. 3 18 to 22 ft–lb (24.5 to 29.5 N–m) 6 2 5 1 B. Position three (3) keeper plates (Item 13) and secure with three (3) cap screws (Item 12). Torque cap screws from 11 to 13 ft–lb (15 to 17 N–m). C. Apply Loctite #680 (or equivalent) to threads of 2–3 shift fork arms. 8 7 4 10 11 13 12 Apply Loctite #680 to threads 11 to 13 ft–lb (15 to 17 N–m) 8 7 9 D.
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12.Install reduction shaft and countershaft together with 1st–reverse fork shaft. Insert head of shift arm into groove of fork (Item 1) when installing assembly. 1 NOTE: This shaft not used on Multi Pro Figure 84 NOTE: Not used on Multi Pro Figure 85 13.Install main shaft together with 2nd–3rd fork shaft. Insert head of shift arm into groove of fork (Item 1) while installing.
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14.Install reverse shaft (Item 1) into transaxle case. Rotate main shaft and reverse shaft gears to mesh gears when installing. 1 Figure 88 15.Install center plate onto transaxle: 18 to 22 ft–lb (24.5 to 29.5 N–m) A. Thoroughly clean mating surfaces of transaxle case and center plate. Insert two (2) dowel pins into transaxle case. B. Apply silicone sealant onto mating surface of center plate. Carefully install center plate onto transaxle case. C.
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IMPORTANT: The center plate uses one tabbed shim (Item 4) with three tabless shims (Item 3) (Fig. 90). NOTE: The thickest shim of the shim set (Item 3) should be positioned against the retaining ring (Fig. 90). 2 4 1 3 16.Insert tabbed shim (Item 4) against the bearing. Insert shim set (Item 3) against the tabbed shim. Use thickest shims in set possible, that will permit installation of the snap ring (Fig. 90 and 91). Figure 90 5 3 1 6 2 4 Figure 91 1. Countershaft 2. Bearing 3. Shims 4.
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18.Measure countershaft end play. Rotate one of the axle shafts back and forth to take up all back lash. Rotating the shaft in one direction will pull the shaft and bearing away from the snap ring. Rotate axle shaft in this direction, then measure space between the retaining ring and shim (set) with a feeler gauge. Make sure shim set is pressed against the bearing during the measurement. End play should be 0.000” to 0.0039” (0.0 to 0.10 mm) (Fig. 93).
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20.Install fork shaft case: A. Thoroughly clean mating surface of transaxle case and fork shaft case. B. Insert spindle lock (Item 1) between fork shafts. 1 Figure 95 C. Insert two (2) steel balls (Item 2) and two (2) springs (Item 1) into the grooves of the center plate. 1 2 1 2 Figure 96 D. Apply silicone sealant to mating surface of fork shaft case. Install fork shaft case (Item 3). Install cap screws (Items 2 and 1) noting location of longer screw (Item 1).
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21.Install differential gear assembly (Item 2) into transaxle case. 1 2 22.Insert two (2) dowel pins (Item 1) into transaxle case. 1 Figure 98 23.Install side cover: 18 to 22 ft–lb (24.5 to 29.5 N–m) A. Thoroughly clean mating surfaces of transaxle case and side cover. Apply silicone sealant onto mating surface of side cover. B. Install side cover and secure with cap screws. Torque cap screws from 18 to 22 ft–lb (24.5 to 29.5 N–m). NOTE: This shaft not used on Multi Pro Figure 99 24.Install R.H.
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25.Install L.H. axle shaft assembly: A. Thoroughly clean mating surface of differential carrier and side cover (Item 2). 2 B. Insert selected shims (Item 1) into housing of side cover. NOTE: The thickest shim should be inserted against the bearing. 1 Figure 101 C. Install axle shaft assembly and secure with cap screws (Item 1). Torque cap screws from 18 to 22 ft– lb (24.5 to 29.5 N–m). 18 to 22 ft–lb (24.5 to 29.5 N–m) 1 Figure 102 26.Measure backlash of ring gear through P.T.O.
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27.Apply multi–purpose grease to P.T.O. cover O–ring and insert O–ring into groove of transaxle case. Position P.T.O. cover (Item 5) to transaxle case. Install five (5) cap screws (Item 4) and nut with lock washer (Item 3). Tighten cap screws and nut to a torque of 11 to 13 ft–lb (15 to 17 N–m). 3 1 11 to 13 ft–lb (15 to 17 N–m) 28.If removed, install oil cap (Item 2) with O–ring to transaxle case. 29.If removed, apply sealing tape to threads of air breather (Item 1) and install air breather.
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Chapter 8 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Front Wheels and Brakes . . . . . . . . . . . . . . . . . . . . 4 Front Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear Wheels and Brakes . . . . . . . . .
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Specifications Item Description Front tire pressure (18 x 9.5 – 8, 4 ply, tubeless) 18 PSI (1.24 bar) Maximum Rear tire pressure (24 x 13 – 12, 4 ply, tubeless) 18 PSI (1.24 bar) Maximum Front wheel lug nut torque 55 to 65 ft–lb (75 to 88 N–m) Rear wheel lug nut torque 45 to 65 ft–lb (61 to 88 N–m) Front wheel Toe–in Chassis 0 to 1/8 inch (0 to 3.
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Adjustments Front Suspension Any time the front wheel toe–in is checked, the front suspension should be checked as well. Incorrect suspension setting can affect steering and can cause accelerated tire wear and scuffing. IMPORTANT: When checking suspension, vehicle spray tank should be approximately half full and operator should be in seat. IMPORTANT: Prior to checking front suspension, drive the machine straight forward at least 15 feet to allow the suspension to relax. Do not turn steering wheel.
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Service and Repairs Front Wheels and Brakes 12 5 6 11 10 55 to 65 ft–lb (75 to 88 N–m) 8 9 7 13 6 14 5 17 to 19 ft–lb (23 to 25 N–m) 4 3 2 1 See text for tightening procedure Figure 3 1. 2. 3. 4. 5. Dust cap Slotted hex nut Washer Wheel and tire assembly Wheel bearing cone 6. 7. 8. 9. 10. Wheel bearing cup Wheel hub/drum Lock nut (4 per wheel) Front brake assembly Front spindle Removal (Fig. 3) 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. 11. 12.
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A. Clean hydraulic brake line area of brake assembly to prevent contamination. Loosen and disconnect brake line from wheel cylinder. Cap brake line and position it away from brake assembly. B. Remove four flange head screws and lock nuts that secure the brake assembly to the front spindle. C. Remove brake assembly from spindle. 4. Install the wheel hub/drum onto the spindle shaft taking care to not damage seal. 5. Install greased outer bearing cone, washer, and slotted hex nut onto spindle shaft. 6.
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Front Brake Service 1 110 to 120 in–lb (12.4 to 13.6 N–m) 5 3 2 10 4 8 9 7 110 to 120 in–lb (12.4 to 13.6 N–m) 6 8 13 6 11 12 10 13 Figure 4 1. 2. 3. 4. 5. Flange head screw Cap screw (2 used per wheel) Flat washer (2 used per wheel) Lock washer Brake backing plate 6. 7. 8. 9. 10. 11. 12. 13. Belleville washer Dust cover Adjuster lever Wheel cylinder Disassembly (Fig. 4) 4. If brake assembly is still on machine and wheel cylinder removal is necessary: A.
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Inspection 1. Inspect brake shoes. IMPORTANT:Replace front brake shoes as a set (all four shoes on both wheels) to maintain equal braking forces. 2. If removed, position lubricated belleville washer between adjuster lever and backing plate. Secure adjuster to backing plate with washer and cap screw. Torque bolt from 110 to 120 in–lb (12.4 to 13.6 N–m). 3. If removed, install wheel cylinder: A. Secure wheel cylinder to backing plate with two flange head screws. Torque screws from 110 to 120 in–lb (12.
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Rear Wheels and Brakes Thread locking compound 17 10 12 18 40 to 60 ft–lb (54 to 81 N–m) 11 9 8 45 to 65 ft–lb (61 to 88 N–m) 7 6 5 16 4 15 14 1 13 RIGHT FRONT 3 2 Figure 5 1. 2. 3. 4. 5. 6. Lug nut (5 used per wheel) Flange head screw Wheel assembly Brake drum Stub axle Lock washer (5 used per wheel) 7. 8. 9. 10. 11. 12. Drive stud (5 used per wheel) Cap screw (4 used per wheel) Lock washer (4 used per wheel) Brake assembly Brake cable clip Axle housing 13. 14. 15. 16. 17. 18.
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6. Inspection and service of rear brakes can be completed with brake assembly on machine (see Rear Brake Service). If required, brake assembly can be removed from machine as follows: A. Remove parking brake cable from brake assembly (see Parking Brake Cable Removal). B. Clean hydraulic brake line area of brake assembly to prevent contamination. Loosen and disconnect brake line from wheel cylinder. Cap brake line and position it away from brake assembly. C.
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Rear Brake Service 15 49 to 97 in lb (5.5 to 11 N–m) 1 16 2 14 3 13 17 18 12 19 4 7 6 5 8 9 3 11 10 Figure 7 1. 2. 3. 4. 5. 6. 7. Pin Parking brake lever Brake shoe Upper spring Lower spring Brake adjuster assembly Brake cylinder assembly Chassis 8. 9. 10. 11. 12. 13. Parking brake pawl with pin Adjuster spring Hold down washer (2 used per wheel) Hold down spring (2 used per wheel) Bleed screw Cap Page 8 – 10 14. 15. 16. 17. 18. 19.
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Disassembly (Fig. 7) Assembly (Fig. 7) 1. If brake assembly is still on machine, remove parking brake cable (see Parking Brake Cable Removal). IMPORTANT:Brake shoe lining surfaces must be free of grease, oil, and other foreign matter. 1. Apply a light film of lubricant to the following: CAUTION A. Ledges on which the brake shoes rest. Be careful when removing springs from brake shoes. The springs are under heavy tension and may cause personal injury. 2. Remove upper and lower springs from brake shoes.
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Brake Lines 6 7 2 4 3 5 4 2 3 5 2 8 3 2 2 4 3 1 5 10 4 9 11 3 10 12 13 4 3 4 2 3 2 RIGHT FRONT 14 15 Figure 8 1. 2. 3. 4. 5. Rear LH brake tube Tube clamp Flat washer Lock nut R–clamp 6. 7. 8. 9. 10. Tee fitting Rear RH brake tube Rear supply brake tube Front RH brake tube Retainer clip 11. 12. 13. 14. 15.
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Parking Brake Cables Removal 1. Loosen set screw on parking brake lever knob (Fig. 9). Turn knob on parking brake lever counterclockwise fully to loosen cable adjustment. 2 2. Raise seat to allow access to cable connection at parking brake lever. 3. Remove cotter pin, flat washer, and clevis pin that secure brake equalizer to parking brake lever (Fig. 10). 1 4. Remove retaining rings that secure brake cables to frame. Remove cable ends from equalizer plate (Fig. 10). 5.
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Brake Master Cylinder Service Testing 1 1. Insure that brake system is properly adjusted and bled. 2 12 3 2. Apply light pressure to brake pedal. 3. If brake pedal fades or falls away while applying light pressure to pedal, the master cylinder should be serviced. 4 11 Disassembly (Fig. 12) 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2. Disconnect lower end of the dust cover from the housing. 3.
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Bleed Brake System After loosening or removing any hydraulic brake component, the brake system should be bled to insure proper brake operation. NOTE: A power/vacuum brake bleeding tool will provide faster and more effective brake bleeding than manual bleeding. 4. Repeat procedure until a continuous flow of brake fluid, with no air bubbles, is released from bleeder valve. Make sure fluid level is maintained in brake fluid reservoir at all times. 5. Repeat steps 1 to 4 for other wheel cylinders. 1.
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Front Suspension 200 to 250 ft–lb (271 to 339 N–m) 1 1 130 to 150 ft–lb (176 to 203 N–m) 2 30 24 23 22 29 3 21 12 4 17 28 6 27 15 13 19 26 5 18 25 20 12 11 10 9 14 Minimum 140 ft–lb (189 N–m) 15 13 12 16 7 FRONT 17 RIGHT 19 11 18 8 10 9 Minimum 140 ft–lb (189 N–m) Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cap screw Cap screw Flange head screw (4 used) Skid plate Flange head screw Pivot pin Flange bushing A–arm Cotter pin Slotted hex nut Chassis 11. 12. 13. 14. 15. 16.
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3. Lubricate suspension grease fittings (see Operator’s Manual). Disassembly (Fig. 13) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key. 2. Lift front of machine using a jack or hoist to allow front suspension to hang freely from machine. Chock rear wheels to prevent vehicle from shifting. 3. Remove front wheel assembly (see Front Wheels and Brakes). 4. Support brake and spindle assembly to prevent them from falling during disassembly.
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Steering Assembly 3 2 4 1 3 11 5 6 10 9 7 1 8 9 1 8 7 10 12 13 14 4 3 5 26 3 15 16 19 20 1 22 21 10 17 24 3 23 18 3 19 FRONT RIGHT Minimum 140 ft–lb (189 N–m) 20 21 25 22 24 23 Minimum 140 ft–lb (189 N–m) Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. Cotter pin Slotted hex nut Grease fitting Jam nut Tie rod end Retaining ring Thrust washer Bearing Slotted hex nut Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Disassembly (Fig. 15) Assembly (Fig. 15) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1. Assemble steering components using Figure 15 as a guide. 2. Jack front of machine off ground (see Operator’s Manual). Front of machine should be lifted enough to allow front suspension to hang freely from machine. 2.
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Tie Rod End Replacement Removal (Fig. 16) 4 1. Loosen jam nut on tie rod end. Note: outside tie rod end that is attached to spindle has left hand threads. 5 6 2. Remove cotter pin and slotted hex nut from tie rod end to be removed. 3. Use a suitable puller to separate tie rod end from spindle (outside tie rod end) or steering pivot (inside tie rod end). 8 7 6 2 4.
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Ball Joint Replacement Removal (Fig. 17) 2 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. 1 3 2. Lift front wheel off the ground using a jack (see Jacking Instructions in Operator’s Manual). Block front and rear of other wheels. 4 5 9 Minimum 140 ft–lb (189 N–m) 3. Remove lug nuts and wheel assembly. 8 7 4. Support axle, spindle, and a–arm to prevent them from falling during disassembly. 5.
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Seat Base (Multi Pro 1200) 8 13 11 2 10 14 8 9 12 2 3 4 5 10 5 8 1 7 12 5 4 3 3 4 5 2 5 5 4 4 2 3 2 3 FRONT RIGHT 15 16 6 Figure 18 1. 2. 3. 4. 5. 6. Seat base Cap screw Flat washer Rubber washer Spacer Flange head screw Chassis 7. 8. 9. 10. 11. L bracket Phillips head screw Console Well nut Spray control panel Page 8 – 22 12. 13. 14. 15. 16.
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Removal (Fig. 18) 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. 2. Disconnect negative (–) cable and then positive (+) cable from battery (see Operator’s Manual). 1 3. Remove seat assembly by tilting seat forward and removing hitch pin and clevis pin (Fig. 19). 2 4. Remove screws that secure control panels to seat base. Carefully place control panels into seat base openings. 3 5. Remove knob from shift lever. 6.
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Seat Base (Multi Pro 1250) 2 11 10 12 9 2 8 9 3 4 13 8 1 5 5 2 3 12 4 5 5 4 3 6 5 4 2 3 7 5 4 3 2 2 FRONT RIGHT Figure 20 1. 2. 3. 4. 5. Seat Base Flange head screw Flat washer Rubber washer Spacer Chassis 6. 7. 8. 9. Support bracket Flange nut Well nut Phillips head screw Page 8 – 24 10. 11. 12. 13.
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Removal (Fig. 20) 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. 2. Disconnect negative (–) cable and then positive (+) cable from battery (see Operator’s Manual). 1 3. Remove seat assembly by tilting seat forward and removing hitch pin and clevis pin (Fig. 21). 2 4. Remove screws that secure control panels to seat base. Carefully place control panels into seat base openings. 3 5. Remove knob from shift lever. 6.
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Sonic Boom System (Optional Kit) Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . 2 Precautions Concerning Chemicals Used in Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Precautions for Removing or Adjusting Spray System Components . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATIC . .
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General Information Installation Instructions The Sonic Boom Kit Installation Instructions provides information regarding the installation, operation and general maintenance for your Sonic Boom System. Refer to that publication for additional information when servicing the machine. Precautions Concerning Chemicals Used in Spray System Chemicals can injure persons, animals, plants, soil and other property. To eliminate environmental damage and personal injury: 1. Select the proper chemical for the job. 2.
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Sonic Boom System Special Tools Diagnostic Display The Diagnostic Display (Fig. 1) can be connected to the Sonic Boom wire harness communication connector to verify correct electrical functions of the Sonic Boom System. electronic control unit (ECU) inputs and outputs for the Sonic Boom System can be checked using the Diagnostic Display.
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Sonic Boom System (Optional Kit) Page 8.1 -- 4 Rev.
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Sonic Boom System This page is intentionally blank. Multi Pro 1200/1250 Page 8.1 -- 5 Rev.
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Sonic Boom System (Optional Kit) Page 8.1 -- 6 Rev.
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Sprayer Operation on Level Turf Sonic Boom System During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo.
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Sonic Boom System (Optional Kit) Page 8.1 -- 8 Rev.
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During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the elapsed time between the sensor signal generation and the received echo.
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Sonic Boom System (Optional Kit) Page 8.1 -- 10 Rev.
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During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo.
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Sonic Boom System (Optional Kit) Page 8.1 -- 12 Rev.
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During sprayer operation with the sonic boom switch in the automatic position (sonic boom light is illuminated), the boom mounted sonic boom sensors continually send impulse signals and then receive echos as the signals bounce off the turf. The electronic control unit (ECU) determines the sensor distance from the ground based on the time between the sensor signal generation and the received echo.
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Sonic Boom System (Optional Kit) Page 8.1 -- 14 Rev.
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During sprayer operation with the sonic boom switch in the manual position, the spray booms will remain in position unless the operator presses a boom actuator switch. When the sonic boom switch is in the manual position, the sonic boom light should be illuminated. The operator will control the boom position with the boom actuator switches.
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Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on the Sonic Boom System (see Sonic Boom System Operation in this chapter). NOTE: When troubleshooting an electrical problem on your Sonic Boom System, refer to information regarding the sonic boom light in this section. Also, use the Diagnostic Display (see Special Tools in this chapter) to test electronic control unit (ECU) inputs and outputs.
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The Sonic Boom System is equipped with an electronic control unit (ECU) which controls machine sonic boom electrical functions. The ECU monitors various input switches (e.g. boom actuator switches, sonic boom sensors) and energizes outputs to actuate relays for appropriate machine functions. For the ECU to control the machine as desired, each of the inputs (switches and sensors) and outputs (relays) must be connected and functioning properly.
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Diagnostic Display Inputs Diagnostic Display LED Operation AUTO MODE Sonic mode switch in auto position: LED ON Sonic mode switch not in auto position: LED OFF L RAISE Left boom actuator switch in raise position: LED ON Left boom actuator switch not in raise position: LED OFF L LOWER Left boom actuator switch in lower position: LED ON Left boom actuator switch not in lower position: LED OFF R RAISE Right boom actuator switch in raise position: LED ON Right boom actuator switch not in raise position
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The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the electronic control unit (ECU). This is a quick way to determine which electrical component is malfunctioning. NOTE: An open output (e.g. an unplugged connector or a broken wire) cannot be detected with the Diagnostic Display. NOTE: It may be necessary to toggle between “INPUTS DISPLAYED” and “OUTPUTS DISPLAYED” several times to perform the following step.
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Troubleshooting Chart The chart that follows contains suggestions that can be used to assist in diagnosing Sonic Boom System performance issues. These suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem. NOTE: When troubleshooting an electrical problem on your Sonic Boom System, refer to information regarding the sonic boom light in this section.
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Possible Cause One of the boom actuators will not extend. 30 amp auto resetting fuse for affected boom actuator is faulty. Power switch relay or circuit wiring for affected boom actuator is faulty. Boom actuator switch or circuit wiring for affected boom actuator is faulty. Affected boom actuator or circuit wiring is faulty. Neither of the boom actuators will extend. Loop back connector is unplugged from wire harness connector. 5 amp or 10 amp fuse in sonic boom fuse block is faulty.
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Service and Repairs Sonic Mode Switch The sonic mode switch is used as an input for the ECU to activate the Sonic Boom System. This switch has three (3) positions: automatic, manual and off. The sonic mode switch is located on the console. If the sonic mode switch is in the automatic position, the sonic sensors will be activated to allow automatic movement of the boom. The tips of the booms will remain at a constant distance from the ground.
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The Sonic Boom System uses six (6) identical relays to control the boom actuators and ultimately the boom height. Three (3) of the relays control the right actuator and the other three (3) relays control the left actuator. The electronic control unit (ECU) controls the operation of the relays. The relays are located on a mounting plate under the vehicle dash panel (Fig. 31) and can be identified by a label on the wire harness connector.
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Electronic Control Unit (ECU) The Sonic Boom System uses an electronic control unit (ECU) to control electrical system operation. The ECU is attached to a mounting plate under the vehicle dash panel (Fig. 33). 3 Power is provided to the ECU when the vehicle ignition switch is ON. A 5 amp fuse provides circuit protection for this logic power to the ECU. The fuse is located in the Sonic Boom System fuse block.
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Two (2) identical sonic sensors are used in the Sonic Boom System. The sensors are mounted to the spray booms (Fig. 34). During sprayer operation with the sonic mode switch in the automatic position, the sonic sensors will provide inputs for the electronic control unit (ECU) to keep the booms at a constant distance from the ground. During sprayer operation, the sonic boom sensor continually sends an impulse signal and then receives an echo as the signal bounces off the turf.
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Chapter 9 Electrical Diagrams ELECTRICAL SCHEMATICS Multi Pro 1200/1250 Vehicle Electrical Schematic Serial Numbers Below 260000000 . . . . . . . . . . . 3 Serial Numbers Above 260000000 . . . . . . . . . . 4 Multi Pro 1200 Spray System Electrical Schematic Serial Numbers Below 260000000 . . . . . . . . . . . 5 Serial Numbers Above 260000000 . . . . . . . . . . 6 Multi Pro 1250 Spray System Electrical Schematic Serial Numbers Below 260000000 . . . . . . . . . . . 7 Serial Numbers Above 260000000 . . . . .
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NEUTRAL ENGINE SPEED CONTROL COIL HEADLIGHTS S M L BLK 14 GA. WHITE 16 GA.BLACK 14 GA. BLACK S YELLOW/RED L S 16 GA. RED/BLACK 16 GA. WHITE M L S G B RED A START IGNITION SWITCH (SEE LEGEND AT LEFT) L BLUE/BLACK B HEADLIGHT SWITCH ORANGE 14 GA. WHITE OFF 12 GA. BLACK A BLACK B 16 GA. YELLOW/RED YELLOW/RED G 2 1 C2 47 uF 5 AMP FUSE 3 5 18 GA. VIOLET 30 85 87 86 NEUTRAL ENGINE SPEED CONTROL RELAY P6 SPRAY 16 GA. FOAM BOOM LIFTS 16 GA.
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BK BATTERY (GRP 26, 540 CCA) (+) GROUND BLOCK (–) R BK BK PK PK CHASSIS GRD ENGINE GRD 5 LEFT ACTUATOR POWER (30A RESETTABLE) J07 OR RIGHT ACTUATOR POWER (30A RESETTABLE) 4 J12 R FOAM MARKER POWER (15A) J03 6 Y 7 SPARE 8 PK 1 OFF G,M,A RUN B,L,A START B,L,S 2 3 J08 B R L M G B BK A S BU/BK S L R/BK A HR NEUTRAL SWITCH GN/R P17&J18 G AUXILIARY FUSE BLOCK–4 WAY (+) (+) P04 P29 METER–HR (–) VOLT P28 METER–VOLT (–) PK M BK R PK Y J01 2 30A 3 4 10A 7 J09 J15 SOLENO
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VEHICLE FUSE BLOCK FOAM MARKER BOOM LIFTS J 3 10 GA. RED D1 P3 14 GA. RED SPRAY SYSTEM + B A PUMP SWITCH ON–OFF 30A 2 3 5 6 7 8 BLUE 16 GA. RED VEHICLE GROUND BLOCK GRN/WHITE GRN/WHITE PUMP RELAY OFF POSITION BLACK 16 GA. GREEN/WHITE ACCESSORY SOLENOID A B MULTI PRO 1200 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000308 AND 260000000 USE A RELAY AND TWO DIODES IN PLACE OF SCR DIODE D1 AND RESISTOR R1. D2 TO BATTERY + A 16 GA.
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P39 RIGHT ACTUATOR RELAY Y BK P30 RIGHT ACTUATOR SWITCH 2 R 5 1 Y 3 OR R BK 86 87 87a RIGHT ACTUATOR P32 85 BU 30 4 DIODE, TVS, 24V P16 6 P38 RIGHT ACTUATOR RELAY OR BK DPDT–(ON)OFF(ON) 86 87 87a R BK R 85 30 BK 1 2 LEFT ACTUATOR (30A THERMAL BREAKER) 3 4 RIGHT ACTUATOR (30A THERMAL BREAKER) 5 6 FOAM MARKER POWER (15A) 8 SPARE 7 OR Y FUSE BLOCK–4 WAY OR FROM MAIN HARNESS 5 4 P42 LEFT ACTUATOR RELAY BK 86 85 BU 87 87a OR BK 6 2 MAIN VEHICLE (30A) 3 4 MAIN VEHICLE (10
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MASTER BOOM (FOOT) SWITCH VEHICLE FUSE BLOCK 18 GA . RED FOAM MARKER 86 85 86 85 86 18 GA . BLACK J3 18 GA . TAN/BLACK 14 GA . RED + 87A 30 P3 SPRAY SYSTEM 10 GA . RED RED/YELLOW BLACK 85 RED/YELLOW BOOM LIFTS RED/YELLOW BLACK 87A 30 87 87 RUN/HOLD RELAY K3 30A 87 SPRAY VALVE RELAY K4 18 GA . TAN 87A 30 SPRAY VALVE RELAY K5 14 GA . BLACK 16 GA .
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P39 RIGHT ACTUATOR RELAY Y 86 BK 85 RIGHT ACTUATOR SWITCH P30 1 Y 2 R 3 OR 5 87 R 87a BK 30 BU 6 R BK 87 87a 30 W BK BK LEFT ACTUATOR SWITCH P31 1 2 OR 3 5 2 3 4 5 6 30 A THERMAL BREAKER 8 30 A THERMAL BREAKER 7 P42 LEFT ACTUATOR RELAY BK 86 BU 87 87a OR BK 4 6 T R OR J07 FUSE BLOCK–4 WAY 87 87a OR BK OR 85 30 P33 LEFT ACTUATOR GN 30 DIODE, TVS, 24V P43 Y Y 1 P27 2 1 2 3 5 4 FOAM MARKER POWER 6 SPRAY SYSTEM POWER 7 8 J03 J05 PK W/BU BK BK SPRAY MONITOR P23 8
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NEUTRAL ENGINE SPEED CONTROL COIL HEADLIGHTS S M L BLK 14 GA. WHITE 16 GA. BLACK 14 GA. BLACK OFF L S 16 GA. RED/BLACK 16 GA. WHITE M L S G B RED A START IGNITION SWITCH (SEE LEGEND AT LEFT) L BLUE/BLACK B HEADLIGHT SWITCH ORANGE 14 GA. WHITE A YELLOW/RED YELLOW/RED 12 GA. BLACK B BLACK G 16 GA. YELLOW/RED S D1 C1 47 uF 5 18 GA. VIOLET 85 87 NEUTRAL ENGINE SPEED CONTROL RELAY P6 86 SPRAY 16 GA. FOAM BOOM LIFTS 16 GA. YELLOW/RED 2 3 30 16 GA.
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NEUTRAL ENGINE SPEED CONTROL COIL HEADLIGHTS M L S BLK 16 GA. BLACK 14 GA. WHITE 14 GA. BLACK S YELLOW/RED L S 16 GA. RED/BLACK 16 GA. WHITE M L S G B RED A START IGNITION SWITCH (SEE LEGEND AT LEFT) L BLUE/BLACK B HEADLIGHT SWITCH ORANGE 14 GA. WHITE OFF 12 GA. BLACK A BLACK B 16 GA. YELLOW/RED YELLOW/RED G 2 1 C2 47 uF 5 AMP FUSE 3 5 18 GA. VIOLET 30 85 87 86 NEUTRAL ENGINE SPEED CONTROL RELAY P6 SPRAY 16 GA. FOAM BOOM LIFTS 16 GA.
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NEUTRAL ENGINE SPEED CONTROL COIL HEADLIGHTS S M L BLK 14 GA. WHITE 16 GA.BLACK 14 GA. BLACK S YELLOW/RED L S 16 GA. RED/BLACK 16 GA. WHITE M L S G B RED A START IGNITION SWITCH (SEE LEGEND AT LEFT) L BLUE/BLACK B HEADLIGHT SWITCH ORANGE 14 GA. WHITE OFF 12 GA. BLACK A BLACK B 16 GA. YELLOW/RED YELLOW/RED G D1 C1 47 uF 5 18 GA. VIOLET 85 87 NEUTRAL ENGINE SPEED CONTROL RELAY P6 (ENERGIZED) 86 SPRAY FOAM BOOM LIFTS 16 GA. YELLOW/RED 16 GA. 16 GA.
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VEHICLE FUSE BLOCK FOAM MARKER PUMP SWITCH ON–OFF BOOM LIFTS BLUE J 3 SPRAY SYSTEM 10 GA. RED 2 3 16 GA. RED P3 14 GA. R1 510 OHM RED + 6 5 30A MOMENTARY (ON) GRN 8 7 VEHICLE GROUND BLOCK RESISTOR D1 SCR DIODE GREEN/WHITE ON POSITION 14 GA. BLACK 16 GA. GREEN/WHITE NOTE: SCR DIODE IS USED FOR CIRCUIT PROTECTION FROM VOLTAGE SPIKES THAT CAN OCCUR WHEN PUMP CLUTCH IS DE–ENERGIZED.
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MASTER BOOM (FOOT) SWITCH ON POSITION VEHICLE FUSE BLOCK 18 GA . RED RED/YELLOW BLACK FOAM MARKER 85 RED/YELLOW 85 86 86 85 NOTE: SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 260000000 SHOWN. 86 18 GA . BLACK BOOM LIFTS J3 18 GA . TAN/BLACK 14 GA. RED + 87A 30 P3 SPRAY SYSTEM 10 GA . RED RED/YELLOW BLACK 87A 30 87 87 SPRAY VALVE K3 (ENERGIZED) 87A 30 87 SPRAY VALVE K4 (ENERGIZED) 30A 18 GA . TAN SPRAY VALVE K5 (ENERGIZED) 14 GA . BLACK TO SUPERVISOR SWITCH 16 GA .
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MASTER BOOM (FOOT) SWITCH OFF POSITION VEHICLE FUSE BLOCK 18 GA . RED RED/YELLOW BLACK FOAM MARKER 85 RED/YELLOW 85 86 86 85 NOTE: SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 260000000 SHOWN. 86 18 GA . BLACK BOOM LIFTS J3 18 GA . TAN/BLACK 14 GA. RED + 87A 87A 30 P3 SPRAY SYSTEM 10 GA . RED RED/YELLOW BLACK 30 87 87 SPRAY VALVE K3 (NOT ENERGIZED) 87A 30 87 SPRAY VALVE K4 (NOT ENERGIZED) 30A 18 GA . TAN SPRAY VALVE K5 (NOT ENERGIZED) 14 GA . BLACK 16 GA .
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MASTER BOOM (FOOT) SWITCH OFF POSITION VEHICLE FUSE BLOCK 18 GA . RED RED/YELLOW BLACK FOAM MARKER 85 RED/YELLOW BOOM LIFTS 85 86 NOTE: SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 260000000 SHOWN. 86 85 86 18 GA . BLACK J3 18 GA . TAN/BLACK 14 GA . 87A 87A 30 P3 SPRAY SYSTEM 10 GA . RED RED/YELLOW BLACK 87A 30 30 87 87 SPRAY VALVE K3 SPRAY VALVE K4 87 RED + 30A SPRAY VALVE K5 18 GA . TAN 14 GA . BLACK 16 GA .
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BLACK RED BLUE/RED BLACK RED (5 AMP) BLACK BLACK BLACK RED ENGINE PLUG RED BLACK WHITE RED/BLACK RED RED/WHITE YELLOW/RED BLACK BLUE/RED VIOLET BLACK GREEN/ RED GREEN/ RED GREEN/RED START RELAY BLUE/WHITE RED/WHITE NEUTRAL RELAY BLUE/BLACK RED/BLACK RED RED NEUTRAL INTERLOCK SWITCH BLACK RED GREEN/ RED BLACK RED/BLACK YELLOW/RED YELLOW/RED BLACK RED RED YELLOW/RED YELLOW/RED BLUE/WHITE BLACK BLACK YELLOW/RED IGNITION SWITCH YELLOW/RED RED ORANGE BLUE/BLACK WHITE R
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SPRAYERS WITH SERIAL NUMBERS BETWEEN 240000400 AND 260000000 USE RELAYS WITH DIFFERENT TERMINAL ORIENTATION. NEUTRAL RELAY VEHICLE GROUND BLOCK START RELAY IGNITION SWITCH IGNITION SWITCH CHASSIS GROUND SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000301 AND 260000000 COMBINE RING TERMINALS P31 AND P32 IN ONE CONNECTOR. Multi Pro 1200/1250 Main Wire Harness (Serial Numbers Below 260000000) Page 9 - 17 Rev.
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3 4 5 6 7 8 1 1 2 3 4 5 6 7 8 1 1 1 1 P07 30 85 87A 87 86 1 2 3 4 5 1 2 3 4 5 6 7 8 BLACK 2 J07 PINK 1 J12 CRUISE CONTROL SWITCH P06 BLUE 1 J03 CRUISE ENABLE RELAY BROWN 1 LEFT ACTUATOR POWER VIOLET 1 J08 RIGHT FOAM MARKER ACTUATOR POWER POWER GREEN/RED 1 J05 RED/WHITE J15 SPARE P37 PINK J09 RED/WHITE J02 AUXILARY FUSE BLOCK BLACK P02 RED RED SPRAY SYSTEM POWER MAIN FUSE BLOCK GND BLACK RED ENERGIZE J01 RED/WHITE A POWER P31 B INPUT
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J10 RIGHT HEADLIGHT J11 4 5 3 2 1 B P19 ENGINE CONNECTION J14 LEFT HEADLIGHT J13 LEFT HEADLIGHT A P31 POWER INPUT B A P04 NEUTRAL SWITCH J04 ENGINE GROUND 85 (2) 1 23 P29 HOUR METER P06 CRUISE ENABLE RELAY P07 CRUISE CONTROL SWITCH 87A (3) 30 (1) 87 (4) 86 (5) J05 SPRAY POWER P05 START RELAY J06 ”G” P02 MAIN FUSE BLOCK VOLT METER J16 ”I” P17 IGNITION SWITCH 3 4 6547 2 1 J18 IGNITION SWITCH 5 3218 P15 HEADLIGHT SWITCH J15 GND J01 INPUT AUXILARY RELAY 7 5 3 1 J03 FOAM MARKE
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BLUE PUMP SWITCH RED RED RED RED GREEN BLACK BLACK BLACK BLACK BLACK GREEN/WHITE GREEN/WHITE BLACK D1 B P3 PUMP SWITCH BLACK 2 3 5 6 7 8 P9 A BLUE RED PINK/RED PINK/BLACK PINK GRAY/RED GRAY/BLACK PINK/BLACK SP3 PINK PUMP RELAY GREEN/WHITE GRAY/RED P10 GRAY/BLACK A P4 B PUMP CLUTCH GRAY A BLACK GRN/WHITE OFF POSITION BLACK D2 GRAY GRN/WHITE PINK/RED BLACK B MULTI PRO 1200 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000308 AND 230999999 USE RELAY AND TWO DIODES IN PL
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MULTI PRO 1200 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000308 AND 230999999 USE A RELAY AND TWO DIODES IN PLACE OF SCR DIODE D1 AND RESISTOR R1. PUMP RELAY VEHICLE GROUND BLOCK SCR DIODE D1 AND RESISTOR R1 USED ON MULTI PRO 1200 SPRAYERS WITH SERIAL NUMBERS BELOW 230000308 PUMP SWITCH Multi Pro 1200 Spray System Wire Harness (Serial Numbers Below 240000400) Page 9 - 21 Rev.
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SPRAY POWER J1 RED 1 RED SP1 2 3 FOAM MARKER POWER J3 VEHICLE GROUND BLOCK J4 RED 4 RED VEHICLE GROUND BLOCK J2 BOOM LIFT POWER J5 6 BLACK BLACK BLACK 7 GREEN/WHITE BLACK SP2 8 SP3 RED SP17 VEHICLE GROUND BLOCK J6 BLACK BLACK 4 YELLOW WHITE RED SP12 BLUE 6 7 P31 GREEN/WHITE BLUE GREEN/WHITE BLACK 2 3 4 SP16 5 WHITE 6 7 8 SP15 YELLOW BLACK GREEN 6 SP14 7 1 30 2 85 P8 3 87A 8 A RH FOAM MARKER SWITCH 1 YELLOW 4 5 P2 6 RED RED 3 LEFT ACTUATOR SW
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J3 FOAM MARKER POWER BACK A B C P6 SPEED SENSOR 5 J1 SPRAY POWER 1 4 P11 MASTER FOAM SOLENOID J5 BOOM LIFT POWER 2 P8 PUMP LATCH RELAY J4 J2 2 VEHICLE GROUND BLOCK J6 1 P32 RIGHT ACTUATOR 3 P12 FOAM COMPRESSOR BACK B A P19 RH FOAM SOLENOID P33 LEFT ACTUATOR P4 PUMP CLUTCH DIODE D1 P20 LH FOAM SOLENOID P7 FLOW MONITOR 1 A B C D E SP3 K J H G F BACK 2 DIODE D2 SP2 SP1 RH ACTUATOR SWITCH P30 BACK LH ACTUATOR SWITCH P5 FLOW METER P31 RH FOAM SWITCH BACK PUMP SWITCH P3 LH FOA
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A A B B A J03 P01 P02 B 1 2 YELLOW YELLOW BLACK GREEN/WHITE BLACK BLACK GREEN/WHITE GREEN/WHITE PINK YELLOW BLUE BLACK YELLOW BLUE 1 3 4 5 6 7 8 1 2 3 4 P20 P19 5 6 7 8 1 2 P12 P11 1 2 1 1 2 2 WHITE 4 BLACK 5 3 FOAM COMPRESSOR WHITE 86 2 BLACK 85 87A 87 1 BLACK 30 MASTER FOAM SOLENOID LH FOAM SOLENOID YELLOW 8 BLUE 7 RH FOAM SOLENOID BLACK 6 RH FOAM MARKER SWITCH WHITE 5 P04 LH FOAM MARKER SWITCH YELLOW 4 P09 P10 FOAM MARKER
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30 (1) 87A (3) 87 (4) 1 86 (5) 2 P08 PUMP RELAY P15 P41 P13 P11 MASTER FOAM SOLENOID LEFT ACTUATOR RELAYS RIGHT ACTUATOR RELAYS P32 RIGHT ACTUATOR J05 RIGHT ACTUATOR POWER 0 A P10 LATCHING DIODE B A A B J03 FOAM MARKER POWER P07 SPRAY MONITOR P16 TVS DIODE J01 GROUND BLOCK B P31 LEFT ACTUATOR SWITCH P02 RH FOAM MARKER SWITCH A 2 P01 LH FOAM MARKER SWITCH 1 P20 LH FOAM SOLENOID 0 A B P17 TVS DIODE P33 LEFT ACTUATOR P04 PUMP CLUTCH A C B P30 RIGHT ACTUATOR SWITCH B P19 RH FOA
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Page 9 - 26 Rev.
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zl Multi Pro 1200 Spray System Wire Harness (Serial Numbers Above 280000111) Page 9 - 27 Rev.
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RED/BLACK BLACK BLACK/RED RED CENTER SPRAY YELLOW/ VALVE SWITCH BLACK GREEN/ BLACK RIGHT SPRAY VALVE SWITCH BLACK GREEN/ BLACK BLACK BLACK GREEN BLACK YELLOW/ BLACK BLACK YELLOW BLACK BLUE/BLACK BLUE BLACK BLACK RED RED RED/ BLACK BLUE GREEN BLACK RED/ BLACK RED BLACK BLACK RED RED TAN BLACK/ RED TAN/BLACK BLACK RED BLACK/ RED RED RED LEFT SPRAY VALVE SWITCH BLUE/ BLACK RED/BLACK BLACK BLACK/RED RED BLACK/RED RED/BLACK BLACK BLACK RED/ YELLOW RED/ YELLOW BLACK RE
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MULTI PRO 1250 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000413 AND 240000400 USE A RELAY AND TWO DIODES IN PLACE OF SCR DIODE AND RESISTOR. PUMP RELAY VEHICLE GROUND BLOCK LEFT SPRAY VALVE SWITCH CENTER SPRAY VALVE SWITCH RIGHT SPRAY VALVE SWITCH SCR DIODE D1 AND RESISTOR R1 USED ON MULTI PRO 1250 SPRAYERS WITH SERIAL NUMBERS BELOW 230000413. APPLICATION RATE SWITCH PUMP SWITCH Multi Pro 1250 Spray System Wire Harness (Serial Numbers Below 240000400) Page 9 - 29 Rev.
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RED J6 BLACK J7 VEHICLE GROUND BLOCK J8 SP2 SP18 BLUE WHITE SP13 WHITE SP11 SP12 P18 RH FOAM MARKER SWITCH WHITE 1 2 P21 MASTER FOAM SOLENOID WHITE 1 2 P22 FOAM COMPRESSOR BLUE RED P35 YELLOW YELLOW BLACK RED WHITE P36 A B P1 P11 SPEED SENSOR FLOW METER P33 LEFT ACTUATOR P32 RIGHT ACTUATOR P15 PRESSURE REGULATOR P12 LEFT SPRAY VALVE 1 2 3 4 5 6 7 8 P9 APPLICATION RATE SWITCH A B P13 CENTER SPRAY VALVE A B C P23 FLOW MONITOR 1 2 P19 LH FOAM SOLENOID 1 2 P20 RH FOAM SOLE
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2 1 P32 RIGHT ACTUATOR P19 LH FOAM SOLENOID 2 3 4 P20 RH FOAM SOLENOID 1 2 3 4 1 2 3 4 5 1 5 2 1 P21 MASTER FOAM SOLENOID P22 FOAM COMPRESSOR 5 3 P3 RUN/HOLD RELAY 3 4 5 P4 SPRAY VALVE RELAY 4 P5 SPRAY VALVE RELAY 5 P24 PUMP LATCH RELAY BACK J3 FOAM MARKER POWER 9.
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1 P34 P12 P35 P13 A B A B A B A B 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 P23 A B C YELLOW BLACK PINK BLACK BLACK PINK SPRAY MONITOR BLACK BLACK GREEN SP04 A B YELLOW BLUE RED/BLACK BLUE RED/BLACK SP03 BROWN YELLOW YELLOW/BLACK PINK BROWN GREEN/BLACK BLACK BLACK PINK BLACK YELLOW WHITE YELLOW BLACK YELLOW WHITE SP14 SP12 PINK BLUE YELLOW PINK SUPERVISOR SWITCH P09 J10 1 J09 1 ORANGE/ BLACK FOAM COMPRESSOR BLACK BLACK BLACK BLACK BLACK BLACK BLAC
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1 2 85 (2) 87A (3) 30 (1) 87 (4) 1 86 (5) 2 P22 FOAM COMPRESSOR P24 PUMP RELAY P19 RH FOAM SOLENOID P42 LEFT ACTUATOR P41 RELAYS P39 RIGHT ACTUATOR P38 RELAYS B A J05 SPRAY SYSTEM POWER 0 P02 SPRAY MONITOR E F G H J K B J12 RIGHT ACTUATOR POWER B A .000 P25 LATCHING DIODE P26 PROTECTION DIODE 86 (5) 30 (1) 87 (4) 85 (2) 87A (3) P04 SPRAY VALVE RELAY P05 SPRAY VALVE RELAY B C B A A B P15 PRESSURE REGULATOR VALVE P12 LEFT SPRAY VALVE A A .000 .
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Page 9 - 34 Rev.
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Multi Pro 1250 Spray System Wire Harness (Serial Numbers From 270000001 to 280000237) Page 9 - 35 Rev.
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Page 9 - 36 Rev.
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Multi Pro 1250 Spray System Wire Harness (Serial Numbers Above 280000238) Page 9 - 37 Rev.
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