Form No. 3429-517 Rev C Multi Pro® 5800-D Turf Sprayer with ExcelaRate Spray System Model No. 41393—Serial No. 403460001 and Up Register at www.Toro.com.
Introduction This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. This machine is a dedicated turf spray application vehicle and is intended to be used by professional, hired operators in commercial applications. It is designed primarily for spraying on well-maintained lawns in parks, golf courses, sports fields, and on commercial grounds.
Sprayer Functions for Application Rate Mode and Manual Mode ......................................... 34 Spraying with the ExcelaRate Sprayer System.......................................................... 34 Positioning the Spray Sections ......................... 38 Taking Proper Turf Care Precautions while Operating in Stationary Modes ...................... 39 Spraying Tips.................................................... 39 Unclogging a Nozzle.........................................
Safety Cooling System Maintenance .............................. 68 Cooling System Safety ..................................... 68 Coolant Specification........................................ 68 Checking the Coolant Level .............................. 68 Coolant Quantity............................................... 69 Changing the Coolant ....................................... 69 Brake Maintenance ............................................. 70 Adjusting the Brakes....................................
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal93-6686 93-6686 1. Hydraulic fluid 2. Read the Operator's Manual. decal107-8667 107-8667 1. Jacking 2. Jack-point locations 3. Warning—Read the Operator's Manual for more information on jacking the vehicle decal106-5517 106-5517 1. Warning—do not touch the hot surface. decal106-6755 106-6755 1.
decal107-8732 107-8732 1. Warning—read the Operator's Manual. 2. Torque the lug nuts to 95 to 122 N∙m (75 to 90 ft-lb). decal133-2758 133-2758 1. Tec Logic—2 A 2. Tec power—7.5 A 3. Extra fuse slot—10 A 4. Ignition—15 A 8. Tec power—7.5 A 9. Cruise control—10 A 5. Tec power—7.5 A 10. InfoCenter—1 A 11. Boom and headlight—30 A 12. USB power—15 A 6. Boom control—10 A 13. Tank spray—40 A 7. Work light—15 A decal119-6035 119-6035 decal117-4955 117-4955 1. Engine—stop 1.
decal120-0625 120-0625 1. Pinch point, hand—keep hands away. decal120-0622 120-0622 1. Warning—read the Operator's Manual. 2. Warning—do not enter the tank. 3. Caustic liquid/chemical burn and toxic gas inhalation hazards—wear hand, skin, eye, and respiratory protection. decal120-0617 120-0617 1. Pinch point—keep hands away from the hinge. 2. Crushing hazard, boom—keep bystanders away. decal120-0623 120-0623 1. Tow hitch location 2. Tie down locations 3. Warning—Read the Operator's Manual.
decal127-6981 127-6981 1. Bypass-return flow 3. Section spray 2. Flow decal132-7689 132-7689 1. Auto spray mode 7. Rinse system—off 2. Spray mode 8. Sonic sensor—on 3. Manual spray mode 9. Sonic sensor—off 4. Foam marker—on 10. Application rate—increase 5. Foam marker—off 11. Application rate—decrease 6. Rinse system—on decal127-6982 127-6982 1. Pump-return flow 2. Section spray decal132-7708 132-7708 1. Headlight—on 2. Headlight—off 8 3.
decal133-8062 133-8062 decal136-2351 136-2351 1. To engage the parking brake, press down the brake and parking-brake pedal. 2. To disengage the parking brake, press and release the parking-brake pedal. decal139-3065 139-3065 1. Read the Operator's Manual.
decal120-0619 120-0619 1. Warning—read the Operator's Manual. 5. Tipping hazard—do not turn sharply while traveling fast, drive slowly when turning; use caution and drive slowly when traveling across or up and down slopes. 2. Warning—do not operate this machine unless you are trained. 6. To start the engine, engage the parking brake, insert the ignition key and turn it to the start position. 3. Warning—stay away from moving parts, keep all guards and shields in place. 7.
decal132-7695 132-7695 1. Pump—on 5. Speed control—on 9. Lower the right section. 2. Pump—off 6. Speed control—off 10. Raise the right section. 14. Center section spray 15. Right section spray 3. Agitation—on 7. Lower the left section. 11. Engine speed—fast 4. Agitation—off 8. Raise the left section. 12. Engine speed—slow 11 13.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 Description Use Qty. Quick-disconnect fitting 1 Assemble the sprayer tank fill fitting. No parts required – Check the section-hinge springs. No parts required – Remove the shipping bumper. Media and Additional Parts Description Starter key Operator's Manual Engine owner's manual Parts Catalog Instruction Card Screen filter Use Qty. 2 1 1 1 2 Read the manuals before operating the machine.
1 Assembling the Sprayer Tank Fill Fitting g191615 Figure 4 Parts needed for this procedure: 1 1. PTFE thread sealant 3. Quick-disconnect fitting 2. Fill hose fitting (1 inch—national pipe thread) Quick-disconnect fitting Procedure 6. Note: To complete this procedure, you will need to supply a hose with 1 inch male national pipe thread (NPT) fitting and PTFE thread sealant. 1. Thread the quick-disconnect coupling onto the fill hose and tighten it by hand (Figure 4).
3 Removing the Shipping Bumper No Parts Required Procedure 1. Remove the bolts, washers, and nuts that secure the shipping bumper to the front chassis plate (Figure 6). g035648 Figure 5 1. Section-hinge spring 3. Compressed spring dimension—4 cm (1-1/2 inches) 2. Jam nut 4. Repeat the procedure for each spring on both section hinges. 5. Move the sections into the transport ‘X’ position. See Changing the Spray Section Position (page 38) for more information. g028179 Figure 6 1. Nut 2.
Product Overview g190621 Figure 7 1. Fresh-water tank 4. Roll bar (ROPS) 7. Drain valve (sprayer tank) 2. Passenger seat 5. Tank lid 8. Spray pump 3. Operator’s seat 6. Chemical tank 9. Battery 10. Work lights g190600 Figure 8 1. Lift cylinder 3. Valve manifolds 5. Hydraulic tank 7. Center boom section 2. Boom-transport cradle 4. Fuel tank 6. Right boom section 8.
Controls g216445 Figure 9 1. Work-light switch 6. Storage compartment 2. Steering wheel 7. InfoCenter 3. Pressure gauge 8. Quick Find™ console 4. Fuel gauge 5. Passenger-hand hold 9. Armrest 10. Ignition switch Vehicle Controls begins to decrease, release the traction pedal slightly to allow the engine speed to increase. Traction Pedal The traction pedal (Figure 10) controls the movement of the machine, both forward and reverse.
Brake Pedal Use the brake pedal to stop or slow the machine (Figure 10). CAUTION If you operate the sprayer with poorly adjusted or worn brakes, you could lose control of the sprayer, resulting in serious injury or death to you or bystanders. Always check the brakes before operating the sprayer and keep them properly adjusted and repaired. Parking Brake g032469 Figure 11 The parking brake is a pedal to the left of the brake pedal (Figure 10).
USB Power Port Oil-Pressure-Warning Light The 2-socket USB power port is located at the back of the armrest (Figure 12). The engine oil-pressure warning light illuminates when the oil pressure drops below 48 kPa (7 psi). When the machine is operating normally, the oil-pressure warning light illuminates when the ignition switch is rotated to the ON and shuts off when the engine is running.
Sprayer Controls Spray-Pump Switch The spray-pump switch is located on the center console to the right of the seat (Figure 14). Toggle this switch forward to run the spray pump or rearward to stop the pump. When the switch is turned on, a light on the switch illuminates. Important: Engage the spray-pump switch only when the engine is at LOW IDLE to avoid damaging the pump drive.
Section Bypass Valves The section bypass valves are used to adjust the sprayer system pressure to the section valves in order to ensure that the sprayer pressure to the spray section remains constant no matter how many spray sections are on. (Figure 17). Note: Use the bypass valves when spraying in the manual mode (open loop) only. g194246 Figure 15 1. Actuator (agitation valve) 3. Flow meter 2.
InfoCenter Controls The InfoCenter controls use the 5 buttons below the LED display to navigate menus, enter data, and change functions. g013787 Figure 18 1. Anti-siphon fill receptacle 2. Tank cover Tank Cover The tank cover is located in the center, top of the tank. To open the cover, shut off the engine, turn the front half of the cover to the left, and swing it open. You can remove the strainer inside for cleaning. To seal the tank, close the cover and rotate the front half toward the right.
Specifications Operation Note: Specifications and design are subject to Note: Determine the left and right sides of the machine from the normal operating position. change without notice.
• Always wash your hands and other exposed areas • Do not store the machine or fuel container where • as soon as possible after working with chemicals. there is an open flame, spark, or pilot light, such as on a water heater or other appliance. If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated. • Keep chemicals in their original packages and stored in a safe location.
Checking the Hydraulic System Using summer-grade fuel above -7°C (20°F) contributes toward longer fuel pump life and increased power compared to winter-grade fuel. Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic Fluid (page 71). Biodiesel Fuel Specification Checking the Tire Air Pressure Use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel).
4. Use the suction filter table to identify the screen mesh for the spray nozzles you are using based on chemicals products or solutions with a viscosity equivalent to water. Fill the tank to about 2.5 cm (1 inch) below the top of the tank (bottom of the filler neck). Note: This air space in the tank allows fuel to expand. Do not overfill the tank. 5. Install the fuel-tank cap to the tank securely. 6. Wipe up any fuel that may have spilled.
Pressure Filter Table (cont'd.) Spray Nozzle Color Code (flow rate) Screen Mesh Size* Filter Color Code As required for high viscosity chemicals or solutions or high application rates 16 Brown *The mesh size of the pressure filters in this table are based on spray chemicals or solutions with the viscosity equivalent to water. Important: When you spray with higher viscosity g214214 Figure 22 Mesh size—application rate 1.
g214240 g214245 Figure 24 Mesh size—application rate 1. Higher application rate Figure 25 Mesh size—chemical or solution viscosity 1. Higher-viscosity chemicals 3. Screen mesh size or solutions 2. Lower-viscosity chemicals or solutions 3. Screen mesh size 2. Lower application rate Selecting a Nozzle-Tip Filter (Optional) When you spray at a higher application rate, consider using a coarser tip-filter mesh; refer to Figure 26.
Always fill the fresh-water tank with clean water before handling or mixing any chemicals. 4. Assemble the fill hose to the quick disconnect fitting of the anti-siphon fill receptacle. • To fill the tank, unscrew the cap at the top of the 5. Add 3/4 of the required water to the spray tank (Figure 28). tank, fill the tank with fresh water, and install the cap (Figure 27). Important: Always use fresh, clean water in the spray tank. Do not pour concentrate into an empty tank.
Preparing the Machine Inspecting the Tank Straps Service Interval: Before each use or daily—Check the tank straps. 1. Fill the spray tank halfway with clean water. 2. Lower the spray sections. Important: Overtightening the tank strap 3. Engage the parking brake. 4. Set the spray control switch to manual. 5. Set the 3 section switches to the ON position, but leave the master section switch in the OFF position. 6. Set the spray-pump switch to the ON position, and turn on the agitation. 7.
g214029 Figure 31 g191413 1. Open Figure 30 1. Section-bypass adjustment knobs 2. Sections-bypass shutoff valve 3. Turn on the left-section switch and turn off the right-section switch. 4. Adjust the right section-bypass knob (Figure 30) until the rate displayed is at the previous level according to the table. 5. Turn on the right-section switch and turn off the center-section switch. 6.
During Operation During Operation Safety General Safety • The owner/operator can prevent and is responsible • g191362 Figure 32 1. Actuator (agitation valve) • 2. Agitation-bypass valve • 12. Turn the spray-pump switch to the OFF position. 13. Move the throttle lever to the IDLE/SLOW position and turn the key switch to the OFF position. • • Locating the Spray Pump The spray pump is located near the back of the tank on the left side (Figure 33). • • • • • • g194233 Figure 33 • 1.
• • • • • • • • Review the slope instructions listed below for an abnormal vibration in the machine. Make all necessary repairs before resuming operation. Slow down and use caution when making turns and crossing roads and sidewalks with the machine. Always yield the right-of-way. Use extra caution when operating the machine on wet surfaces, in adverse weather conditions, at higher speeds, or with a full load. Stopping time and distance increase in these conditions.
Setting the Ground-Speed-Lock Switch Operating the Machine Starting the Engine 1. Sit on the operator’s seat and keep your foot off the traction pedal. 2. Ensure that the following controls are set: CAUTION If you press the ground-speed-lock switch and do not have your foot on the traction pedal, the traction unit may suddenly stop and cause you to lose control, possibly injuring you or bystanders. • The parking brake is engaged. • The traction pedal is in the NEUTRAL position.
• The diagnostic screens the chemicals and possible damage to the sprayer components. • The About screens During Operation CAUTION Chemicals are hazardous and can cause personal injury. • Entering job information • Read the directions on the chemical labels before handling the chemicals and follow all manufacturer recommendations and precautions. • InfoCenter advisories • InfoCenter spray-area screens Spraying with the ExcelaRate Sprayer System • Keep chemicals away from your skin.
g193437 Figure 35 1. Application-rate mode position 2. Sprayer-mode switch g192944 4. Move the sprayer to the area of turf that you are spraying. 5. If you are collecting area sprayed and volume sprayed data for each job site, select a sub-area screen (sub-areas 1 through 20) to record for the individual area and volume information; refer to Using the Sub-Area Screen in the Software Guide for the Multi Pro 5800-D and 5800-G turf sprayer with ExcelaRate spray system. Figure 36 1.
sections, then set the spray-pump switch to the OFF position. nozzle-selection guide provided with the sprayer (Figure 39). Note: Raise the outer spray sections to the transport position and drive the sprayer to the cleaning area.
Catch Test 2. Set the throttle to the FAST position. Customer provided equipment: A graduated catch container (a container with 0.01 ml (1/2 fl. oz) increments is preferred) and stop watch. 3. Set the master section switch to the ON position. 4. Perform a 15-second catch test at 1 of the active spray nozzles. Preparing for the Catch Test Important: Whenever possible, do not use reclaimed water (gray water) in the spray tank. 1.
Positioning the Spray Sections The boom-section lift switches on the sprayer control panel allows you to move the outer spray sections between transport position and spray position without leaving the operator's seat. Whenever possible, stop the machine before changing spray section positions. Changing the Spray Section Position Perform the following steps to move the outer spray sections to the SPRAY position: g193829 Figure 42 1. Highest point of the 3.
Taking Proper Turf Care Precautions while Operating in Stationary Modes Important: Under some conditions, heat from the engine, radiator, and muffler can damage grass when operating the sprayer in a stationary mode. Stationary modes include tank agitation, hand spraying with a spray gun, or using a walking boom. Use the following precautions: • Avoid stationary spraying when conditions are very hot and/or dry, as turf can be more stressed during these periods.
3. Remove the clogged nozzle and clean it using a spray bottle of water and a toothbrush. Cleaning the Sprayer System 4. Install the nozzle. Draining the Tank 1. After Operation 2. After Operation Safety Stop the sprayer, engage the parking brake, shut off the engine, and remove the key. Locate the tank-drain valve at the left, rear fender of the machine (Figure 44). Note: The drain valve is attached to the drain-valve bracket that is mounted to the left, rear fender.
4. Align the end of the valve with the drain container and rotate valve handle to the open position (Figure 45B). 5. When the tank has drained completely, rotate the drain-valve handle to the closed position and assemble the valve onto the drain-valve bracket (Figure 45B and Figure 45A). 8. Allow all water in the tank to spray out through the nozzles. 9. Set the master section switch to the OFF position, the set the agitation switch and spray-pump switch to the OFF position, and shut off the engine.
3. Remove the hose and hose fitting from the filter housing (Figure 46). 4. Pull the suction strainer out of the filter housing in the tank (Figure 47). g028235 Figure 48 g033578 Figure 47 1. Screen vane 5. 6. 7. 2. Suction strainer 1. Filter head 2. Gasket (bowl) 4. Bowl 5. Gasket (drain cap) 3. Filter element 6. Drain cap 3. Clean the suction filter with clean water. Rotate the drain cap counterclockwise and remove it from the bowl of the pressure filter (Figure 48).
2. Conditioning the Spray System Remove the nozzle from the spray turret (Figure 49). Service Interval: After each use—Condition the spray system at the end of each daily use. Conditioner Specification Conditioner specification: propylene glycol "non-toxic RV antifreeze” with corrosion inhibitor Important: Use only propylene glycol with corrosion inhibitor. Do not use recycled propylene glycol. Do not use ethylene glycol base antifreeze.
Towing the Sprayer Note: Most propylene glycol RV antifreeze is colored pink. Use the catch container to sample the sprayer discharge at several of the nozzles. 5. In case of an emergency, the sprayer can be towed for a short distance after you open the tow valve. However, we do not recommend this as a standard procedure. Shut off the master section switch, 3 section switches, agitation switch, spray-pump switch, and engine.
g002213 Figure 53 1. Front towing points g002214 Figure 54 1. Rear towing points 5. Release the parking brake. 6. Tow the sprayer at less than 4.8 kph (3 mph). 7. When finished, close the tow valve and torque it to 7 to 11 N∙m (5 to 8 ft-lb). Important: Before returning the machine to service, install the undercarriage shroud; refer to Installing the Undercarriage Shroud (page 52).
Maintenance Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual for additional maintenance procedures. Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety – Handle chemicals in a well-ventilated area.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Torque the wheel-lug nuts. • Change the lubricant in the planetary-gear drive. • Check the fan/alternator belt. After the first 50 hours • Change the engine oil filter. • Change the engine oil. • Check the fuel lines and connections.
Maintenance Service Interval Every 400 hours Every 800 hours Maintenance Procedure • • • • • • • • • • • • • • Grease the actuator-rod bearings. Perform yearly engine maintenance. Check the fuel lines and connections. Replace the fuel-filter canister. Replace the in-tank fuel filter. Drain and clean the fuel tank. Pack the front wheel bearings. Change the lubricant in the planetary-gear drive or yearly, whichever comes first. Check the coolant (as directed by the manufacturer) and change if necessary.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Monday Tuesday Wednesday Thursday Check the brake and parking-brake operation. Check the neutral-lockout-switch operation. Check the fuel level. Check the engine-oil level. Check the hydraulic-fluid level. Check the coolant level. Inspect the air filter. Inspect the radiator and oil cooler for debris. Check for any unusual engine noises. Check for any unusual operating noises.
Pre-Maintenance Procedures CAUTION If you leave the key in the starter switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the starter switch before you do any maintenance. g203111 Figure 56 1. Rear jacking points Raising the Sprayer Whenever running the engine for routine maintenance and/or engine diagnostics, the rear wheels of the sprayer should be 25 mm (1 inch) off the ground with the rear axle supported on jack stands.
Removing the Undercarriage Shroud Installing the Forward Heat Shield 1. Align the rear flange of the forward heat shield over the forward flange of the rear heat shield (Figure 58). 1. Remove the 5 flange-head bolts (5/16 x 7/8 inch) and 5 washers (5/16 inch) that secure the rear of the undercarriage shroud to the chassis of the machine (Figure 59). Note: Retain the flange-head bolts and washers for installation in step 5 of Installing the Undercarriage Shroud (page 52). g028177 Figure 58 1.
Removing the Seat-Base-Access Panel 1. Remove the 2 flanged-head bolts that secure the seat-base-access panel to the seat base (Figure 61). g189583 Figure 60 1. Engine mount 4. Flange locknuts (5/16 inch) 2. Bolt—shown for clarity; do not remove 3. Mounting tabs (undercarriage shroud) 5. Front of the machine 3. Move the mounting tabs off the bolts that secure the undercarriage shroud to the engine-mount brackets. 4. Remove the undercarriage shroud from the machine (Figure 59 and Figure 60).
Lubrication Note: The grease fittings positions are illustrated in Figure 63. Greasing the Spray Pump Service Interval: Every 50 hours—Lubricate the pump. Every 50 hours/Yearly (whichever comes first) Grease Type: Mobil XHP 461. 1. Wipe the 2 remote grease fitting clean (Figure 62). g187456 Figure 63 1. Grease fitting g204693 Figure 62 1. Back of the machine 3. Grease point (2) 2. Spray pump 2. 3. Pump grease into the remote grease fitting (Figure 62).
g013780 Figure 66 g002014 Figure 65 Right Boom 1. Actuator 4. Hairpin 2. Actuator rod 5. Clevis pin 1. Grease fitting 3. Boom-pivot-pin housing 3. Wipe off excess grease. 5. 4. Repeat the procedure for each boom pivot. Swivel the rod-end bearing and apply grease into the bearing (Figure 67). Note: Wipe off excess grease. Greasing the Actuator-Rod Bearings Service Interval: Every 400 hours/Yearly (whichever comes first) Grease Type: No. 2 lithium grease. 1.
9. Engine Maintenance Repeat steps 2 through 8 to the actuator-rod bearing at the other side of the machine. Engine Safety Shut off the engine before checking the oil or adding oil to the crankcase. Checking the Air Cleaner Service Interval: Before each use or daily Service the air cleaner more frequently if operating conditions are extremely dusty or sandy. 1. Engage the parking brake, shut off the spray pump, shut off the engine, and remove the key. 2.
7. Check the air-filter element for excessive accumulation of dust, dirt, and debris (Figure 68). Note: Do not clean the air-filter element if it is dirty; replace the air-filter element if it is dirty. 8. Install the dust cap onto the air-cleaner body and secure the cap with the 2 latches (Figure 68). Note: Ensure that the dust valve aligns between the 5 to 7 o’clock position when viewed from the end. 9. Lower the passenger seat.
8. Install the cover onto the air-cleaner body and secure the cover with the 2 latches (Figure 69). Note: Ensure that the dust valve is aligned between the 5 to 7 o’clock position when viewed from the end (Figure 69). 9. Align the coolant-overflow tank to the tank-support bracket and seat the tank firmly (Figure 69). g195188 Important: Ensure that the pressure-relief hose is routed forward and down, and the tank-vent hose is routed rearward as shown in Figure 69. 10. Lower the passenger seat.
Changing the Engine Oil Filter Note: Do not overtighten the oil filter. 9. Service Interval: After the first 50 hours Engine-Oil Quantity Every 200 hours Change the filter more often when operating the machine under heavy load or in high temperatures. 1. Remove the forward heat shield; refer to Removing the Forward Heat Shield (page 50). 2. Raise the seats. Wipe clean any residual oil. 4.6 L (4.9 US qt) with the filter; refer to Engine-Oil Specification (page 57).
Fuel System Maintenance DANGER Under certain conditions, fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. g195187 • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 25 mm (1 inch) below the bottom of the filler neck.
9. Open the air-bleed screw at the fuel-injection pump (Figure 76). 10. Turn key in starter switch to the ON position. Note: The electric fuel pump will begin operation, forcing air out around the air-bleed screw at the fuel-injection pump. 11. Leave the key in the ON position until a solid stream of fuel flows out around the bleed screw (Figure 76). 12. Tighten the bleed screw (Figure 76) and turn the key to the OFF position. Note: Normally, the engine should start after you bleed the fuel system.
Replacing the In-Tank Fuel Filter Servicing the Fuel Filters Service Interval: Every 400 hours Replacing the Water-Separator Filter Removing the In-Tank Fuel Filter Service Interval: Every 400 hours assembly. Note: The fuel filter is a part of the standpipe 1. Remove the forward heat shield; refer to Removing the Forward Heat Shield (page 50). 1. Engage the parking brake, shut off the spray pump, shut off the engine, and remove the key. 2.
5. Rotate the fuel-standpipe/sender cap counterclockwise, then remove the cap (Figure 79). 6. Assemble the cover to the tank (Figure 78A) with the 4 screws (#10 x 3/4 inch) that you removed in step 2 of Removing the In-Tank Fuel Filter (page 61). 7. Torque the screws to 113 N∙cm (10 in-lb).
Servicing the Battery Electrical System Maintenance Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Electrical System Safety • Disconnect the battery before repairing the • • machine. Disconnect the negative terminal first and the positive last.
Charging the Battery WARNING Important: Always keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 32°F (0°C). Battery terminals or metal tools could short against metal sprayer components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 1. Remove the battery from the chassis; refer to Removing the Battery (page 63).
Drive System Maintenance Inspecting the Wheels/Tires Service Interval: After the first 8 hours—Torque the wheel-lug nuts. Every 100 hours—Torque the wheel-lug nuts. Every 100 hours—Inspect the condition and wear of the tires. Torque the lug nuts at the front wheels to 75 to 102 N∙m (55 to 75 ft-lb) and the lug nuts at the rear wheels to 95 to 122 N∙m (75 to 90 ft-lb).
g238951 Figure 86 1. Fill plug 4. Drain-plug hole (planetary lubricant) 2. Fill-plug hole (planetary lubricant) 5. Drain plug 3. Check-plug hole (planetary lubricant) 6. Check plug g238948 Figure 85 1. Fill plug 3. Check plug 2. Fill-plug hole (planetary lubricant) 5. 3. Check the O-rings of the fill plug for the damage. If the O-ring is damaged, replace it. 6. Install the fill plug and the check plug (Figure 85). 7.
Planetary-Gear-Drive with Lubricant Quantity 0.62 L (21 fl oz); refer to Planetary-Gear-Drive Lubricant Specification (page 65) Filling the Planetary-Gear-Drive with Lubricant 1. Through the fill-plug hole, slowly add the specified gear lubricant; refer to Figure 85 in Checking the Planetary-Gear-Drive Lubricant (page 65). g002247 Figure 88 1. Tire center line—back 2. Tire center line—front You should see the lubricant level at the bottom of the threads in the check-plug hole. 3.
Cooling System Maintenance 3. Carefully remove the radiator cap and the expansion-tank cap (Figure 90). Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap.
Coolant Quantity 8. Start the engine with the cap loose on the radiator (Figure 90). 5.5 L (5.8 US qt); refer to Coolant Specification (page 68) 9. Allow the engine to warm up until the thermostat opens. Note: The engine thermostat should open Changing the Coolant when the hand-held thermometer indicates the coolant temperature is between 79° to 88°C (175° to 190°F).
Brake Maintenance Belt Maintenance Adjusting the Brakes Servicing the Alternator Belt If the brake pedal travels more than 2.5 cm (1 inch) before you feel resistance, adjust the brakes as follows: 1. Service Interval: After the first 8 hours Every 100 hours Position the sprayer on a level surface, shut off the spray pump, shut off the engine, and remove the key. 2. Engage the parking brake. 3. Put blocks under the wheels to prevent the machine from rolling. 4. Release the parking brake. 5.
Hydraulic System Maintenance High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) 140 or higher Hydraulic System Safety Viscosity Index ASTM D2270 • Seek immediate medical attention if fluid is injected Pour Point, ASTM D97 -37°C to -45°C (-34°F to -49°F) Industry Specifications: Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S) into skin. Injected fluid must be surgically removed within a few hours by a doctor.
filled the reservoir with an alternative fluid, replace the hydraulic filter. WARNING Hot hydraulic fluid can cause severe burns. Allow the hydraulic fluid to cool before performing any maintenance to the hydraulic system. Important: You may void the warranty on some components if you use any other filter. g014217 Figure 94 1. Hydraulic-fluid tank 3. Dipstick cap Use the Toro replacement filter (See your Parts Manual for the correct part number.) 2.
WARNING Hot hydraulic fluid can cause severe burns. Allow the hydraulic fluid to cool before performing any maintenance to the hydraulic system. Important: You may void the warranty on some components if you use any other fluid. 1. Replace the hydraulic-fluid filters; refer to Replacing the Hydraulic Filters (page 72). 2. Clean the area around a hydraulic-hose fitting on the bottom of the hydraulic-fluid tank (Figure 98). g013790 Figure 97 1. Rear filter 2. Rear wheels 3.
Spray System Maintenance Inspecting the Hoses Service Interval: Every 200 hours—Inspect all hoses and connections for damage and proper attachment. Every 400 hours/Yearly (whichever comes first)—Inspect the O-rings in the valve assemblies and replace them if necessary. g033578 Examine each hose in the spray system for cracks, leaks, or other damage. At the same time, inspect the connections and fittings for similar damage. Replace any hoses and fittings if damaged. Figure 100 1. Screen vane 5.
Changing the Nozzle Filter Note: Determine the appropriate nozzle filter mesh size that you need for your job; refer to Selecting a Nozzle-Tip Filter (Optional) (page 27). 1. Park the machine on a level surface, engage the parking brake, shut off the sprayer pump, shut off the engine, and remove the key. 2. Remove the nozzle from the spray turret (Figure 102). g028235 Figure 101 1. Filter head 2. O-ring (bowl) 4. Bowl 5. O-ring (drain plug) 3. Filter element 6. Drain plug 3.
Adjusting the Booms to Level The following procedure can be used to adjust the actuators on the center boom to keep the left and right booms at level. 1. Extend the booms to the spray position. 2. Remove the cotter pin from the pivot pin (Figure 103). g014220 Figure 104 1. Flat on the actuator rod 5. Eyelet adjusted 2. Jam nut 6. Eyelet position for assembly 3. Eyelet 7. Jam nut tightened to lock new position 4. Jam nut loosened 6. g013780 Figure 103 1. Actuator 2. Actuator rod 3.
2. Extend the outer-boom sections to the spray position and support the boom sections using stands or straps and lifting equipment. Pump Maintenance 3. Remove the bolt and nut that secure the pivot pin, and remove the pin (Figure 105). Inspecting the Pump Service Interval: Every 400 hours/Yearly (whichever comes first)—Inspect the pump diaphragms and replace if necessary (see an authorized Toro distributor).
Cleaning 2. Remove the flow meter from the sprayer and flush it with clean water. Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine. 3. Remove the retainer ring on the upstream side (Figure 106). Important: Do not use brackish or reclaimed water to clean the machine. Note: Do not use power-washing equipment to wash the machine.
4. Assembling the Manifold Valve (page 82) 5. Installing the Agitation-Manifold Valve (page 84) 6. Installing the Valve Actuator (page 85) Removing the Agitation-Manifold Valve 1. • To clean the 3 section valves; refer to the following Remove the quick connect pin that secures the quick-connect coupler for the agitation hose to the manifold for the agitation valve (Figure 108). sections: 1. Removing the Valve Actuator (page 79) 2. Removing the Section-Manifold Valve (page 80) 3.
g191303 Figure 110 g191302 Figure 109 1. Manifold (agitation valve) 4. Flange-head bolt (1/4 x 3/4 inch) 2. Valve support 5. Gasket 1. Section-bypass valve 3. Quick-connect coupler (section supply hose) 2. Quick-connect pins 4. Quick-connect fitting (agitation valve manifold) 3. Flange locknut (1/4 inch) 4. 2. Remove the quick connect pin that secures the quick-connect coupler for the section supply hose to the manifold for the quick-connect fitting of the section-manifold valve (Figure 110).
g027562 Figure 113 1. Valve open 2. Valve closed g191304 2. Figure 112 1. Flange locknut (1/4 inch—left and right section-valve manifold positions) 4. Flange (coupling adapter) 2. Section-bypass valve 5. Gasket 3. Quick-connect fitting (section-valve manifold) 6. Flange-head bolt (1/4 x 3/4 inch—left and right section-valve manifold positions) 5. Remove the 2 end-cap-fitting assemblies from each end of the manifold body (Figure 114 and Figure 115).
Assembling the Manifold Valve Operator supplied material: Clear silicone grease. Important: Use only silicone grease when assembling the valve. 1. Check the condition of the outlet fitting O-rings (section valve manifold only), end cap O-rings, back seating O-rings, and ball seat for damage or wear (Figure 114 and Figure 115). Note: Replace any damaged or worn O-rings or seats. g028240 2. Apply silicone grease to the valve stem and insert it into the valve stem seat (Figure 114 and Figure 115). 3.
Installing the Section-Manifold Valve 1. Align the 2 gaskets that you removed in Removing the Section-Manifold Valve (page 80) to the flanges of the section-valve manifold (Figure 117). Note: If needed, loosen the mounting hardware for the left or right section-valve manifolds as needed to provide clearance. g191303 Figure 118 1. Section-bypass valve 3. Quick-connect coupler (section supply hose) 2. Quick-connect pins 4. Quick-connect fitting (agitation valve manifold) 4. g191304 Figure 117 1.
6. Torque the flange-head bolts and flange locknuts to 1978 to 2542 N∙cm (175 to 225 in-lb). 7. Tighten the 2 flange clamps by hand (Figure 119). 8. Assemble the quick-connect coupler of the section hose onto the quick-connect fitting of the section-valve manifold with the quick-connect pin (Figure 118). 9. If you loosened the mounting hardware of the left or right section-valve manifolds, tighten the nut and bolt to 1978 to 2542 N∙cm (175 to 225 in-lb). Installing the Agitation-Manifold Valve 1.
Installing the Valve Actuator 1. Align the actuator to the manifold valve (Figure 107). 2. Secure the actuator and valve with the retainer that you removed in step 2 of Removing the Valve Actuator (page 79). Storage Storage Safety • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
4. 5. Prepare rust inhibiting, non-alcohol based, RV antifreeze solution; refer to Preparing the Conditioner (page 43). Remove the tube from the back of the pressure gauge and place the end of the tube into a container (Figure 122). 4. Turn the master section switch to the OFF position. 5. Turn the pump switch to the OFF position. 6. Use the boom-section lift switches to raise the outer boom sections.
3. Preparing the Machine for Service Check the condition of all spray hoses. Note: Replace any hoses that are worn or damaged. 4. 1. Tighten all hose clamps and fittings. Servicing the Engine 1. Service the air cleaner; refer to Checking the Air Cleaner (page 55). 2. Change the engine-oil filter and oil; refer to Changing the Engine Oil Filter (page 58) and Changing the Engine Oil (page 58). Insert the pressure-gauge tube into the tube coupler at back of the pressure gauge (Figure 123).
Troubleshooting Troubleshooting the Engine and Vehicle Problem The starter does not rotate the engine. The engine cranks but does not start. Possible Cause 1. The electrical connections are corroded or loose. 1. Check the electrical connections for good contact. 2. A fuse is blown or loose. 3. The battery is discharged. 4. A broken starter or starter solenoid. 5. There are seized internal engine components. 2. Correct or replace fuse. 3. Charge or replace the battery. 4.
Problem The engine overheats. Possible Cause 1. The crankcase-oil level is incorrect. 1. Fill or drain to the Full mark. 2. The coolant level is low. 2. Check the coolant level and replenish it as needed. 3. Reduce load; use lower ground speed. 3. The engine is operated under excessive load. 4. The air-intake screens are dirty. 5. The cooling fins and air passages under the engine-blower housing and/or the rotating-air-intake screen are plugged. The engine loses power. Corrective Action 4.
Problem A spray section valve is leaking. Possible Cause Corrective Action 1. An O-ring is deteriorated. 1. Disassemble the valve and replace the seals using the Valve Repair Kit; contact your authorized Toro distributor. 2. A valve seat is worn or damaged. 2. Remove the valve actuator and replace the valve seals and seat using the Valve Repair Kit; contact your authorized Toro distributor. 1. The section-bypass valve is improperly adjusted. 1. Adjust the section-bypass valve. 2.
Schematics g034336 Sprayer System Schematic (Rev.
Notes:
Notes:
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