Service Manual

ManualsBrandsToro ManualsRiding ProductsMulti-Pro 5600 Turf Sprayer

PART NO. 03123SL (Rev. A)

Service Manual

Multi Pro

5600

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 5600.

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 Toro Company reserves the 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 instructionswhich must befollowed to pre-

vent damage to systems or components on the

machine.

E T h e To ro Company -- 2003, 2009

Summary of content (206 pages)

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PART NO. 03123SL (Rev. A) Service Manual Multi ProR 5600 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 5600. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, 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.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–2 2–3 2–7 Chapter 3 – Ford Gasoline Engine Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2 Adjustments . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Multi Pro 5600 2 2 2 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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Safety Instructions The Multi Pro 5600 Turf Sprayer is 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. Improper use or maintenance of the machine can result in injury or death.
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1. Before servicing or making adjustments, turn spray pump off, put traction pedal 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. 10.
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Jacking Instructions CAUTION When raising the machine to change tires or to perform 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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Chapter 2 Product Records and Maintenance 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 Product Records and Maintenance Page 2 – 2 Multi Pro 5600
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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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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) 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.
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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 5600 Page 2 – 7 Product Records and Maintenance Maintenance procedures and recommended service intervals for the Multi Pro 5600 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 Ford Gasoline Engine Table of Contents Ford Gasoline Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Choke Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Throttle Control . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Make / Designation Ford, VSG–413, 4–Stroke, Liquid Cooled, OHV Number of Cylinders 4 Bore x Stroke 73.9mm x 75.4mm (2.90” x 2.96”) Total Displacement 1300 cc (79.3 cu. in.) Compression Ratio 9.5:1 Firing Order 1 – 2 – 4 – 3 (1 at crankshaft pulley end of engine) Fuel Unleaded, Regular Gasoline (Minimum 87 Octane) Fuel Tank Capacity 40 liter (10.
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Adjustments Governor Oil Level 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. Tip passenger seat to gain access to engine governor assembly. 4. If oil level is low, remove oil fill plug and slowly add 10W–30 motor oil until oil in governor begins dripping from oil level plug hole. 1 3 5. Reinstall oil level and oil fill plugs to governor. Figure 1 1. Oil level plug 2. Oil fill plug 3. Belt pulley Adjust Choke Cable 1.
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Adjust Throttle Control If the throttle control will not stay in position or if engine speed cannot be adjusted for both low idle and high idle speed, the throttle control may need adjustment. 4 2 3 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove knob from throttle lever and remove switch panel from spray control console to gain access to throttle control. 1 5 6 3.
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Adjust Engine Speed 8. If governor operation is incorrect or if the engine surges, check the following: A. Governor drive belt is loose or damaged (see Operator’s Manual). 2. With engine stopped, move throttle control to FAST position. Check distance between carburetor throttle shaft lever and stop on carburetor base to make sure there is a 1/32” to 1/16” (.8 mm to 1.6 mm) gap. If this gap is incorrect, adjust throttle control rod (Fig. 4) by turning ball joint ends until gap is correct.
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Service and Repairs Radiator 2 22 21 18 23 1 4 3 4 5 10 20 19 18 6 5 9 17 7 18 1 12 13 14 16 11 8 9 10 15 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. Radiator LH radiator support brace Upper radiator shroud Flange head screw Hex nut Lower radiator shroud Oil cooler shroud Oil cooler 9. 10. 11. 12. 13. 14. 15. 16. Lock washer (11 used) Self–tapping screw (11 used) RH radiator support brace Bolt (2 used) Cushion (2 used) Flat washer (2 used) Hex nut (2 used) Engine support frame Removal (Figs.
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A. Remove four (4) self–tapping screws and lock washers that secure oil cooler shroud to radiator. B. Remove self–tapping screw and lock washer that secures lower radiator shroud to radiator. 8. Remove control cables from engine (Fig. 7). A. Loosen and remove cap screw and nut that secure end of throttle cable to governor lever. Loosen and remove screw, flat washer and flange nut that secure throttle cable clamp to control bracket. B. Loosen screw that secures choke cable to choke lever swivel.
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Fuel System 7 Thread Sealant FRONT 1 8 11 12 3 RIGHT 13 12 8 2 14 9 4 5 10 6 Figure 9 1. 2. 3. 4. 5. Fuel tank Hold down strap (2 used) Flange head screw (4 used) Flange nut (4 used) Cushion strip (2 used) Ford Gasoline Engine 6. 7. 8. 9. 10. Elbow fitting Fuel cap with gauge Hose clamp Fuel line conduit Fuel hose Page 3 – 8 11. 12. 13. 14.
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DANGER 1 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. 2 Check Fuel Lines and Connections Figure 10 1. Fuel filter 2.
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Air Cleaner 21 18 22 18 17 20 15 19 16 LEFT 15 3 FRONT 4 14 7 8 9 1 2 10 5 6 23 11 13 12 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. Air cleaner housing Air filter element Baffle skirt Clamp Cup Vacuator valve Hex nut (4 used) Square nut (1 used per band) Ford Gasoline Engine 9. 10. 11. 12. 13. 14. 15. 16. Screw (1 used per band) Mounting band Flat washer (2 used per band) Cap screw (4 used) Air cleaner cap Foam seal Hose clamp Hose elbow Page 3 – 10 17. 18. 19. 20. 21. 22. 23.
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Removal (Fig. 11) 2 NOTE: For air cleaner maintenance information, refer to the Operator’s Manual. 1. Remove air cleaner access panel from the front panel of the seat base and raise passenger seat to access air cleaner assembly. 2. Remove air cleaner components as needed using Figures 11 and 12 as guides. 1 Installation (Fig. 11) Figure 12 1. Engine oil fill 2. Breather tube 1. Reassemble air cleaner system using Figures 11 and 12 as guides.
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Exhaust System RIGHT FRONT 11 13 16 9 15 12 3 14 11 4 10 1 9 3 5 3 17 6 7 10 8 1 1 1 2 1 Figure 13 1. 2. 3. 4. 5. 6. Muffler clamp Muffler Flange nut Flat washer Foil tape Spark arrester Ford Gasoline Engine 7. 8. 9. 10. 11. 12. Tailpipe shield Tailpipe Flat washer Exhaust pipe hanger Cap screw Carriage bolt Page 3 – 12 13. 14. 15. 16. 17.
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Removal (Fig. 13) Installation (Fig. 13) CAUTION The muffler and exhaust pipes may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. IMPORTANT: While installing exhaust system components to machine, tighten muffler clamps only enough to keep components in position. Fully tighten clamps after complete exhaust system has been installed to machine. 1.
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Engine 1 2 LEFT 8 6 FRONT 5 3 7 9 19 10 4 11 14 12 13 15 18 16 150 ft–lb (203 N–m) 17 21 20 Figure 14 1. 2. 3. 4. 5. 6. 7. Engine assembly Hydraulic pump assembly Air cleaner elbow Hose clamp Intake tube Hose clamp Hose clamp 8. 9. 10. 11. 12. 13. 14. Lock washer Cap screw Ground cable Hose (to engine oil fill) Lock nut (4 used) Washer (4 used) Lock nut 15. 16. 17. 18. 19. 20. 21.
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CAUTION 2 3 Exhaust system components may be hot. To avoid possible burns, allow the exhaust system to cool before working on or near the muffler. 1 5. Remove exhaust system from engine (see Exhaust System Removal in this section). 6. Disconnect engine electrical connections. Position wires away from engine. Figure 15 1. Starter motor 2. Solenoid stud A. Remove nut from electric starter motor solenoid stud (Fig. 15).
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10.Remove throttle and choke cables from engine (Fig. 20). A. Loosen and remove cap screw and nut that secure end of throttle cable to governor lever. GD O/S BAT IGN ACC ST TEMP PRES ALT TACH B. Loosen and remove screw, flat washer and flange nut that secure throttle cable clamp to control bracket. RIGHT C. Loosen screw that secures choke cable to choke lever swivel. Figure 18 D. Loosen screw with washer that secures choke cable to carburetor. E. Position cables away from the engine. 1 11.
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IMPORTANT: Support engine assembly from below to prevent it from falling and being damaged during installation. IMPORTANT: Make sure not to damage the engine, fuel hoses, hydraulic lines, electrical harness, or other parts while installing the engine assembly. 5. Using a hoist or lift, slowly raise engine assembly from under machine and position to frame. Insert cap screws through frame, motor mounts and engine brackets from below (Fig. 17). Install washers and lock nuts on cap screws.
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Crankshaft Pulley Installation (Fig. 21) 1. Insert locking rings into crankshaft pulley. 6 5 NOTE: Outside locking rings have tapered I.D. and flat O.D. Inside locking rings have flat I.D. and tapered O.D. 3 4 A. Install first outside ring with the flat edge of the ring seated against small internal shoulder of pulley (Fig. 22). B. Install inside ring, mating taper to taper with the installed outside ring. C.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 4 Towing Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 6 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Piston (Traction) Pump System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Variable displacement piston pump 4000 PSI (276 bar) 4000 PSI (276 bar) 250 to 300 PSI (17 to 21 bar) Gear Pump Steering Circuit Relief Pressure Spray Pump Circuit Relief Pressure Single section, positive displacement gear pump 1000 PSI (69 bar) 1500 PSI (103 bar) Rear Wheel Motors Fixed displacement piston motor Spray Pump Motor Orbital rotor motor Hydraulic Filte
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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. Size 4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.) F.F.F.T. 1.
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Towing Sprayer IMPORTANT: If towing limits are exceeded, severe damage to the piston (traction) pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) at a speed below 3 mph (4.8 kph). The piston (traction) pump is equipped with a by–pass valve that needs to be turned 90o for towing (or pushing). See Operator’s Manual for Towing Procedures. 1 Figure 7 1.
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Hydraulic System This page is intentionally blank.
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Hydraulic System FLOW DURING FORWARD MOTION WHEEL MOTOR Page 4 – 8 TO REMOTE (5.8 GPM) (275 PSI) WHEEL MOTOR HYDRAULIC RESERVOIR (5.8 GPM VAC) (13 GPM VAC) (0–17 GPM MAX) MAIN RETURN (12.5 GPM) (0–20 PSI) 1.
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Hydraulic Flow Circuits Traction Circuit Traction circuit pressure (forward or reverse) can be measured by installing a tee fitting and gauge into the traction system hydraulic lines. Multi Pro 5600 The piston (traction) pump and wheel motors use a small amount of hydraulic oil for internal lubrication. Oil is designed to leak across pump and motor parts into the case drain. This leakage results in the loss of hydraulic oil from the closed loop traction circuit that must be replaced.
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Steering Circuit that flow goes through the top of the spool. Flow entering the steering control valve from the gear pump goes through the spool and is routed through the rotary meter (V1) and out the L port. Pressure extends the steering cylinder piston for a left turn. The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel.
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Spray Pump Drive Circuit Spray pump drive circuit hydraulic flow and pressure can be monitored at the outlet of the gear pump. Hydraulic flow control for the spray pump drive hydraulic motor is completed by the Pulse Width Modulated (PWM) Valve. The PWM Valve consists of an electric solenoid valve that allows the operator to adjust hydraulic flow to the spray pump motor. The spray pump on/off and application rate (increase/decrease) switches are used to adjust electrical current to the PWM Valve solenoid.
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Special Tools Order these special tools from your Toro Distributor. 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. Use gauges as recommended in Testing section of this chapter.
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O--Ring Kit Toro Part Number: 16--3799 The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection is loosened. Figure 12 Toro Part Number: TOR4079 This kit includes a variety of O--ring Face Seal fittings to enable connection of test gauges to the hydraulic system. TORO TEST FITTING KIT (NO. TOR4079) 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 The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the hydraulic circuits during various operational checks (See the Special Tools section in this Chapter).
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Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 1 CAUTION Prevent personal injury and/or damage to equipment.
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Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 9. Release traction pedal and stop engine. Record test results. 10.
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Gear Pump Flow Test Output from the gear pump is divided by a priority flow divider to allow priority flow to the steering circuit and secondary flow to the spray pump drive circuit. To test gear pump flow, testing of both circuits is required. Total gear pump flow is the combined flow from the two circuits. If a problem is suspected in one of the two circuits, flow for that circuit should be measured to determine if the problem is pump related or is involved with other circuit components. 6.
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Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 2 CAUTION 1 Prevent personal injury and/or damage to equipment.
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Steering Control Valve and Steering Cylinder Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. NOTE: This steering test procedure will be affected by incorrect tire pressure, binding of the hydraulic steering cylinder, excessive weight on the vehicle, and/or binding of the steering assembly (e.g. wheel spindles, tie rods). Make sure that these items are checked before proceeding with any hydraulic testing procedure. 3.
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Spray Pump Drive Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 8. Open control valve on tester, slow engine speed and shut off engine. Record test results. A.
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Wheel Motor Efficiency: Case Drain Test NOTE: Over a period of time, a wheel motor can wear internally. A worn motor may by–pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the wheel motor to stall under heavy load conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect overall machine performance. 1.
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Pulse Width Modulated (PWM) Valve Flow Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 3. Perform the Gear Pump Flow Test.
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Adjustments Adjust Traction Pedal for Neutral The piston (traction) pump control lever should return to the neutral position when the traction pedal is released. If the machine creeps when in neutral, check the following items: 2 3 1 1. The centering arms should be parallel to each other and also parallel to the centerline of the machine. 2. The centering arms should touch both front and rear bearings on control plate. 4 3. The centering arms should be tensioned by two springs. 4.
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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 hydraulic reservoir 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. Make sure hydraulic oil warm by operating the machine for several minutes. Park machine on a level surface. Stop engine, apply parking brake, and remove key from ignition switch. 2. Clean area around hydraulic filter mounting area and remove filter (see Operator’s Manual).
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Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors or pumps, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 1. Position machine on a level surface, engage parking brake and remove key from the ignition switch. 11.
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Gear Pump 15 14 12 13 12 10 8 11 9 LEFT SIDE OF PUMP 1 7 6 NOTE: ILLUSTRATION FROM BOTTOM OF MACHINE 5 4 2 3 Figure 26 1. 2. 3. 4. 5. Piston (traction) pump O–ring Gear pump O–ring Hydraulic hose (gear pump suction) Hydraulic System 6. 7. 8. 9. 10. Cap screw (2 used) Flat washer (2 used) O–ring Hydraulic hose (to steering control) O–ring Page 4 – 30 11. 12. 13. 14. 15.
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4. Install new hydraulic oil filter and fill hydraulic reservoir with correct oil (see Operator’s Manual). Removal (Fig. 26) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. To prevent contamination of hydraulic system during gear pump removal, thoroughly clean exterior of pump assembly. 5. Properly fill hydraulic system (see Charge Hydraulic System in the Service and Repairs section of this chapter). 6.
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Gear Pump Service 2 6 1 8 21 to 24 ft–lb (29 to 33 N–m) 10 3 4 11 25 to 28 ft–lb (34 to 38 N–m) 14 7 5 15 7 9 12 16 13 19 21 17 30 to 34 ft–lb (41 to 46 N–m) 20 22 18 23 15 21 to 24 ft–lb (29 to 33 N–m) 24 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. Cap screw (8 used) Washer (4 used) Shaft seal Washer Front plate Plug O–ring Backup gasket 9. 10. 11. 12. 13. 14. 15. 16. Pressure seal Wear plate Drive gear Idler gear Body Plug O–ring Backplate 17. 18. 19. 20. 21. 22. 23. 24.
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Piston (Traction) Pump 35 38 39 32 37 2 34 33 32 31 30 36 29 4 28 4 22 40 27 26 LEFT SIDE OF PUMP 21 24 4 23 22 20 19 7 9 18 17 7 15 14 NOTE: ILLUSTRATION FROM BOTTOM OF MACHINE 16 9 1 13 11 7 12 7 6 5 10 9 4 8 25 4 2 3 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
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3. Operate all hydraulic controls to relieve hydraulic system pressure. 4. Remove traction rod from control plate on piston pump by removing lock nut (Fig. 31). 5. Disconnect two (2) wires from neutral switch on piston pump (Fig. 31). 6. Remove flange head screw and flange nut that secures R–clamp and right side brake cable to pump assembly (Fig. 31). 7. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
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Piston (Traction) Pump Service 50 47 49 41 14 37 54 46 15 36 40 48 43 42 51 53 34 44 52 12 19 20 45 38 33 34 35 39 27 23 10 20 9 21 32 30 22 31 19 25 28 8 29 27 24 10 1 26 18 11 6 5 17 12 13 7 14 6 4 2 15 16 5 3 Figure 32 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Manual Servo Control Assembly 44 to 52 ft–lb (60 to 70 N–m) 15 10 1 14 2 3 9 7 4 13 12 5 4 8 6 16 24 17 to 26 in–lb (2 to 3 N–m) 17 23 Loctite #222 11 28 to 34 in–lb (3.2 to 3.8 N–m) 21 Loctite #242 18 20 19 Figure 33 1. 2. 3. 4. 5. 6. 7. 8. Plug O–ring Retaining ring Spring retainer Spring Spool valve Control housing Input shaft 9. 10. 11. 12. 13. 14. 15. 16. O–ring Wiper seal O–ring Adaptor Ball Pin Neutral switch O–ring 17. 18. 19. 20. 21. 22. 23. 24.
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Wheel Motors 1 30 31 29 22 32 60 ft–lb (81 N–m) 7 15 26 21 25 14 10 23 24 22 28 14 20 2 3 17 4 18 21 8 10 5 90 ft–lb (122 N–m) 14 19 18 26 27 19 LEFT FRONT 17 6 9 16 14 15 13 11 12 60 ft–lb (81 N–m) Figure 34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Removal (Fig. 34) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 5. Remove plugs from hydraulic lines, fittings, and ports. Lubricate new o–rings and attach hydraulic hoses to wheel motor. 6. If right side wheel motor was removed, plug speed sensor connector into machine wiring harness. 7. Check fluid level in hydraulic oil reservoir and adjust as required (see Operator’s Manual).
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Wheel Motor Service 15 to 18 ft–lb (20 to 24 N–m) 7 8 4 4 5 6 9 5 12 3 2 1 18 19 10 11 20 13 14 15 16 17 21 Figure 37 1. 2. 3. 4. 5. 6. 7. Retaining ring Shaft seal Washer Retaining ring Thrust bearing race Thrust bearing Drive shaft 8. 9. 10. 11. 12. 13. 14. Cap screw (6 used) Back plate Dowel pin Dowel pin (3 used) O–ring Needle bearing Valve plate NOTE: The wheel motors used on the Multi Pro 5600 are very similar.
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Spray Pump Drive Motor 1 3 4 6 5 7 FRONT 9 8 RIGHT 15 14 10 10 16 Loctite #242 13 26 12 9 8 6 Loctite #242 21 11 4 2 Antisieze Lubricant Antisieze Lubricant 17 18 19 20 21 24 22 23 25 26 22 27 Figure 38 1. 2. 3. 4. 5. 6. 7. 8. 9. Spray pump assembly Flange nut Square key Lock nut Pump hub Coupler spacer Rubber coupling Flat washer Cap screw Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
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1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. CAUTION Rotate steering wheel and depress traction pedal in both forward and reverse to relieve hydraulic system pressure and to avoid injury from pressurized hydraulic oil. 2. Operate all hydraulic controls to relieve hydraulic system pressure. 3.
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Spray Pump Drive Motor Service 17 19 12 13 15 16 18 6 20 2 3 21 1 22 14 22 to 26 ft–lb (30 to 35 N–m) 4 6 5 7 6 8 10 9 6 11 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. Cap screw (5 used) End cover Commutator seal Commutator Commutator ring Ring seal Manifold Stator 9. 10. 11. 12. 13. 14. 15. Vane Rotor Wear plate Drive link Shaft Woodruff key Bearing 16. 17. 18. 19. 20. 21. 22.
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Relief Valve A. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing malfunction. Removal 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. B. If sealing surfaces appear pitted or damaged, the hydraulic system may be over heating or there may be water in the hydraulic system. CAUTION 2. Operate all hydraulic controls to relieve hydraulic system pressure. 3.
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Pulse Width Modulated (PWM) Valve 8 9 13 15 12 11 14 10 RIGHT 10 5 1 FRONT 16 4 9 17 3 8 2 7 18 6 5 19 20 7 17 Figure 42 1. 2. 3. 4. 5. 6. 7. Spray pump assembly Flange nut Flange head screw Rear guard plate Flange nut (3 used) Front guard plate Hydraulic hose (PWM to motor) 8. 9. 10. 11. 12. 13. 14.
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Removal (Fig. 38) 1 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. CAUTION 3 Rotate steering wheel and depress traction pedal in both forward and reverse to relieve hydraulic system pressure and to avoid injury from pressurized hydraulic oil. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. Figure 43 1. PWM Valve 2. Solenoid 3.
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Steering Control Valve 9 8 6 5 4 2 2 1 7 2 3 10 2 11 1 12 13 FRONT RIGHT Figure 45 1. 2. 3. 4. 5. Hydraulic hose (to steering cylinder) O–ring Hydraulic hose (to oil cooler) Hydraulic hose (from pump) Steering control valve Hydraulic System 6. 7. 8. 9. Steering column Cap screw (4 used) Steering wheel Steering wheel cover Page 4 – 48 10. 11. 12. 13.
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Removal (Fig. 45) 1. Park the machine on a level surface, engage parking brake, and stop engine. Remove key from the ignition switch. 3. Lubricate new o–rings and connect hydraulic hoses to steering control valve (Fig. 46). Tighten hose connections. 4. Position dash panel to front hood and secure with fasteners (Fig. 47). 5. Check fluid level in hydraulic oil reservoir and adjust as required (see Operator’s Manual).
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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 (15.8 to 18.1 N–m) 15 18 17 16 Figure 48 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. Disassembly Geroter drive Wear plate Bearing race Thrust bearing Plug O–ring Check ball Quad seal 4. Slide the spool and sleeve assembly from the housing.
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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. 49). 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 hydraulic oil to the spool and sleeve assembly. Carefully slide the assembly into the housing.
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Steering Cylinder Anti–seize Lubricant 3 6 5 2 4 1 7 3 8 4 2 9 1 10 6 20 to 25 ft–lb (27 to 34 N–m) 11 FRONT 12 RIGHT Figure 50 1. 2. 3. 4. Hydraulic hose O–ring Hydraulic fitting O–ring Hydraulic System 5. 6. 7. 8. Jam nut Grease fitting Ball joint Cotter pin Page 4 – 52 9. 10. 11. 12.
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4. Secure barrel end of cylinder to the front axle with locking nut. Removal (Fig. 50) 1. Park the machine on a level surface, engage the parking brake, and stop the engine. Remove the key from the ignition switch. 5. Remove caps and plugs from disconnected hoses and fittings. 6. Lubricate new o–rings and connect hydraulic hoses to steering cylinder (Fig. 51). Tighten hose connections.
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Steering Cylinder Service 2 7 11 14 6 12 10 9 5 8 4 3 1 13 40 ft–lb (54 N–m) Figure 52 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 – 54 11. 12. 13. 14.
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Disassembly (Fig. 52) Reassembly (Fig. 52) 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 that secures head into barrel. 3. Remove plugs from ports. Extract shaft, head, and piston by carefully twisting and pulling on the shaft.
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Oil Cooler 19 LEFT FRONT 1 4 2 5 6 5 3 16 7 5 17 18 12 13 8 5 9 13 15 14 12 9 11 10 NOTE: EARLY PRODUCTION OIL COOLER SHOWN Figure 53 1. 2. 3. 4. 5. 6. 7. Oil cooler shroud Shroud trim Oil cooler Hydraulic hose (from steering) O–ring Hydraulic tee fitting Hydraulic hose (from PWM Valve) Hydraulic System 8. 9. 10. 11. 12. 13. 90o hydraulic fitting 90o hydraulic fitting Cap screw (4 used) Flat washer (8 used) Backing strip (4 used) Armaflex strip (4 used) Page 4 – 56 14. 15. 16. 17. 18.
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Removal (Fig. 53) Installation (Fig. 53) 1. Park the machine on a level surface, engage the parking brake, and stop the engine. Remove the key from the ignition switch. 1. Secure oil cooler to machine: Rotate steering wheel and depress traction pedal in both forward and reverse to relieve hydraulic system pressure and to avoid injury from pressurized hydraulic oil. 2. Operate all hydraulic controls to relieve hydraulic system pressure. 3.
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Hydraulic Reservoir 8 1 2 3 4 5 17 7 16 FRONT 6 8 15 14 13 9 RIGHT 12 11 10 Figure 55 1. 2. 3. 4. 5. 6. Hydraulic reservoir cap Strainer Hydraulic reservoir O–ring (2 used) Hydraulic fitting (2 used) Hydraulic hose (from oil cooler) Hydraulic System 7. 8. 9. 10. 11. 12. O–ring (2 used) Hydraulic hose (from piston pump) Hydraulic hose (to piston pump) Hydraulic hose (to gear pump) O–ring (2 used) Hydraulic fitting (2 used) Page 4 – 58 13. 14. 15. 16. 17. 18.
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Removal (Fig. 55) 1. Park the machine on a level surface, engage the parking brake, and stop the engine. Remove the key from the ignition switch. 3 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 4 3. Disconnect one hydraulic hose from the bottom of the hydraulic reservoir to drain reservoir (see Operator’s Manual). 2 1 4. Disconnect remaining hydraulic hoses from reservoir. Figure 56 5.
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Chapter 5 Electrical System Table of Contents Multi Pro 5600 Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . Traction Speed Sensor . . . . . . . . . . . . . . . . . . . . . . Accessory Solenoid . . . . . . . . . . . . . . . . . . . . . . . . Pressure Rate and Boom Actuator (Optional) Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pump, Agitation and Boom Control Switches . . . . . . . . .
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Electrical Schematics and Electrical Harness and Connector Drawings The electrical schematics and other electrical drawings for the Multi Pro 5600 are located in Chapter 8 – Electrical Diagrams.
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Special Tools Order these 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 Electrical Schematics in Chapter 8 – 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.
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Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Ignition switch is faulty. Engine is malfunctioning (see Chapter 3 – Ford Gasoline Engine). Fuel system is malfunctioning (see Chapter 3 – Ford Gasoline Engine). Engine may be too cold. Engine cranks (but should not) with the traction pedal out of the neutral position. Neutral switch is out of adjustment or faulty. Neutral switch wiring is faulty (see Chapter 8 – Electrical Diagrams).
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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. disconnect the ignition switch connectors before doing a continuity check on the ignition switch). NOTE: See the Ford VSG – 411/413 Engine Service 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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Neutral Switch The neutral switch is located on the top side of the piston (traction) pump (Fig. 5). The switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction (forward or reverse). 1 Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals.
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Headlight Switch The headlight switch is located on the dash panel (Fig. 8) and is used to turn the headlights on and off. 1 Testing 1. Make sure ignition switch is off. Locate headlight switch and unplug wire harness connector from switch. 2. The switch terminals are marked as shown in Figure 9. In the ON position, continuity should exist between the two terminals. In the OFF position, there should be no continuity between the switch terminals. Figure 8 1. Headlight switch 3.
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Cruise Control Switch The cruise control switch is positioned on the dash panel above the ignition switch (Fig. 11). This switch energizes the cruise control coil to allow the operator to maintain a constant ground speed. 1 Testing 1. Make sure ignition switch is off. Locate switch and unplug machine wire harness connector from switch. Figure 11 1. Cruise control switch 2. The switch terminals are marked as shown in Figure 12. In the ON position, continuity should exist between terminals 2 and 3.
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Brake Pedal Switch The brake pedal switch is mounted on the frame under the floorboard (Fig. 14). The brake pedal switch prevents the cruise control coil from being energized when the brake pedal is pushed. 1 Testing 1. Make sure ignition switch is off. Locate switch and unplug wire harness connector from switch. 4 2. When the switch plunger is pressed (brake pedal released), there should be continuity between the switch terminals.
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Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 16). There is a red/white wire attached to the terminal of the switch. Testing 1. Lower coolant level in the engine and remove the temperature sender from water flange. 1 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 17). CAUTION Figure 16 Handle the hot oil with extreme care to prevent personal injury or fire. 1.
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Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by using a DC voltage source and a variable resistance box. Testing CAUTION VARIABLE RESISTANCE Make sure the voltage source is turned OFF before connecting variable resistance to the electrical circuit to avoid electrical shock and to prevent damaging the gauge. 14 VDC + 0.01 VDC 1. Make sure ignition switch is off. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 18).
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Traction Speed Sensor The traction speed sensor is attached to the right side rear wheel motor (Fig. 21). The sensor provides ground speed information for the optional Pro Control Spray System. It uses a magnetically based, Hall Effect integrated circuit. As the piston group in the wheel motor turns, the sensor accurately senses the movement of the pistons passing the sensor.
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Accessory Solenoid The accessory solenoid provides a current supply to the spray system and optional accessories (e.g. 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.22). 1 2 Testing 1. Make sure engine is off. Disconnect battery cables from battery making sure to disconnect negative (–) cable first and then positive (+) cable. 3 4 2.
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Pressure Rate and Boom Actuator (Optional) Switches The pressure rate (increase/decrease) switch is located on the spray control console (Fig. 24). This switch along with the Manual Interface Module (or Pro Control, if equipped) changes the applied current to the PWM valve which controls hydraulic flow to the hydraulic motor that drives the spray pump. Pressing the switch to the increase position allows additional current to the PWM valve which increases flow to the hydraulic motor.
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Spray Pump, Agitation and Boom Control Switches The spray pump (on/off), agitation (on/off) and boom (on/off) control switches are located on the spray control console (Fig. 26). 3 2 Testing 1. Make sure ignition switch is off. Remove console panel, locate switch and unplug machine wire harness connector from switch. 6 4 2. The switch terminals are marked as shown in Figure 27. In the ON position, continuity should exist between terminals 2 and 3 and also between terminals 5 and 6.
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Master Boom (Foot) Switch The master boom switch is located on the floorboard of the machine (Fig. 28). This switch allows the machine operator to control the operation of all boom sections using one switch. Testing 1. Make sure ignition switch is off. Locate switch and unplug machine wire harness connector from switch. 2. The switch, switch harness, and connector are shown in Figure 29. Depress the switch until continuity exists between connector terminals A and C.
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Pulse Width Modulated (PWM) Valve Solenoid The Pulse Width Modulated (PWM) Valve which controls hydraulic flow to the spray pump motor includes an electric solenoid (Fig. 30). When the spray console rate switch is depressed, the available current to the PWM valve solenoid is changed. This solenoid current change causes a valve shift and subsequent change in hydraulic flow to the spray pump motor. Testing of the PWM Valve solenoid can be done without removing the solenoid.
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Manual Interface Module The manual interface module is used in conjunction with the increase/decrease switch to adjust current flow to the PWM Valve and to maintain pump rate settings when the booms are turned off and on again using the master boom (foot) switch. The module is fastened to the head light shield under the dash panel (Fig. 31). The manual interface module is disabled if a Pro Control is installed in the spray system. 5.
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Cruise Relay (Serial Numbers 230000400 and Above) The cruise relay is used to energize the cruise control coil and is located under the operator seat. 86 87A 87 87 Testing 87A NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
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Service and Repairs NOTE: See the Ford VSG – 411/413 Engine Service Manual for engine electrical component repair information. Headlights Removal and Installation 2 1. Set parking brake, turn ignition off, and remove key. 3 2. Remove two (2) flange head screws that secure shield to machine. Position shield away from back of headlight. 3. Unplug wiring harness connector from headlight bulb. 1 4 5 6 NOTE: Headlight bulb can be replaced without removing headlight body. Be careful when servicing bulb.
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Traction Speed Sensor Removal (Fig. 37) 1. Locate speed sensor on right side wheel motor. Disconnect speed sensor from machine wire harness. 2. Loosen lock nut and remove speed sensor from wheel motor. Installation (Fig. 37) 1 1. Thread lock nut fully onto speed sensor threads. 2 2. Center a wheel motor piston in the center of the sensor port (see Sensor Port View in Fig. 38). Use a suitable tool to feel when a motor piston is in the center of the sensor port. 4 3.
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Cruise Control Coil Removal (Fig. 39) 1. Set parking brake, turn ignition off, and remove key. 2 2. Remove hex nut and lock washer that secure shaft to machine frame. Remove shaft with collar, flange bushing, plate, and compression spring. 3. Unplug cruise control coil connector from machine wiring harness. Remove four (4) cap screws, lock washers, and hex nuts that secure coil to frame. Remove cruise control coil. 1 Installation (Fig. 39) 1.
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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). 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). 2. Either store battery on a shelf or on the machine. 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. 2. Make sure battery compartment is clean and repainted if necessary. Make sure all battery cables, connections and battery retainer are in good condition. 3. Place battery in its compartment with the battery posts toward the front of the vehicle. Make sure battery is level and flat.
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C. If the difference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If these charging conditions can not be met, replace the battery. Inspection, Maintenance, and Testing 1.
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H. Using the table below, determine the minimum voltage for the cell temperature reading: Minimum Voltage Battery Electrolyte Temperature 9.6 70oF (and up) 21.1oC (and up) 9.5 60oF 15.6oC 9.4 50oF 10.0oC 9.3 40oF 4.4oC 9.1 30oF –1.1oC 8.9 20oF –6.7oC 8.7 10oF –12.2oC 8.5 0oF –17.8oC I. If the test voltage is below the minimum, replace the battery. If the test voltage is at or above the minimum, return the battery to service.
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Chapter 6 Spray System Table of Contents Spray Control Assembly . . . . . . . . . . . . . . . . . . . . Boom Valve Motor Assembly . . . . . . . . . . . . . . . . Agitation Valve Motor Assembly . . . . . . . . . . . . . . Boom and Agitation Valve Motor Service . . . . . . Boom Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Drain Valve (Serial Numbers below 230000400) . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Spray Pump Diaphragm Pump, 30 GPM (114 LPM) @ 200 PSI Spray Pressure Relief Valve Poppet Style, 220 PSI Maximum Sprayer Tank 300 Gallon (1136 Liter), Polyethylene Suction Strainer Spray System 50 Mesh (Blue), Stainless Steel, Tank Mounted (30 Mesh (Red) and 80 Mesh (Green) Optional) Page 6 – 2 Multi Pro 5600
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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: 4. Always wear protective clothing, chemical resistant gloves, eye protection, and other personal protective equipment as recommended by the chemical manufacturer. 1. Select the proper chemical for the job. 2.
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Spray System SUCTION DAMPENER AGITATION DIAPHRAGM PUMP TANK PRESSURE DAMPENER TOP MOUNTED TANK DRAIN VALVE PRESSURE GAUGE PRESSURE RELIEF VALVE AGITATION AGITATION Page 6 – 4 AGITATION FLOWMETER (if equipped) BOOM BYPASS TOP MOUNTED SUCTION & SCREEN LEFT BOOM CENTER BOOM RIGHT BOOM BOOM SUPPLY BOOM CONTROL VALVES AGITATION AGITATION Spray System Flow Diagram SUCTION PRESSURE AGITATION BOOM SUPPLY FLOW DIRECTION Multi Pro 5600
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Spray System Operation The downward stroke of the pumps’ two connecting rods and diaphragms create suction to allow fluid to be drawn from the spray tank to the pump via the suction tube, suction strainer, hoses, and connectors. A suction dampener placed in the suction line dampens suction pulses to smooth suction flow. Suction valves positioned in the pump valve chamber prevent fluid from being pumped back into the suction line.
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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. Spray tank drain valve not seating. 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.
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Erratic spray operation from booms. Clogged strainer. Damaged suction dampener. Damaged pressure dampener. Clogged or damaged spray nozzle(s). Spray nozzles are different sizes. Console boom switch(es) dirty, corroded, or damaged. Boom valve motor seat loose or damaged. Boom valve motor actuating cam worn or sticking. Boom bypass set incorrectly. No spray output from one spray boom. Hoses on boom are pinched or kinked. Boom valve motor for affected boom not opening. Fuse for affected boom blown.
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Service and Repairs Suction Dampener The suction dampener is mounted to the suction line at the spray pump (Fig. 1) and is used to dampen suction pulses to smooth suction flow. During normal 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. 3 1 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. 3) and is used to smooth system pressure pulsation. Adjust air pressure on the pressure dampener from 12 to 15 PSI (.83 to 1.03 bar). 2 3 IMPORTANT: Any fluid in the pressure dampener will include spray system chemicals so take necessary precautions when working with the dampener. Use appropriate protective equipment: protective clothing, chemical resistant gloves, and eye protection.
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Spray Pump 1 3 4 6 5 7 FRONT 9 8 14 10 RIGHT 15 13 2 10 16 Loctite #242 12 9 8 6 Loctite #242 11 4 2 Antisieze Lubricant Antisieze Lubricant 17 19 18 20 21 Figure 5 1. 2. 3. 4. 5. 6. 7. Spray pump assembly Flange nut Square key Lock nut Pump hub Coupler spacer Rubber coupling 8. 9. 10. 11. 12. 13. 14.
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6. Remove four (4) flange head screws and flange nuts that secure pump to pump mount bracket. 7. Remove pump from machine. 1 8. If needed, loosen set screws in pump hub. Pull hub from pump shaft. Locate and remove key from pump shaft. Remove set screws from pump hub. Clean threads of set screws and hub. 2 9. If needed, remove pressure dampener, tee fitting (pressure), and elbow fitting (pressure) from pump outlet (Fig. 7). 10.
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Spray Pump Service 26 1 60 ft–lb (80 N–m) 2 30 27 3 2 30 25 4 9 3 5 60 ft–lb (80 N–m) 4 6 29 28 7 8 7 5 6 18 8 24 9 32 ft–lb (44 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 (44 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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C. Slide connecting rods onto rod bearings. Offsets of the connecting rods should face each other. Install hex bolt, flat washers, and hex nut to connecting rod. Torque hex nuts to 25 ft–lb (34 N–m) to secure connecting rod to 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. D. Position dust plate and felt seal on both ends of crankshaft.
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3. Install three (3) shorter (30 mm) and two (2) longer (55 mm) bolts into pump casing assembly (Fig. 10). Thread hex nuts onto bolts but do not fully tighten. Check that crankshaft turns freely. 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 (80 N–m). 2 1 5.
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Agitation Nozzles (Tank mounted) 1 2 21 4 3 10 5 9 1 8 6 7 7 10 2 1 8 9 2 6 11 9 10 12 13 4 1 2 8 6 4 5 3 1 3 1 1 14 5 7 19 5 12 5 13 15 1 5 FRONT 16 20 RIGHT 5 17 NOTE: ARROWS SHOW FLUID FLOW DIRECTION 15 18 Figure 13 1. 2. 3. 4. 5. 6. 7. O–ring Fork Hosebarb Bulkhead nut Hose clamp Bulkhead gasket Bulkhead fitting Spray System 8. 9. 10. 11. 12. 13. 14. Elbow fitting Agitation nozzle Nut Hose (3/4”) Nut Hosebarb Hose (3/4”) Page 6 – 16 15. 16. 17. 18. 19. 20.
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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 Disassembly (Fig. 13) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain spray tank (see Operator’s Manual). 2 3. Label disconnected hoses for proper installation after repairs are completed. 4.
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Pressure Relief Valve (Tank Mounted) 1 12 2 13 6 11 3 FRONT 10 4 3 9 5 RIGHT 7 5 4 NOTE: ARROWS SHOW FLUID FLOW DIRECTION 8 Figure 15 1. 2. 3. 4. 5. Spray tank Pressure supply hose (1”) Hose clamp Hosebarb O–ring Spray System 6. 7. 8. 9. Fork Tee fitting assembly Pressure relief valve hose (1”) Hosebarb Page 6 – 18 10. 11. 12. 13.
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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. 2 1 Removal (Fig. 15) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 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 Assembly 10 12 9 5 13 9 14 20 6 15 19 4 9 16 17 11 5 7 18 10 6 3 5 9 4 21 2 35 22 3 5 1 23 20 27 24 25 28 34 26 33 29 8 32 18 29 30 FRONT RIGHT 31 22 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Boom valve motor assembly O–ring Flange nut Flange nut Flange head screw Boom mounting bracket Cross support angle RH boom mount Flange nut Boom hold–in assembly Valve mounting bar LH boom mount 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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4. If boom valve motor assembly is to be removed: A. Unplug boom valve motor electrical connectors from machine wiring harness. 1 4 3 5 B. Remove pressure gauge tube from boom valve motor assembly. 2 C. Remove three (3) flange head screws and three (3) locknuts that secure boom valve motors to mount bracket (Fig. 20). Remove boom valve motor assembly from machine. 6 6 5. If agitation valve motor is to be removed: 6 A. Unplug agitation valve motor electrical connectors from machine wiring harness.
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Boom Valve Motor Assembly 15 1 FRONT 14 18 17 4 RIGHT 3 13 16 2 3 2 2 5 2 2 11 7 20 12 2 19 21 7 22 16 10 8 6 7 8 9 7 7 23 26 8 7 27 24 25 8 6 26 26 28 27 29 30 28 27 NOTE: ARROWS SHOW FLUID FLOW DIRECTION 28 29 29 30 30 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. RH boom valve motor O–ring Valve joiner Center boom valve motor LH boom valve motor Boom bypass joiner O–ring Fork End cap O–ring Spray System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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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. 1 3 2 4 Disassembly (Fig. 21) 1. Separate boom valve motors as needed using Figures 21 and 22 as guides. Discard all removed o–rings and gaskets. 7 2. See Boom and Agitation Valve Motors in this section for disassembly and reassembly information of boom valve motor. 5 6 Assembly (Fig.
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Agitation Valve Motor Assembly 1 FRONT RIGHT 7 6 2 5 4 3 19 2 21 7 20 8 9 10 18 10 9 8 17 16 15 13 NOTE: ARROWS SHOW FLUID FLOW DIRECTION 12 11 14 Figure 23 1. 2. 3. 4. 5. 6. 7. Agitation valve motor O–ring End cover O–ring Washer Rod Nut Spray System 8. 9. 10. 11. 12. 13. 14. O–ring End cap Fork Nut Hosebarb O–ring Mounting bracket Page 6 – 24 15. 16. 17. 18. 19. 20. 21.
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The agitation switch on the spray console is used to energize the agitation valve motor and open the valve. The open valve allows system flow to reach the three agitation nozzles located in the spray tank. 1 4 3 5 IMPORTANT: Make sure to remove and neutralize chemicals from spray components before disassembly. Wear protective clothing, chemical resistant gloves, and eye protection during repair. Disassembly (Fig. 23) 1. Disassemble agitation valve motor as needed using Figures 23 and 24 as guides.
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Boom and Agitation Valve Motor Service 9 8 1 10 11 12 5 13 14 7 6 28 15 29 2 16 17 19 3 18 4 20 21 30 31 22 34 35 36 32 23 24 25 26 27 33 70 in–lb (7.9 N–m) Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Housing cover Cover seal Valve motor Phillips head screw O–ring Lock washer Hand grip Roller Roller pin Spindle Spring Spring seat 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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4. Remove rear housing cover from valve motor to inspect motor components. 1 3 2 4 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. 27). 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 (7.9 N–m). 4. Position spindle section on motor section so that green indicator on spindle section is opposite the motor hand grip. Secure spindle section to motor section with four phillips head screws (item 15). 7. Assemble valve motor assembly.
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Boom Bypass 1 10 4 3 12 2 11 15 5 6 14 FRONT 13 7 RIGHT 12 8 11 NOTE: ARROW SHOWS FLUID FLOW DIRECTION 9 10 Figure 29 1. 2. 3. 4. 5. Spray tank Boom valve motor assembly O–ring Hosebarb Hose clamp Spray System 6. 7. 8. 9. 10. Boom bypass hose (1”) Fork Boom supply hose (1 1/2”) Hose clamp Elbow fitting Page 6 – 30 11. 12. 13. 14. 15.
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Disassembly (Fig. 29) Assembly (Fig. 29) 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 2 3 1 FRONT 4 5 RIGHT 20 7 6 9 8 16 10 11 15 12 13 14 15 15 14 17 18 NOTE: ARROW SHOWS FLUID FLOW DIRECTION 14 19 16 Figure 30 1. 2. 3. 4. 5. 6. 7. Suction hose (1 1/2”) Hose clamp Hosebarb O–ring Suction screen vane Suction screen Fork Spray System 8. 9. 10. 11. 12. 13. 14. Filter housing Expansion pin (2 used) Gasket Hosebarb O–ring Bulkhead nut Hose clamp Page 6 – 32 15. 16. 17. 18. 19. 20.
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NOTE: If suction tube in tank develops an air leak, spray performance will diminish when tank level reaches the leak. 1 Removal (Fig. 30) 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. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove suction strainer from spray tank (see Operator’s Manual).
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Tank Drain Valve (Serial Numbers below 230000400) 1 18 17 2 16 FRONT 3 15 RIGHT 14 4 7 13 12 11 5 6 7 19 8 9 10 Figure 32 1. 2. 3. 4. 5. 6. 7. Tank drain knob Bolt Ringnut Expansion pin Flex tube Drain screw Gasket Spray System 8. 9. 10. 11. 12. 13. Bulkhead fitting Gasket Ringnut Pin Expansion pin Tube connector Page 6 – 34 14. 15. 16. 17. 18. 19.
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Disassembly (Fig. 32) 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 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain spray tank (see Operator’s Manual). 3. Remove bolt and lock nut that secure tank drain knob to drain tube. Slide knob from tube. 4. Loosen bulkhead nut from bulkhead.
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Tank Drain Valve (Serial Numbers 230000400 and above) 1 2 4 3 FRONT 5 RIGHT 6 7 8 9 11 10 Figure 34 1. 2. 3. 4. Drain handle Nut O–ring Bulkhead Spray System 5. 6. 7. 8. Gasket Ringnut Chain Drain assembly Page 6 – 36 9. Bulkhead 10. Hosebarb 11.
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Disassembly (Fig. 32) 2 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. 4 1 5 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3 7 2. Drain spray tank (see Operator’s Manual). 6 3.
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Turret Bodies 6 7 3 8 3 5 4 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 36 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. 36) Installation (Fig.
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Turret Body Service Disassembly (Fig. 37) 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. 18 3 6 4 17 1. Pull e–clip from body and slide plug with o–ring from body. 7 5 2 8 9 10 2. Disassemble turret body using Figure 37 as a guide. 3. Discard all removed seals, gaskets, o–rings, and diaphragms. 6 16 13 14 Assembly (Fig.
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Boom Frame Breakaway Pivot Assembly 6 5 7 4 3 8 9 2 1 10 10 15 16 12 11 14 6 18 13 11 17 19 20 12 Figure 39 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 assembly Page 6 – 40 15. 16. 17. 18. 19. 20.
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Disassembly (Fig. 39) 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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Pro Control Spray System (Optional) The Multi Pro 5600 has an optional Pro Control Spray System available. This system includes a computer and flowmeter and is designed to automatically control spray application at varying vehicle speeds. The Operator’s Manual for the Pro Control System includes information regarding installation, operation, programming, and maintenance. Refer to your Operator’s Manual for information on the Pro Control Spray System.
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Boom Actuator (Optional) 1 2 3 4 1 2 3 Figure 44 1. Cotter pin 2. Clevis pin 3. Boom actuator 4. Wire harness Removal (Fig 44) Installation (Fig 44) 1. Park machine on a level surface, lower booms, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position actuator to clevis attachment points on center and side booms. 2. Label actuator electrical leads to ease reassembly. Unplug boom actuator connector wires from machine harness. 3.
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Adjustment 1. Loosen end nut that secures adjustable clevis to boom frame (Fig. 45). 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. 46). 4.
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Boom Actuator Service 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 Figure 47 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. Thick washer Hex nut (2 used) Motor gear Housing gasket Front housing Cover tube gasket Motor seal Page 6 – 46 15. 16. 17. 18. 19. 20.
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Disassembly (Fig. 47) Assembly (Fig. 47) 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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Chapter 7 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 3 Tie Rod Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Wheels and Hubs . . . . . . . . . . . . . . . . . . . . . . 4 Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brake Assembly . . . . . .
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Specifications Item Description Front Tire Pressure (23 x 10.5 – 12, 4 ply, tubeless) 18 PSI (1.24 bar) Maximum Rear Tire Pressure (26.5 x 14 – 12, 4 ply, tubeless) 18 PSI (1.24 bar) Maximum Front Wheel Lug Nut Torque 65 ft–lb (88 N–m) Rear Wheel Lug Nut Torque 90 ft–lb (122 N–m) Planetary, Brake Assembly and Wheel Motor Mounting Screw Torque 60 ft–lb (81 N–m) Front Wheel Toe–In 1/8 to 1/4 inch (3.2 to 6.
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Service and Repairs Tie Rod Ends Removal (Fig. 1) 10 1. Loosen jam nut on tie rod end. Note: Left side tie rod end has left hand threads. 2. Remove cotter pin and castle nut that secure tie rod end to spindle. 3. Use a suitable puller to separate tie rod end from spindle. 7 4 7 6 20 to 25 ft–lb (27 to 34 N–m) 9 5 FRONT 8 5 Figure 1 1. 2. 3. 4. 5. 6. 1. Install dust boot on new tie rod end. 2 6 4.
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Front Wheels and Hubs See text for tightening procedure 65 ft–lb (88 N–m) 12 2 8 6 3 4 7 7 5 1 9 6 10 11 FRONT RIGHT Figure 3 1. 2. 3. 4. Lug nut (5 used per wheel) Wheel and tire assembly Dust cap Slotted hex nut Chassis 5. 6. 7. 8. Washer Wheel bearing cone Wheel bearing cup Wheel hub Page 7 – 4 9. 10. 11. 12.
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Removal (Fig. 3) Installation (Fig. 3) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1. Clean all parts thoroughly before reassembly. 2. If wheel bearings were removed from wheel hub, assemble wheel hub: A. If bearing cups were removed from the wheel hub, press inner and outer cups into the hub until they seat against the hub shoulder. CAUTION When changing tires or performing other service, use correct blocks, hoists, and jacks.
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Spindles 5 9 3 4 2 3 2 1 4 8 7 9 20 to 25 ft–lb (27 to 34 N–m) 6 10 9 65 ft–lb (88 N–m) 11 See text for adjustment procedure 26 20 24 23 12 14 15 13 19 20 16 25 20 to 25 ft–lb (27 to 34 N–m) 8 27 19 18 22 21 17 15 12 FRONT RIGHT Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. Front axle Flat washer Washer head screw King pin Hydraulic steering cylinder Lock nut LH spindle assembly Castle nut Cotter pin Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Disassembly (Fig. 4) Assembly (Fig. 4) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1. If removed, install bushings and steering stop bolt into spindle. 2. Place thrust bearing in top of spindle. Position spindle to front axle. Slide king pin into front axle and spindle. CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks.
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Front Suspension 5 6 7 3 13 12 9 3 8 4 14 3 10 15 16 10 4 3 17 2 11 19 1 2 13 12 2 18 65 ft–lb (88 N–m) 23 21 22 24 20 6 FRONT 5 RIGHT 35 ft–lb (47 N–m) Figure 5 1. 2. 3. 4. 5. 6. 7. 8. Front axle Flat washer Lock washer Hex nut Hex nut Lock washer Hex nut Inside shackle Chassis 9. 10. 11. 12. 13. 14. 15. 16. Shackle bushing Shoulder bolt Outside shackle Spacer Shoulder bolt Shock absorber Axle bumper Cap screw (4 used per spring) Page 7 – 8 17. 18. 19. 20. 21. 22. 23.
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Disassembly (Fig. 5) Assembly (Fig. 5) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key. 1. Assemble front suspension using Figure 5 as a guide. A. When installing suspension components, loosely install all fasteners before tightening any of the fasteners. 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.
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Brake Assembly 1 16 17 15 18 60 ft–lb (81 N–m) 7 10 14 3 2 4 8 10 5 90 ft–lb (122 N–m) 6 60 ft–lb (81 N–m) 9 11 13 12 Figure 6 1. 2. 3. 4. 5. 6. Planetary assembly Lock nut (8 used per wheel) Flat washer (8 used per wheel) Tire and wheel assembly Gasket RH brake assembly 7. 8. 9. 10. 11. 12. Flange head screw (4 used per brake) Splined brake shaft Retaining ring O–ring RH wheel motor Flat washer (2 used per motor) 13. 14. 15. 16. 17. 18.
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3. Chock front wheels and jack up rear of machine (see Jacking Instructions in Operator’s Manual). Support machine with jack stands or solid wood blocks. 4. Remove rear wheel assembly. 5. Remove hydraulic wheel motor (see Rear Wheel Motors in Service and Repairs section of Chapter 4 – Hydraulic System). 6. Disconnect brake cable from pull rod on brake. WARNING Failure to maintain proper lug nut torque could result in failure or loss of wheel and may result in personal injury. 7.
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Brake Inspection and Repair 3 2 1 4 5 5 6 7 7 9 15 10 14 13 12 8 11 8 Figure 9 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin Link (2 used) 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Hitch pin (2 used) Stationary disc Rotating disc Retaining ring Gasket Rotating actuator Extension spring (3 used) Ball (3 used) Plug (2 used) O–ring Brake Inspection and Repair (Fig. 9) 6. Remove seal (2) from brake housing. 1.
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Brake Cables Removal PHOTO TAKEN FROM BELOW 4 1. Remove brake cable from brake equalizer at front of machine under floorboard (Fig. 10 and 11): 5 A. Remove cotter pin, flat washer, and clevis pin that secure brake cable to brake equalizer. B. Loosen jam nuts that secure cable to cable bracket on frame. 2 4 2. Remove brake cable from rear brake (Fig. 12): 1 3 A. Loosen and remove cable end from pull rod on brake assembly. B. Loosen jam nut that secures brake cable to cable bracket on frame.
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Planetary Wheel Drive Assembly 1 16 17 15 18 60 ft--lb (81 N--m) 7 10 14 3 2 4 8 10 5 90 ft--lb (122 N--m) 6 60 ft--lb (81 N--m) 9 11 12 13 Figure 13 1. 2. 3. 4. 5. 6. Planetary assembly Lock nut (8 used per wheel) Flat washer (8 used per wheel) Tire and wheel assembly Gasket RH brake assembly 7. 8. 9. 10. 11. 12. Flange head screw (4 used per brake) Splined brake shaft Retaining ring O--ring RH wheel motor (with speed sensor) Flat washer (2 used per motor) 13. 14. 15. 16. 17. 18.
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Removal (Fig. 13) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (see Operator’s Manual). 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.
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Planetary Wheel Drive Service 118 to 144 in–lb (13.3 to 16.3 N–m) 3 4 7 8 9 11 12 1 13 2 14 15 5 16 6 10 28 20 27 19 18 26 17 25 24 23 22 21 29 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Bearing cone Bearing cup Wheel stud (8 used) Socket head screw (16 used) Lock washer (16 used) Housing Dowel pin Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Bearing cup Bearing cone O–ring Bearing shim Snap ring Ring gear Retaining ring Plug End cap O–ring Page 7 – 16 21.
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NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 15 and 16) 1. If planetary wheel drive assembly is installed on machine: A. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. B. Drain oil from planetary wheel drive/brake assembly. C.
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F. Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spindle shaft shoulder. G. Install outer bearing cone (item 12) onto spindle. NOTE: The planetary shim kit includes the retaining ring and several thrust washers with thickness in incremental steps of 0.004 in. (0.10 mm). H. Measure thickness of thrust washer (item 14) that was removed during disassembly.
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Chapter 8 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 3 Vehicle Electrical Schematic (Serial Numbers below 230000400) . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Vehicle Electrical Schematic (Serial Numbers 230000400 and above) . . . . . . . . . . . . . . . . . . . . . . 4 Spray System Electrical Schematic . . . . . . . . . . . . . 5 CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . .
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TO IGNITION TO TEMP. SENDER TO OIL PRESSURE SWITCH TO ALTERNATOR (APPLIED) (NOT IN NEUTRAL) (OFF) Multi Pro 5600 Vehicle Electrical Schematic (Serial Numbers below 230000400) (OPTIONAL) All relays and solenoids are shown as de–energized.
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ACCESSORY SOLENOID GN/R GN/R LOW OIL PRESSURE GROUND JUNCTION BLOCK (+) HOUR METER HR VOLT TEMP (–) 1 (+) I S G (–) 2 3 R R/W 4 5 6 7 W/R 8 9 Y/R BK 10 11 B+ Start (+) (–) FRAME GROUND BATTERY BK PARKING BRAKE (APPLIED) OFF: NONE ON: 2&3 ENGAGE: 2&3; 5&6 R/BK ACC ––––– B+A STOP –––– NONE RUN –––– B+I+A START ––– B+I+S R/BK R/BU 2 5 7 8 1 2 87a 30 W BU D2 2 BN BU 3 6 D1 1 87 85 BU BN CRUISE CONTROL COIL 86 CRUISE RELAY BU BK 1F 1 20 A B Y/R I S BK PK BK R/
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BN BN BN PK PK PK R R BN R BN BN 5 6 5 PK 4 R R 2 3 2 1 2 6 5 V/BK 4 5 2 1 V/W 3 GN/R 4 2 1 3 7 8 BK 7 8 BK 7 8 3 2 BK 7 BK 1 8 V/BK 7 R/W 4 R/W 3 2 2 1 Y/BU 2 1 W/BK 3 1 3 2 8 Y GN BU 1 6 W/BK 4 OR 5 4 5 3 (OPTIONAL) 6 5 6 5 BU/PK R/W (OPTIONAL) (OPTIONAL) 6 4 Y/R 3 1 6 5 6 PK 4 R/W R/W (OPTIONAL) 4 3 R/BK R 6 5 PK 4 R R R 6 R R 7 BU/GY 8 7 8 1 BU/R (OFF) (OFF) (OFF) BK BK BK BK BK (OF
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(NOT ENERGIZED) TO IGNITION TO TEMP.
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(ENERGIZED) TO IGNITION TO TEMP.
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(ENERGIZED) TO IGNITION SCR DIODE TO TEMP. SENDER (NOT APPLIED) TO OIL PRESSURE SWITCH FROM ALTERNATOR FROM HEADLIGHTS NOTE: SCR DIODE IS USED FOR CIRCUIT PROTECTION FROM VOLTAGE SPIKES THAT CAN OCCUR WHEN CRUISE CONTROL COIL IS DE–ENERGIZED. THE MOMENTARY SWITCH CONTACTS (5 & 6) ALLOW THE SCR DIODE TO BE TURNED ON TO ALLOW CURRENT FLOW FROM THE SWITCH TO THE CRUISE CONTROL COIL.
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BN BN BN PK PK PK R R BN R BN BN 6 PK 4 6 5 R R 4 2 3 2 1 2 6 5 V/BK 4 5 BU/PK 2 1 V/W 3 2 1 GN/R 4 1 3 3 7 8 BK 7 8 BK 7 8 2 BK 7 BK 1 8 V/BK 7 R/W R/W 3 2 1 Y/BU 2 1 W/BK 3 2 1 3 2 8 Y GN BU 4 W/BK 4 OR 6 5 4 5 3 (OPTIONAL) 6 5 6 5 R/W (OPTIONAL) (OPTIONAL) 6 4 Y/R 3 1 6 5 6 PK R/W R/W (OPTIONAL) 4 3 R/BK R 6 5 PK 4 R R R 5 R R 7 BU/GY 8 7 8 1 BU/R (ON) (ON) (ON) BK BK BK BK (OFF) BK
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BN BN BN PK PK PK R R BN R BN BN 6 PK 4 6 5 R R 4 2 3 2 1 2 6 5 V/BK 4 5 BU/PK 2 1 V/W 3 GN/R 4 2 1 1 3 3 7 8 BK 7 8 BK 7 8 2 BK 7 BK 1 8 V/BK 7 R/W 4 R/W 3 2 2 1 Y/BU 2 7 1 W/BK 3 1 3 2 8 Y GN BU 6 W/BK 4 OR 5 4 5 3 (OPTIONAL) 6 5 6 5 R/W (OPTIONAL) (OPTIONAL) 6 4 Y/R 3 1 6 5 6 PK R/W R/W (OPTIONAL) 4 3 R/BK R 6 5 PK 4 R R R 5 R R BU/GY 8 7 8 1 BU/R (ON) (ON) (ON) BK BK BK BK (OFF) BK
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BN BN BN PK PK PK R R BN R BN BN 6 PK 4 6 5 R R 4 2 3 2 1 2 6 5 V/BK 4 5 2 1 V/W 3 2 1 GN/R 4 1 3 7 8 BK 7 8 BK 7 8 3 2 BK 7 BK 1 8 V/BK 7 R/W 4 R/W 3 2 2 1 Y/BU 2 1 W/BK 3 1 3 2 8 Y GN BU 6 W/BK 4 OR 5 4 5 3 (OPTIONAL) 6 5 6 5 BU/PK R/W (OPTIONAL) (OPTIONAL) 6 4 Y/R 3 1 6 5 6 PK R/W R/W (OPTIONAL) 4 3 R/BK R 6 5 PK 4 R R R 5 R R 7 BU/GY 8 7 8 1 BU/R (ON) (ON) (ON) BK BK BK BK BK BK BK
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BN BN BN PK PK PK R R BN R BN BN 6 PK 4 6 5 R R 2 3 2 1 2 6 5 V/BK 4 5 2 1 V/W 3 GN/R 4 2 1 3 3 7 8 BK 7 BK 8 7 8 2 BK 7 BK 1 8 V/BK 7 R/W 4 R/W 3 2 2 1 Y/BU 2 1 W/BK 3 1 3 2 8 Y GN BU 1 6 W/BK 4 OR 5 4 5 3 (OPTIONAL) 6 5 6 5 BU/PK R/W (OPTIONAL) (OPTIONAL) 6 4 Y/R 3 1 6 5 6 PK 4 R/W R/W (OPTIONAL) 4 3 R/BK R 6 5 PK 4 R R R 5 R R 7 BU/GY 8 7 8 1 BU/R (ON) (ON) (ON) BK BK BK BK (ON) BK
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GREEN/RED BLACK RED/WHITE GREEN/RED ORANGE/WHITE ORANGE YELLOW/RED PINK BLACK RED/BLUE ORANGE/WHITE GREEN/RED YELLOW/RED BLACK GREEN/RED GREEN/RED BLACK BLACK WHITE/RED GREEN/RED GREEN/RED RED/WHITE GREEN/RED GREEN/RED BLACK BLACK RED/BLUE BLACK RED/BLUE WHITE/RED BLACK BLACK YELLOW/RED BLACK YELLOW/RED RED BLACK BLUE/WHITE RED/BLACK GRAY ORANGE RED PINK RED GRAY GRAY GRAY GRAY WHITE BROWN BROWN BROWN RED/BLACK BLUE BLACK GREEN/RED BLUE BLACK BLACK BLUE/WHITE
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Multi Pro 5600 Vehicle Wire Harness (Serial Numbers below 230000400) Page 8 – 14
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GREEN/RED PINK ORANGE/WHITE RED/WHITE YELLOW/RED RED/BLUE ORANGE/WHITE YELLOW/RED GREEN/RED GREEN/RED GREEN/RED BLACK BLACK BLACK WHITE/RED ORANGE GREEN/RED GREEN/RED RED/WHITE BLACK BLACK YELLOW/RED WHITE/RED BLACK BLACK BLACK BLACK RED/BLUE RED/BLUE BLACK RED/BLACK WHITE YELLOW/RED BLACK RED/BLACK BLUE PINK RED BLUE BLACK BLACK RED RED/BLACK GRAY GRAY ORANGE RED GREEN/RED BLACK BROWN BLACK BLUE BLACK BROWN BROWN BROWN BROWN RED GRAY GRAY GRAY Multi Pro 5600
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Multi Pro 5600 Vehicle Wire Harness (Serial Numbers 230000400 and above) Page 8 – 16
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RED/BLACK BLACK RED/ WHITE GREEN BLACK BLACK BLACK RED BLUE/GRAY BLACK BLACK BLACK RED BLACK RED BLACK BLACK ORANGE/BLACK RED BLUE/GRAY BLACK BLACK BLACK ORANGE BLUE RED BLUE/RED RED/BLUE VIOLET/BLACK YELLOW BLACK RED GREEN WHITE/BLACK BROWN VIOLET/WHITE VIOLET/BLACK BLACK GREEN/RED PINK BLUE/BLACK YELLOW/RED GREEN/BLACK ORANGE/BLACK BLUE/PINK GREEN/ BLACK ORANGE/WHITE BLUE/WHITE BLACK YELLOW VIOLET/ BLACK BLACK BLUE/BLACK BLACK BLACK GREEN/ BLACK WHITE/BLAC
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Multi Pro 5600 Spray System Wire Harness Page 8 – 18