Multi Pro 1200/1250: Service Manual

PART NO.
11182SL (Rev A)
Service Manual
(Serial Number Above 310000000)
Multi ProR 1200/1250

Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Multi Pro 1200 and Multi Pro 1250 sprayers with a serial
number above 310000000. This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
REFER TO THE OPERATOR’S MANUAL FOR OPER- TION. When you see this symbol, carefully read
ATING, MAINTENANCE, AND ADJUSTMENT the instructions that follow. Failure to obey the
INSTRUCTIONS. Space is provided in Chapter 2 of this instructions may result in personal injury.
book to insert the Operator’s Manual and Parts Catalog
for your machine. Additional copies of the Operator’s NOTE: A NOTE will give general information about the
Manual and Parts Catalog are available on the internet correct operation, maintenance, service, testing, or re-
at www.Toro.com. pair of the machine.
The Toro Company reserves the right to change product IMPORTANT: The IMPORTANT notice will give im-
specifications or this publication without notice. portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - 2011, 2014

This page is intentionally blank.
Multi Pro 1200/1250

Table Of Contents
Chapter 1 - Safety Chapter 6 - Spray System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Safety
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 - 4 Spray System Operation . . . . . . . . . . . . . . . . . . . . 6 - 3
Spray System Flow Diagrams . . . . . . . . . . . . . . . . 6 - 4
Chapter 2 - Product Records and Maintenance Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
and Maintenance
Product Records
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 - 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2- 2 Chapter 7 - Drive Train
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2- 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
Chapter 3 - Kohler Gasoline Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Gasoline Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
Kohler
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
KOHLER COMMAND ENGINE SERVICE MANUAL Chapter 8 - Chassis
Chapter 4 - Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Hydraulic
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
System
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 - 9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
Electrical
System
Chapter 5 - Electrical System
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Electrical System Quick Checks . . . . . . . . . . . . . . 5 - 7
System
Spray
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
Drive Train
Chassis
Multi Pro 1200/1250

Multi Pro 1200/1250

Table Of Contents (Continued)
Sonic Boom
Chapter 9 -- Sonic Boom System (Optional Kit)
System
General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4
Sonic Boom System Operation . . . . . . . . . . . . . . . 9 -- 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 16
Boom System
Ultra Sonic
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 9 -- 22
Chapter 9.1 -- Ultra Sonic Boom System (Optional

Kit)
General Information . . . . . . . . . . . . . . . . . . . . . . 9.1 -- 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -- 3
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 9.1 -- 4
Drawings
Electrical
Sonic Boom System Operation . . . . . . . . . . . . . 9.1 -- 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -- 17
Service and Repairs . . . . . . . . . . . . . . . . . . . . . 9.1 -- 26
Chapter 10 -- Electrical Drawings
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 10 -- 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -- 6
Wire Harness Drawings . . . . . . . . . . . . . . . . . . 10 -- 14
Multi Pro 1200/1250 Rev. A

Multi Pro 1200/1250

Chapter 1
Safety
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
Multi Pro 1200/1250 Page 1 -- 1 Safety

Safety Instructions
The Multi Pro 1200 and Multi Pro 1250 Turf Sprayers are
designed and tested to offer safe service when operated
and maintained properly. Although hazard control and WARNING
accident prevention are partially dependent upon the
design and configuration of the machine, these factors To reduce the potential for injury or death,
are also dependent upon the awareness, concern and comply with the following safety instructions.
proper training of the personnel involved in the opera-
tion, transport, maintenance and storage of the ma-
chine. Improper use or maintenance of the machine can
result in injury or death. To reduce the potential for injury
or death, comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s 4. Since gasoline is highly flammable, handle it careful-
Manual before starting and operating the machine. Be- ly:
come familiar with the controls and know how to stop the
machine and engine quickly. Additional copies of the A. Store fuel in containers specifically designed for
Operator’s Manual are available on the internet at this purpose.
www.Toro.com.
B. Do not remove machine fuel tank cap while en-
2. Keep all shields, safety devices and decals in place. gine is hot or running.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the C. Do not smoke while handling fuel.
machine. Also tighten any loose nuts, bolts or screws to
D. Fill fuel tank outdoors and only to within an inch of
ensure machine is in safe operating condition.
the top of the tank, not the filler neck. Do not overfill
3. Assure interlock switches are adjusted correctly so the fuel tank.
engine cannot be started unless range selector is in
E. Wipe up any spilled fuel.
NEUTRAL.
While Operating
1. Sit on the seat when starting and operating the ma- 5. Before getting off the seat:
chine.
A. Ensure that range selector is in neutral.
2. Before starting the engine:
B. Set parking brake.
A. Engage the parking brake.
C. Turn pump switch OFF.
B. Make sure range selector is in NEUTRAL and the
pump switch is OFF. D. Stop engine and remove key from ignition switch.
3. Do not run engine in a confined area without ade- E. Do not park on slopes unless wheels are chocked
quate ventilation. Exhaust fumes are hazardous and or blocked.
could possibly be deadly.
6. Follow chemical manufacturer’s recommendations
4. Do not touch engine, muffler, exhaust pipe or drive for handling precautions, necessary protective equip-
system components while engine is running or soon af- ment, mixing proportions and clean up procedures.
ter it is stopped. These areas could be hot enough to
cause burns.
Safety Page 1 -- 2 Multi Pro 1200/1250

Maintenance and Service
1. Before servicing or making adjustments, turn spray 11. Do not overspeed the engine by changing governor
pump off, put range selector in neutral, stop engine, set setting. To assure safety and accuracy, check maximum
Safety
parking brake and remove key from the switch. engine speed.
2. Prior to servicing sprayer components, determine 12.Shut engine off before checking or adding oil to the
what chemical(s) have been used in the sprayer. Follow crankcase.
precautions and recommendations printed on chemical
container labels or Material Safety Data Sheets when 13.Disconnect battery before servicing the machine.
servicing sprayer components. Use appropriate protec- Disconnect negative battery cable first and positive
tive equipment: protective clothing, chemical resistant cable last. If battery voltage is required for troubleshoot-
gloves and eye protection. ing or test procedures, temporarily connect the battery.
Reconnect positive cable first and negative cable last.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight. 14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
4. Never store the machine or fuel container inside face, eyes and clothing when working with a battery.
where there is an open flame, such as near a water heat-
er or furnace. 15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
5. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition be- 16.To assure optimum performance and continued
fore applying pressure to the system. safety of the machine, use genuine Toro replacement
parts and accessories. Replacement parts and acces-
6. Keep body and hands away from pin hole leaks in hy- sories made by other manufacturers may result in non-
draulic lines that eject high pressure hydraulic fluid. Use conformance with the safety standards and the warran-
cardboard or paper to find hydraulic leaks. Hydraulic ty may be voided.
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin 17.When changing attachments, tires or performing
must be surgically removed within a few hours by a doc- other service, use correct jacks, hoists and jack stands.
tor familiar with this form of injury or gangrene may re- Make sure machine is parked on a solid level surface
sult. such as a concrete floor. Prior to raising the machine, re-
move any attachments that may interfere with the safe
7. Before disconnecting or performing any work on the and proper raising of the machine. Always chock or
hydraulic system, all pressure in system must be re- block wheels. Use jack stands to support the raised ma-
lieved. To relieve system pressure, rotate steering chine. If the machine is not properly supported by jack
wheel in both directions after the key switch has been stands, the machine may move or fall, which may result
turned off. in personal injury (see Jacking Instructions in this chap-
ter).
8. If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor. 18.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an envir-
9. To reduce potential fire hazard, keep engine area onmentally safe manner. Follow all local codes and reg-
free of excessive grease, grass, leaves and dirt. Clean ulations when recycling or disposing of waste.
protective screen on machine frequently.
10.If engine must be running to perform maintenance or

an adjustment, keep hands, feet, clothing and other
parts of the body away from moving parts. Keep by-
standers away.
Multi Pro 1200/1250 Page 1 -- 3 Rev. A Safety

Jacking Instructions
CAUTION
When changing attachments, tires or perform-
ing other service, use appropriate jacks and
supports. Make sure machine is parked on a sol-
id, level surface such as a concrete floor. Prior
to raising machine, remove any attachments
that may interfere with the safe and proper rais-
ing of the machine. Always chock or block
wheels. Use appropriate jack stands to support 1 1
the raised machine. If the machine is not proper-
ly supported by jack stands, the machine may Figure 1
move or fall, which may result in personal inju- 1. Front jacking points
ry.
IMPORTANT: Before raising the sprayer, it is rec-

ommended to empty the spray tank. If the spray
tank is not emptied, consider the extra weight of
spray tank contents when choosing appropriate
jacks, hoists and jack stands for raising and sup-
porting the machine.
Jacking the Front End

1 1
1. Set parking brake and chock both rear tires to pre-
vent the machine from moving.
2. Position jack securely under the A--arms, just to the Figure 2

inside of the front tire (Fig. 1). 1. Rear jacking points
3. Jack front of machine off the ground.
4. Position jack stands under the A--arms as close to

the wheel as possible to support the machine.
Jacking the Rear End
1. Set parking brake and chock both front tires to pre-

vent the machine from moving.
2. Place jack securely under the rear most frame sup-

ports between the angle welds (Fig. 2).
3. Jack rear of machine off the ground.
4. Position jack stands under the frame to support the

machine.
Safety and Instruction Decals

Numerous safety and instruction decals are affixed to
the Multi Pro 1200 and Multi Pro 1250. If any decal be-
comes illegible or damaged, install a new decal. Decal
part numbers are listed in your Parts Catalog. Order re-
placement decals from your Authorized Toro Distributor.
Safety Page 1 -- 4 Multi Pro 1200/1250
Chapter 2
Product Records and Maintenance

Table of Contents
and Maintenance
Product Records
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Using a Torque Wrench with an Offset Wrench . . 3
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series Fasteners) . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Records
Insert Operator’s Manual and Parts Catalog for your
Multi Pro 1200 and 1250 at the end of this chapter. Refer
to Operator’s Manual for recommended maintenance
intervals. Additionally, insert Installation Instructions,
Operator’s Manuals and Parts Catalogs for any acces-
sories that have been installed on your Multi Pro at the
end of this chapter.
Maintenance
Maintenance procedures and recommended service in-
tervals for the Multi Pro 1200 and Multi Pro 1250 are cov-
ered in the Operator’s Manual. Refer to that publication
when performing regular equipment maintenance. Sev-
eral maintenance procedures have break--in intervals
identified in the Operator’s Manual. Refer to the Engine
Operator’s Manual for additional engine specific main-
tenance procedures.
Multi Pro 1200/1250 Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions
0.09375
Product Records and Maintenance Page 2 -- 2 Multi Pro 1200/1250

Torque Specifications
Recommended fastener torque values are listed in the As noted in the following tables, torque values should be
following tables. For critical applications, as determined reduced by 25% for lubricated fasteners to achieve
by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may
is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded
cified in this Service Manual. into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
These Torque Specifications for the installation and material strength, fastener size, length of thread en-
and Maintenance
Product Records
tightening of fasteners shall apply to all fasteners which gagement, etc.
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered The standard method of verifying torque shall be per-
when applying torque: cleanliness of the fastener, use formed by marking a line on the fastener (head or nut)
of a thread sealant (e.g. Loctite), degree of lubrication and mating part, then back off fastener 1/4 of a turn.
on the fastener, presence of a prevailing torque feature, Measure the torque required to tighten the fastener until
hardness of the surface underneath the fastener’s head the lines match up.
or similar condition which affects the installation.
Fastener Identification
Grade 1 Grade 5 Grade 8 Class 8.8 Class 10.9
Inch Series Bolts and Screws Metric Bolts and Screws

Figure 1 Figure 2
Using a Torque Wrench with an Offset Wrench

Use of an offset wrench (e.g. crowfoot wrench) will affect If the listed torque recommendation for a fastener is
torque wrench calibration due to the effective change of from 76 to 94 ft--lb, the proper torque when using this
torque wrench length. When using a torque wrench with torque wrench with an offset wrench would be from 72
an offset wrench, multiply the listed torque recommen- to 89 ft--lb.
dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening Offset wrench Torque wrench
torque when using a torque wrench with an offset (effective length of
wrench will be lower than the listed torque recommen- torque wrench)
A
dation.
Example: The measured effective length of the torque

wrench (distance from the center of the handle to the
center of the square drive) is 18”. B
(effective length of torque
The measured effective length of the torque wrench with wrench + offset wrench)
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”. TORQUE CONVERSION FACTOR = A / B
The calculated torque conversion factor for this torque Figure 3

wrench with this offset wrench would be 18 / 19 = 0.947.

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners)
Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, &
Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts
Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts)
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
# 6 -- 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

10 + 2 13 + 2 147 + 23
# 6 -- 40 UNF 17 + 2 190 + 20 25 + 2 280 + 20
# 8 -- 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

13 + 2 25 + 5 282 + 30
# 8 -- 36 UNF 31 + 3 350 + 30 43 + 4 485 + 45
# 10 -- 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

18 + 2 30 + 5 339 + 56
# 10 -- 32 UNF 48 + 4 540 + 45 68 + 6 765 + 70
1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 -- 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
ft--lb ft--lb N--m ft--lb N--m ft--lb N--m
3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 -- 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
NOTE: Reduce torque values listed in the table above on the fastener size, the aluminum or base material
by 25% for lubricated fasteners. Lubricated fasteners strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite. NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
NOTE: Torque values may have to be reduced when mum proof load specified in SAE J429. The tolerance is
installing fasteners into threaded aluminum or brass. approximately + 10% of the nominal torque value. Thin
The specific torque value should be determined based height nuts include jam nuts.

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with
Thread Size Regular Height Nuts Regular Height Nuts
(Class 8 or Stronger 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
and Maintenance
Product Records
M6 X 1.0 96 + 9 in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm
M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 27 + 2 ft--lb 36 + 3 N--m
M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 53 + 5 ft--lb 72 + 7 N--m
M12 X 1.75 66 + 7 ft--lb 90 + 10 N--m 92 + 9 ft--lb 125 + 12 N--m
M16 X 2.0 166 + 15 ft--lb 225 + 20 N--m 229 + 22 ft--lb 310 + 30 N--m
M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 37 ft--lb 610 + 50 N--m
NOTE: Reduce torque values listed in the table above on the fastener size, the aluminum or base material
by 25% for lubricated fasteners. Lubricated fasteners strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
NOTE: Torque values may have to be reduced when based on 75% of the minimum proof load specified in
installing fasteners into threaded aluminum or brass. SAE J1199. The tolerance is approximately + 10% of the
The specific torque value should be determined based nominal torque value.

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 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m
Grade 5
1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb
1/2 -- 20 UNF 80 + 10 ft--lb 108 + 14 N--m
5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb Grade 5
3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb M12 X 1.25 80 + 10 ft--lb 108 + 14 N--m

Class 8.8
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
M12 X 1.5 80 + 10 ft--lb 108 + 14 N--m
Class 8.8
** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws Thread Cutting Screws
(Zinc Plated Steel) (Zinc Plated Steel)
Type 1, Type 23 or Type F Thread Threads per Inch

Size Baseline Torque*
Thread Size Baseline Torque* Type A Type B
No. 6 -- 32 UNC 20 + 5 in--lb No. 6 18 20 20 + 5 in--lb
1/4 -- 20 UNC 85 + 15 in--lb No. 12 11 14 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb * Hole size, material strength, material thickness and fin-
ish must be considered when determining specific
3/8 -- 16 UNC 200 + 100 in--lb torque values. All torque values are based on non--lubri-
cated fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

Chapter 3
Kohler Gasoline Engine

Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Engine Mounting Plate Assembly . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjust Choke Cable . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 16
Gasoline Engine
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Evaporative Control System . . . . . . . . . . . . . 18
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 KOHLER COMMAND ENGINE SERVICE MANUAL
Kohler
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction
This chapter gives information about specifications and tools are described in the Kohler Command Engine Ser-
repair of the Kohler Command engine used in the Multi vice Manual. The use of some specialized test equip-
Pro 1200 and 1250. ment is explained. However, the cost of the test
equipment and the specialized nature of some repairs
General maintenance procedures are described in your may dictate that the work be done at an engine repair
Operator’s Manual. Information on engine troubleshoot- facility.
ing, testing, disassembly and reassembly is identified in
the Kohler Command Engine Service Manual that is in- Service and repair parts for Kohler engines are supplied
cluded at the end of this section. through your Toro Distributor or a local Kohler Dealer.
Most repairs and adjustments require tools which are

commonly available in many service shops. Special
Multi Pro 1200/1250 Page 3 - 1 Rev. A Kohler Gasoline Engine

Specifications
Item Description
Make / Designation Kohler, CH640, 4--stroke, V--Twin

Air Cooled, OHV
Number of Cylinders 2
Bore x Stroke 3.03 in x 2.64 in (77 mm x 67 mm)
Total Displacement 38 in3 (624 cc)
Compression Ratio 8.5:1
Fuel Unleaded, Regular Gasoline (Minimum 87 Octane)
Fuel Tank Capacity 5 U.S. gal (18.9 liters)
Governor Mechanical
Low Idle Speed (no load) 800 to 950 RPM
High Idle Speed (no load) 3275 to 3425 RPM
Engine Oil API SF or SG (see Operator’s Manual for viscosity)
Oil Pump Gear driven trochoid type
Crankcase Oil Capacity 2 U.S. qt (1.9 liters) with filter
Starter 12 VDC
Alternator/Regulator 12 VDC 25 AMP
Dry Weight (approximate) 90 lb (41 kg)
Kohler Gasoline Engine Page 3 -- 2 Multi Pro 1200/1250

Adjustments
Adjust Engine Speed

1. Allow engine to reach operating temperature before
checking or adjusting engine speed. Park machine on
a level surface, shift range selector to neutral and en- 1
gage parking brake.
2. Raise seat to gain access to engine speed control

(Fig. 1).
3. With engine running, move accelerator pedal to 2

FAST position.
4. Using a tachometer, check that engine is operating
Gasoline Engine
from 3275 to 3425 RPM.
Kohler
5. If high idle speed is incorrect, adjust high speed
screw on control bracket (Fig. 2).
Figure 1
A. Loosen jam nut on high speed screw. 1. Engine speed control 2. Accelerator cable
B. Adjust high speed screw to obtain 3275 to 3425

RPM. 3 2
4
C. Tighten lock nut. Recheck high speed. 1
5
6. Allow accelerator pedal to return to SLOW position.
7. Using a tachometer, check that engine is operating

at 800 to 950 RPM.
8. If low speed is incorrect, adjust low speed screw

(Fig. 2).
A. Loosen jam nut on slow speed screw.

Figure 2
B. Adjust slow speed screw to obtain 800 to 950 1. Accelerator cable 4. Low speed screw
2. High speed screw 5. Jam nut
RPM. 3. Jam nut
C. Tighten jam nut. Recheck low speed.
NOTE: When the engine returns to idle speed, the

drive clutch should fully disengage. Idle speed may
have to be reduced to ensure complete clutch disen-
gagement.
Multi Pro 1200/1250 Page 3 -- 3 Kohler Gasoline Engine

Adjust Choke Cable
1. Park machine on a level surface, stop engine, en-
gage parking brake and remove key from the ignition
switch. 1
2. Remove air cleaner cover and air filter from engine

(see Operator’s Manual).
3. Move choke control on control panel while watching

choke plate in carburetor.
A. Choke plate should be fully open when choke 3 2

control is pushed in.
B. Choke plate should be fully closed when choke Figure 3

control is pulled out. 1. Choke cable 3. Choke lever
2. Cable clamp
4. If cable adjustment is needed, loosen cap screw and

nut that secure choke cable clamp. Reposition cable to
allow correct choke operation. Secure choke cable
clamp.
5. Reassemble air cleaner.

Service and Repairs
Cooling System
To ensure proper engine cooling, make sure the grass
screen, cooling fins and other external surfaces of the
engine are kept clean at all times.
NOTE: Perform this maintenance procedure at the in-

terval specified in the Operator’s Manual.
IMPORTANT: The engine that powers the Multi Pro

is air--cooled. Operating the engine with dirty or
plugged cooling fins, a blocked grass screen, or a
dirty or plugged blower housing will result in en-
gine overheating and engine damage.
Gasoline Engine
2
Kohler
switch.
IMPORTANT: Never clean engine with pressurized 1

water. Water could enter and contaminate the fuel
system.
Figure 4
2. Clean cooling fins on both cylinder heads. 1. Grass screen 2. Blower housing
3. Clean grass screen and blower housing of dirt and

debris (Fig. 4). Remove screen and housing if neces-
sary.
IMPORTANT: Never operate engine without the

blower housing installed. Overheating and engine
damage will result.
4. Make sure grass screen and blower housing are re-

installed to the engine if removed.

Fuel System
RIGHT
FRONT
1
18
2
3
16
17 4
5
11
15 12
13
14
9 8 7 6 5
10
Figure 5
1. Cap screw (2 used) 7. Fuel filter 13. Fuel hose
2. Fuel tank strap (2 used) 8. Fuel supply hose (fuel pump to filter) 14. Carbon cannister
3. Flat washer (2 used) 9. U-- nut (2 used) 15. Vacuum check valve
4. Fuel tank assembly 10. Fuel hose 16. Hose clamp (8 used)
5. Flange head screw (4 used) 11. Fuel filter 17. Cannister bracket
6. Fuel supply hose (filter to tank) 12. Fuel hose 18. Fuel hose

Fuel Tank Installation
DANGER 1. Install all removed components to fuel tank using
Figure 6 as a guide.
Because gasoline is highly flammable, use cau-
tion when storing or handling it. Do not smoke 2. Install fuel tank to machine using Figure 5 as a guide.
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot or when machine is 3. Remove plugs placed in fuel hoses during fuel tank
in an enclosed area. Always fill fuel tank outside removal. Connect fuel hoses to fuel standpipe and rol-
and wipe up any spilled fuel before starting the lover valve. Secure fuel hoses with hose clamps.
engine. Store fuel in a clean, safety--approved
container and keep cap in place. Use gasoline 4. Fill fuel tank.
for the engine only; not for any other purpose.
Check Fuel Lines and Connections 4

5
Check fuel lines and connections periodically as recom-
6
Gasoline Engine
mended in the Operator’s Manual. Check lines for dete- 3
rioration, damage, leaks or loose connections. Replace 7
Kohler
hoses, clamps and connections as necessary. 2
8
Drain and Clean Fuel Tank
Drain and clean the fuel tank if the fuel system becomes
contaminated or if the machine is to be stored for an ex-
tended period. 1
To clean fuel tank, flush tank out with clean solvent.

Make sure tank is free of contaminates and debris.
Fuel Tank Removal

switch.
Figure 6
2. Use a fuel transfer pump to remove fuel from the fuel 1. Fuel tank 5. Rollover valve
tank and into a suitable container. 2. Fuel tank cap 6. Standpipe
3. Grommet 7. Grommet
3. Note routing of fuel hoses for installation purposes. 4. Fuel gauge 8. Bushing
Disconnect fuel hoses from fuel standpipe and rollover
valve. Plug fuel hoses to prevent leakage or contami-
nant entry.
4. Remove fuel tank from machine using Figure 5 as a

guide.
5. Remove components from fuel tank as needed us-

ing Figure 6 as a guide.

Exhaust System
10 13
15
2 16
14 15
13
10
12 1
2
3
4
5
11 6
7
10
8
FRONT
RIGHT
Figure 7
1. Muffler 7. Exhaust gasket (2 used) 12. Flange head screw
2. Muffler clamp (2 used) 8. Engine 13. Muffler hanger (2 used)
3. Flange head screw (2 used) 9. Flange nut (2 used) 14. Muffler hanger bracket
4. Exhaust support bracket 10. Flat washer (3 used) 15. Cap screw (2 used)
5. Exhaust manifold 11. Flange nut 16. Flange nut
6. Flange nut (4 used)

Removal (Fig. 7) Installation (Fig. 7)
NOTE: Make sure engine and exhaust manifold seal-

ing surfaces are free of debris or damage that may pre-
CAUTION vent a tight seal.
The muffler and exhaust manifold may be hot. To IMPORTANT: Finger tighten all exhaust system fas-
avoid possible burns, allow the engine and ex- teners before securing so there is no preload on ex-
haust system to cool before working on the exhaust components.
haust system.
1. Place new exhaust gaskets on the exhaust studs on
1. Park machine on a level surface, stop engine, en- engine. Position exhaust manifold to the engine and
gage parking brake and remove key from the ignition install four (4) flange nuts.
switch.
2. Install the muffler:
2. Gaining access from below machine, remove the
A. Install all removed mounting components to muf-
muffler from the machine:
fler using Figure 7 as a guide.
Gasoline Engine
A. Support muffler to prevent it from unexpectedly
B. Slide muffler inlet onto exhaust manifold.
Kohler
shifting.
C. Secure muffler hangers (item 13) to machine
B. Remove muffler clamp (item 2) that secures muf-
frame with removed fasteners.
fler inlet to exhaust manifold and exhaust support
bracket (item 4). D. Install muffler clamp (item 2) to muffler inlet and
exhaust support bracket (item 4).
C. Remove fasteners that secure two (2) muffler
hangers (item 13) to machine frame. 3. Tighten fasteners to secure exhaust system:
D. Slide muffler from exhaust manifold and remove A. Four (4) flange nuts to secure exhaust manifold
from machine. to engine.
E. If necessary, remove remaining mounting com- B. Fasteners to secure muffler hangers (item 13) to
ponents from muffler using Figure 7 as a guide. machine frame. Muffler hangers should be perpen-
dicular to frame after tightening.
3. Remove four (4) flange nuts from the exhaust studs
on engine. Remove exhaust manifold from the engine. C. Two (2) nuts on muffler clamp to secure muffler
inlet to exhaust support bracket and exhaust man-
4. Remove and discard exhaust gaskets from engine.
ifold.

Engine Mounting Plate Assembly
Loctite #242
3 10 11
2
12
4 13
5 6
8
Loctite #242
25 24 16 7
15
14
Antiseize 29
Lubricant
27
28
17 40 to 45 ft--lb
19
(55 to 61 N--m)
9
23
FRONT
LEFT 26
21 18
22
20
Figure 8
1. Engine 11. CVT drive belt 21. Washer (4 used)
2. Pump pulley 12. Driven clutch 22. Engine mount assembly (4 used)
3. Key 13. Pump drive gearbox 23. Flange nut (4 used)
4. Drive clutch 14. Steering pump drive belt 24. Oil drain nipple
5. Flange head screw (4 used) 15. Steering pump pulley 25. Oil drain elbow
6. Stepped washer 16. Hydraulic steering pump 26. Flange nut (4 used)
7. Cap screw 17. Engine mounting plate 27. Flange head screw (4 used)
8. Lock washer 18. Engine support strap (2 used) 28. R-- clamp (3 used)
9. Flange nut (4 used) 19. Machine frame 29. Transaxle driveshaft
10. Set screw (2 used) 20. Cap screw (4 used)
NOTE: For easiest service access to the engine, re-

moval of the spray tank is recommended (see Spray
Tank Removal in the Service and Repairs section of
CAUTION
Chapter 6 -- Spray System). As an alternative, the en-
gine mounting plate can be lowered from the machine The engine, exhaust system and drive compo-
to access the engine. The hydraulic hoses to the steer- nents may be hot. To avoid possible burns, allow
all components to cool before working on the
ing pump and the fuel hoses to the engine do not need
engine mounting plate assembly.
to be disconnected unless the mounting plate is to be
completely removed from the machine.

Removal (Fig. 8)
1. Park machine on a level surface, stop engine and re- 4

1
move key from the ignition switch. Chock wheels to
keep the machine from moving. 2
2. Disconnect negative (--) and then positive (+) battery
cables at the battery.
3. Remove muffler section of the exhaust system (see

Exhaust System Removal in this section). 3
5
4. Remove accelerator cable from engine (Figs. 9 and
10). Figure 9
1. Accelerator cable 4. Choke cable
A. Slide the sleeve back on the cable ball joint and lift 2. Cable ball joint 5. Choke cable clamp
3. Cable jam nut
accelerator cable from the ball stud.
Gasoline Engine
B. Loosen one of the two cable jam nuts that se- 5
cures accelerator cable to control bracket. Antiseize
Kohler
Lubricant 4
3
C. Remove accelerator cable from the engine speed 6
control bracket and position away from the engine. 2
5. Remove choke cable from the engine speed control 6

bracket (Figs. 9 and 10).
1
7
6. Gaining access from under operator seat, loosen
two (2) flange head screws and flange nuts that secure
oil filter adapter to right hand frame rail (Fig. 11). Slide
adapter with oil filter away from frame.
8
7. Disconnect engine electrical connections. Position
unplugged wires away from engine.
A. Unplug engine wire harness from machine wire

harness.
B. Remove nut on starter solenoid stud. Remove

fusible link connector and positive (+) battery cable Figure 10
from solenoid stud. 1. Accelerator cable 5. Cap screw
2. Cable ball joint 6. Ball joint jam nut
C. Remove flange head screw and nut under starter 3. Choke cable 7. Speed control bracket
motor that secures engine and negative (--) cable to 4. Choke cable clamp 8. Hex nut
engine mounting plate (Fig. 12).
8. Remove transaxle drive shaft from pump drive gear-

box (see Pump Drive Gearbox in the Service and Re-
pairs Section of Chapter 7 -- Drive Train). Locate and
retrieve key. 2
9. Disconnect spray pump coupler from pump drive

electric clutch. Unplug clutch wiring connector from ma- 1
chine harness (see Pump Drive Electric Clutch in the
Service and Repairs Section of Chapter 6 -- Spray Sys-
tem).
10.If the mounting plate is being removed from ma- Figure 11

chine, disconnect fuel hose from fuel pump on engine. 1. Oil filter adapter 2. RH frame rail
Pull fuel line from R--clamps on mount plate and position
disconnected fuel line away from engine.

CAUTION 1
3
Rotate steering wheel to relieve hydraulic sys-
tem pressure and avoid injury from pressurized
hydraulic oil.
4
11. If the mounting plate assembly is being removed
2
from machine, label all hydraulic connections for reas-
sembly purposes. Clean hydraulic hose ends prior to 5
disconnecting the hoses. Remove hydraulic hoses from
steering pump. Cap or plug openings of pump and
hoses to prevent contamination.
Figure 12
12.Remove engine mounting plate assembly from ma- 1. Engine starter motor 4. Negative battery cable
chine (Figs. 8 and 12): 2. Engine support strap 5. Engine wire harness
3. Engine mount
A. Support the engine mounting plate assembly
from below to prevent it from falling.
B. Remove four (4) cap screws, washers and flange

2
nuts that secure the engine support straps to the
frame.
3
IMPORTANT: Make sure to not damage the en-
gine, fuel hoses, hydraulic lines, electrical har- 1
ness or other parts while lowering the engine
mounting plate assembly.
C. Carefully lower engine mounting plate assembly

from machine.
Installation (Fig. 8)
2
1. Place machine on a level surface with key removed
from the ignition switch. Chock wheels to keep the ma-
chine from moving. Figure 13
1. Engine support strap 3. Engine mount tube
2. Reinstall engine mounting plate assembly to ma- 2. Engine mount cushion
chine (Figs. 8 and 12):
4. Connect spray pump coupler to pump drive electric
A. Make sure that engine mounts are correctly as- clutch. Plug clutch wiring connector into machine har-
sembled to mounting straps (Fig. 13). Position en- ness (see Pump Drive Electric Clutch in the Service and
gine mounting plate assembly under machine. Repairs Section of Chapter 6 -- Spray System).
IMPORTANT: Make sure to not damage the en- 5. Reconnect engine electrical connections.
gine, fuel hoses, hydraulic lines, electrical har-
ness or other parts while raising the engine A. Pull wire harness into position, keeping harness
mounting plate assembly. away from any moving components.
B. Carefully raise engine mounting plate assembly B. Secure fusible link connector and positive (+) bat-
to machine frame. tery cable to starter solenoid stud with nut.
C. Secure engine mounting plate assembly to frame C. Connect engine wire harness to main wire har-
with four (4) cap screws, washers and flange nuts. ness.
3. Position key in pump drive gearbox shaft. Install D. From below, install flange head screw and nut un-
transaxle drive shaft to pump drive gearbox (see Pump der starter motor that secures engine and negative
Drive Gearbox in the Service and Repairs Section of (--) cable (Fig. 12).
Chapter 7 -- Drive Train).
6. Install choke cable to engine and secure with cable 9. Position oil filter adapter with oil filter to the right hand
clamp (Figs. 9 and 10). Check choke cable adjustment frame rail. Install two (2) flange head screws and flange
(see Adjust Choke Cable in the Adjustments Section of nuts and secure oil filter adapter to machine (Fig. 11).
this chapter).
10.Reinstall the muffler section of the exhaust system
7. Reconnect accelerator cable to engine (Figs. 9 and (see Exhaust System Installation in this section).
10).
11. If hydraulic hoses were disconnected, make sure hy-
A. Position accelerator cable to the engine speed draulic hoses and pump ports are clean. Remove plugs
control bracket. and caps from pump and hoses that were placed during
disassembly. Install hydraulic hoses to steering pump.
B. Slide the sleeve back on the cable ball joint and
place cable ball joint on ball stud. Release the sleeve 12.Check engine oil level and transaxle/hydraulic fluid
so it slides over the stud to secure cable. level (see Operator’s Manual).
C. Tighten cable jam nuts that secure accelerator 13.Connect positive (+) and then negative (--) battery
cable to control bracket. cables to the battery.
Gasoline Engine
8. If fuel line was removed, route fuel line through R-- 14.Check engine speed (see Adjust Engine Speed in
clamps on mounting plate. Connect fuel line to the fuel the Adjustments Section of this chapter).
Kohler
pump and secure with clamp.

Engine
3 10 11
1 2
12
4 13
5 6
8
Loctite #242
25 24 16 7
15
14
Antiseize
Lubricant 40 to 45 ft--lb
(55 to 61 N--m)
19 17
9
23
FRONT
LEFT 18
21
22
20
Figure 14
1. Engine 10. Set screw (2 used) 18. Engine support strap (2 used)
2. Pump pulley 11. CVT drive belt 19. Machine frame
3. Key 12. Driven clutch 20. Cap screw (4 used)
4. Drive clutch 13. Pump drive gearbox 21. Washer (4 used)
5. Flange head screw (4 used) 14. Steering pump drive belt 22. Engine mount assembly (4 used)
6. Stepped washer 15. Steering pump pulley 23. Flange nut (4 used)
7. Cap screw 16. Hydraulic steering pump 24. Oil drain nipple
8. Lock washer (for grounding) 17. Engine mounting plate 25. Oil drain elbow
Engine Removal (Fig. 14) 2. Remove the spray tank from machine to access en-
gine (see Spray Tank Removal in the Service and Re-
pairs section of Chapter 6 -- Spray System).
CAUTION 3. Disconnect negative (--) and then positive (+) battery
cables at the battery.
The engine, exhaust system and drive compo-
nents may be hot. To avoid possible burns, allow 4. Remove exhaust system (see Exhaust System Re-
all components to cool before removing engine moval in this section).
from the machine.
5. Disconnect fuel supply hose from fuel pump on en-
1. Park machine on a level surface, stop engine and re- gine and position disconnected fuel line away from en-
move key from the ignition switch. Chock wheels to gine.
keep the machine from moving.
6. Remove accelerator cable from engine (Figs. 15 and
16).
4
1
A. Slide the sleeve back on the cable ball joint and lift
accelerator cable from the ball stud. 2
B. Loosen one of the two cable jam nuts that se-
cures accelerator cable to control bracket.
C. Remove accelerator cable from the engine speed

control bracket and position away from the engine. 3
5
7. Remove choke cable from the engine speed control
bracket (Figs. 15 and 16). Figure 15
1. Accelerator cable 4. Choke cable
8. Gaining access from under operator seat, loosen 2. Cable ball joint 5. Choke cable clamp
3. Cable jam nut
two (2) flange head screws and flange nuts that secure
oil filter adapter to right hand frame rail (Fig. 17). Slide
Gasoline Engine
adapter with oil filter away from frame. 5
Antiseize
Kohler
9. Disconnect engine electrical connections (Fig. 18). Lubricant 4
3
Position unplugged wires away from engine. 6
2
A. Unplug engine wire harness from machine wire
harness. 6
B. Remove nut on starter solenoid stud. Remove 1

7
fusible link connector and positive (+) battery cable
from solenoid stud.
C. Remove flange head screw, lock washer and nut

under starter motor that secures engine, wire har- 8
ness ground connection and negative (--) cable to
engine mounting plate.
10.Remove CVT drive belt from the drive clutch (see

CVT Drive Belt Service in the Service and Repairs Sec-
tion of Chapter 7 -- Drive Train).
11. Loosen hydraulic steering pump and remove pump Figure 16

drive belt from pulleys. 1. Accelerator cable 5. Cap screw
2. Cable ball joint 6. Ball joint jam nut
12.Loosen and remove three (3) remaining flange head 3. Choke cable 7. Speed control bracket
4. Choke cable clamp 8. Hex nut
screws and flange nuts that secure engine to engine
mounting plate.
IMPORTANT: Make sure to not damage the engine,

fuel hoses, hydraulic lines, electrical harness or
other parts while removing the engine.
2
13.Carefully lift engine from mounting plate and ma-
chine.
1
14.If needed, remove drive clutch from engine crank-
shaft (see Drive Clutch in the Service and Repairs Sec-
tion of Chapter 7 -- Drive Train).
15.If needed, loosen set screws and remove steering Figure 17

pump pulley from engine crankshaft. Locate and re- 1. Oil filter adapter 2. RH frame rail
trieve key.

Engine Installation (Fig. 14)
1. Make sure that all parts removed from the engine

1
during maintenance or rebuilding are reinstalled to the
engine.
2. If steering pump pulley was removed from engine,

position key into keyway of engine shaft. Apply antiseize
lubricant to shaft and key. Assemble pump pulley over 2
key and shaft with hub on pulley away from engine.
3. If drive clutch was removed from engine, make sure 3

that tapers of engine crankshaft and drive clutch bore
are thoroughly clean. Reinstall clutch to engine (see
Drive Clutch in the Service and Repairs Section of
Chapter 7 -- Drive Train). Figure 18
1. Engine starter motor 3. Engine wire harness
IMPORTANT: Make sure to not damage the engine, 2. Negative battery cable
fuel hoses, hydraulic lines, electrical harness or
other parts while installing the engine. 8. Connect fuel supply hose to the fuel pump and se-
cure with clamp.
4. Position engine to engine mounting plate. Secure
engine to engine mounting plate with three (3) flange 9. Position oil filter adapter with oil filter to the right hand
head screws and flange nuts. The flange head screw frame rail. Install two (2) flange head screws and flange
under the starter motor should not be installed at this nuts and secure oil filter adapter to machine (Fig. 17).
time because it is also used to secure the wire harness
ground and negative (--) cable. 10.Install the exhaust system (see Exhaust System
Installation in this section).
5. Reconnect engine electrical connections (Fig. 18).
11. Check engine oil level and adjust if necessary.
A. Move wire harness into position, keeping har-
ness away from any moving components. 12.Connect positive (+) and then negative (--) battery
cables to the battery.
B. Secure fusible link connector and positive (+) bat-
tery cable to starter solenoid stud with nut. 13.Install steering pump drive belt to pump pulleys.
Make sure that pump drive pulleys are aligned. Adjust
C. Connect engine wire harness to main wire har- pump drive belt tension. Make sure that hydraulic pump
ness. mounting bolts are tightened.
D. From below, insert final engine mounting flange 14.Start engine and check engine speed (see Adjust
head screw through lock washer, mounting plate, Engine Speed in the Adjustments Section of this chap-
engine, wire harness ground and negative (--) cable. ter).
Secure screw with flange nut.
15.Place CVT drive belt around drive clutch. Rotate
6. Install choke cable to engine and secure with cable driven clutch while routing the belt onto the driven clutch
clamp (Figs. 15 and 16). Check choke cable adjustment (see CVT Drive Belt Service in the Service and Repairs
(see Adjust Choke Cable in the Adjustments Section of Section of Chapter 7 -- Drive Train).
this chapter).
16.Install the spray tank to the machine (see Spray Tank
7. Reconnect accelerator cable to engine (Figs. 15 and Installation in the Service and Repairs section of Chap-
16). ter 6 -- Spray System).
A. Position accelerator cable to the engine speed

control bracket.
B. Slide the sleeve back on the cable ball joint and

place cable ball joint on ball stud. Release the sleeve
so it slides over the stud to secure cable.
C. Tighten cable jam nuts that secure accelerator

cable to control bracket.

Gasoline Engine
Kohler
Multi Pro 1200/1250 Page 3 -- 17 Rev. A Kohler Gasoline Engine

Fuel Evaporative Control System
TO ENGINE
FITTING
CHECK
VALVE
CARBON
FUEL
CANISTER
TANK
FRESH AIR
FILTER ENGINE
Figure 19
Multi Pro 1200 and 1250 sprayers are equipped with a NOTE: If there is restriction in the fresh air filter, the car-
fuel evaporative control system (EVAP) designed to col- bon canister or the fuel vent valve, the fuel tank may dis-
lect and store evaporative emissions from the fuel tank. tort due to venting issues. If the fuel tank returns to it’s
The EVAP uses a carbon canister to collect these evap- normal shape when the fuel cap is removed, restriction
orative emissions. Fuel vapors from the fuel tank are in the evaporative control system is likely.
vented to the canister where they are stored. Vapors
from the canister are consumed when the engine is run- Machines with a carbon canister include a single engine
ning which purges the canister. connection to the engine intake system that is used to
connect the evaporative system to the engine. These
The fuel tank on these sprayers uses a non--vented fuel machines use an inline check valve between the carbon
cap. To connect the tank to the evaporative control sys- canister and the engine fitting. Evaporative control sys-
tem, a fuel vent valve is positioned in the top of the tank tem components for Multi Pro 1200 and 1250 sprayers
that allows tank venting through the carbon canister. are shown in Figure 19.
Kohler Gasoline Engine Page 3 -- 18 Rev. A Multi Pro 1200/1250

Disassembly
CARBON CANISTER CONNECTIONS
DANGER TO FUEL TANK VENT
Gasoline is flammable. Use caution when stor-

ing or handling it. Wipe up any spilled fuel be-
fore starting the engine.
TO CHECK VALVE
1. Inspect carbon canister and attached hoses for dam-
age or obvious leaks. A damaged or leaking canister
should be replaced. Figure 20
2. Remove EVAP components as needed using Figure
19 as a guide.
Gasoline Engine
A. If check valve (item 7 in Fig. 19) is removed, note
direction of arrow on valve body for assembly pur-
Kohler
poses.
B. If hoses are removed from the carbon canister,

note hose location for assembly purposes. Figure 20
identifies hose location.
Assembly
1. Install all removed components using Figure 19 as

a guide.
A. If check valve (item 7 in Fig. 19) was removed,

make sure that arrow on valve body points toward
engine.
B. Make sure that evaporative system fuel hoses

are not kinked after installation. Also, secure all
hoses with hose clamps.
Multi Pro 1200/1250 Page 3 -- 19 Rev. A Kohler Gasoline Engine

Kohler Gasoline Engine Page 3 -- 20 Rev. A Multi Pro 1200/1250

Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 18
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 General Precautions for Removing and Installing
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic System Components . . . . . . . . . . . . . 18
Relieving Hydraulic System Pressure . . . . . . . . . . 4 Check Hydraulic Lines and Hoses . . . . . . . . . . . . 18
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic Hose and Tube Installation . . . . . . . . . . 5 Steering Pump Drive Belt . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 6 Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 8 Steering Pump Service . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 9 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . 28
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steering Control Valve Service . . . . . . . . . . . . . . . 30
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering Cylinder Service . . . . . . . . . . . . . . . . . . . 34
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Pump Flow and Relief Pressure . . . . . . 14
Hydraulic
System
Steering Control Valve and Steering Cylinder . . 16
Multi Pro 1200/1250 Page 4 -- 1 Hydraulic System

Specifications
Item Description
Gear Pump Positive displacement, gear type pump

Displacement (per revolution) 0.194 in3 (3.18 cc)
Steering Relief Pressure 1000 PSI (69.0 bar)
Hydraulic Filter Spin--on cartridge type
Hydraulic Reservoir In transaxle
Hydraulic System Page 4 -- 2 Multi Pro 1200/1250

Hydraulic
System

General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Multi Pro machine. Refer to that publi-
cation for additional information when servicing the ma-
chine.
Relieving Hydraulic System Pressure

Before disconnecting or performing any work on the hy-
draulic system, all pressure in the hydraulic system
must be relieved. Park machine on a level surface, stop
engine and engage parking brake. Once all moving
parts have come to a complete stop, rotate steering
wheel in both directions to relieve hydraulic system
pressure.
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condi- WARNING
tions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterio- Before disconnecting components or perform-
ration. Some hoses are more susceptible to these ing any work on hydraulic system, all pressure in
conditions than others. Inspect all machine hydraulic the system must be relieved by stopping the en-
hoses frequently for signs of deterioration or damage: gine and rotating the steering wheel in both
directions.
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high
Kinked, crushed, flattened or twisted hose.
pressure. Use paper or cardboard, not hands, to
Blistered, soft, degraded or loose hose cover. search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
Cracked, damaged or badly corroded hose fittings. the skin and cause serious injury. If fluid is in-
jected into the skin, it must be surgically re-
When replacing a hydraulic hose, be sure that the hose moved within a few hours by a doctor familiar
is straight (not twisted) before tightening the fittings. with this type of injury. Gangrene may result from
This can be done by observing the imprint (layline) on such an injury.
the hose. Use two wrenches when tightening a hose;
hold the hose straight with one wrench and tighten the
hose swivel nut onto the fitting with the second wrench
(see Hydraulic Hose and Tube Installation in this sec-
tion). If the hose has an elbow at one end, tighten the
swivel nut on that end before tightening the nut on the
straight end of the hose.
For additional hydraulic hose information, refer to Toro

Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)
1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor-
tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.). The
any foreign material. markings on the nut and fitting body will verify that the
connection has been properly tightened.
2. As a preventative measure against leakage, it is rec-
ommended that the face seal O--ring be replaced any Size F.F.W.R.
time the connection is opened. Make sure the O--ring is
4 (1/4 in. nominal hose or tubing) 1/2 to 3/4
installed and properly seated in the fitting groove. Lightly 6 (3/8 in.) 1/2 to 3/4
lubricate the O--ring with clean hydraulic oil. 8 (1/2 in.) 1/2 to 3/4
10 (5/8 in.) 1/2 to 3/4
3. Place the hose/tube against the fitting body so that 12 (3/4 in.) 1/3 to 1/2
16 (1 in.) 1/3 to 1/2
the flat face of the hose/tube sleeve fully contacts the O--
ring in the fitting.
Swivel Nut Fitting Body
4. Thread the swivel nut onto the fitting by hand. While O--ring
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 3. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
Hydraulic
using a torque wrench with an offset wrench will be lower
System
Tube or Hose
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifica-
Figure 1
tions section of Chapter 2 -- Product Records and Main-
tenance).
5. If a torque wrench is not available or if space at the

swivel nut prevents use of a torque wrench, an alternate Mark Nut Final
method of assembly is the Flats From Wrench Resist- and Fitting Position
ance (F.F.W.R.) method (Fig. 2). Body
A. Using a wrench, tighten the swivel nut onto the fit- Initial
ting until light wrench resistance is reached (approxi- Extend Line Position
mately 30 in--lb).
AT WRENCH RESISTANCE AFTER TIGHTENING
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
Figure 2
Fitting Dash Size Hose/Tube Side Thread Size Installation Torque
4 9/16 -- 18 18 to 22 ft--lb (25 to 29 N--m)
6 11/16 -- 16 27 to 33 ft--lb (37 to 44 N--m)
8 13/16 -- 16 37 to 47 ft--lb (51 to 63 N--m)
10 1 -- 14 60 to 74 ft--lb (82 to 100 N--m)
12 1 3/16 -- 12 85 to 105 ft--lb (116 to 142 N--m)
16 1 7/16 -- 12 110 to 136 ft--lb (150 to 184 N--m)
20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

Figure 3
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)
Non--Adjustable Fitting (Fig. 4) 5. If a torque wrench is not available or if space at the
port prevents use of a torque wrench, an alternate meth-
1. Make sure all threads and sealing surfaces of fitting od of assembly is the Flats From Finger Tight (F.F.F.T.)
and component port are free of burrs, nicks, scratches method.
or any foreign material.
A. Install the fitting into the port and tighten it down
2. As a preventative measure against leakage, it is rec- full length until finger tight.
ommended that the O--ring be replaced any time the
connection is opened. B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fit-
3. Lightly lubricate the O--ring with clean hydraulic oil. ting to 60% of listed F.F.F.T.
Fitting threads should be clean with no lubricant applied.
Size F.F.F.T.
IMPORTANT: Before installing fitting into port, de-
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
termine port material. If fitting is to be installed into 6 (3/8 in.) 1.50 + 0.25
an aluminum port, installation torque is reduced. 8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25
4. Install the fitting into the port. Then, use a torque 12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25
wrench and socket to tighten the fitting to the recom-
mended installation torque shown in Figure 5.
NOTE: Use of an offset wrench (e.g. crowfoot wrench) Fitting

will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the O--ring
Torque Specifications section of Chapter 2 -- Product
Records and Maintenance to determine necessary con-
version information. Figure 4
Fitting Fitting Port Side Installation Torque Into Installation Torque Into
Dash Size Thread Size Steel Port Aluminum Port
4 7/16 -- 20 15 to 19 ft--lb (21 to 25 N--m) 9 to 11 ft--lb (13 to 15 N--m)
12 1 1/16 -- 12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m)
Figure 5

Adjustable Fitting (Fig. 6)
1. Make sure all threads and sealing surfaces of fitting

and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is rec-

ommended that the O--ring be replaced any time the
connection is opened. Lock Nut
3. Lightly lubricate the O--ring with clean hydraulic oil.

Fitting threads should be clean with no lubricant applied.
Back--up Washer
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far O--ring
as possible (Step 1 in Figure 7).
Figure 6
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
5. Install the fitting into the port and tighten finger tight Step 1 Step 3
until the washer contacts the face of the port (Step 2 in
Figure 7). Make sure that the fitting does not bottom in
the port during installation.
Hydraulic
System
6. To put the fitting in the desired position, unscrew it by
Step 2 Step 4
the required amount to align fitting with incoming hose
or tube, but no more than one full turn (Step 3 in Figure
7).
7. Hold the fitting in the desired position with a wrench

and use a torque wrench to tighten the lock nut to the
Figure 7
recommended installation torque shown in Figure 5.
This tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 -- Product Records
and Maintenance).
8. If a torque wrench is not available or if space at the

port prevents use of a torque wrench, an alternate meth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T (Step 4). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25

6 (3/8 in.) 1.50 + 0.25
8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25

Hydraulic Schematic
P: PRESSURE FROM PUMP

T: RETURN TO TRANSAXLE STEERING
R: WORKING PRESSURE (RIGHT TURN) CONTROL UNIT
L: WORKING PRESSURE (LEFT TURN)
P T R L
STEERING
CYLINDER
GEAR
PUMP RETURN
RELIEF FILTER
VALVE
TRANSAXLE
HOUSING
SUCTION
STRAINER
IN TRANSAXLE
Multi Pro 1200/1250

Hydraulic Schematic

Hydraulic Flow Diagrams
Steering Circuit
A single section, belt driven gear pump supplies hydrau- inder is proportional to the amount of the turning on the
lic flow to the steering control valve and steering cylin- steering wheel. Fluid leaving the cylinder flows back
der. The gear pump takes its suction from the transaxle. through the steering control spool valve, then to the oil
Steering circuit pressure is limited to 1000 PSI (69 bar) filter and returns to the transaxle.
by a relief valve located in the gear pump.
The steering control valve returns to the neutral position
Hydraulic flow and pressure to the steering control valve when turning is completed.
can be monitored at the outlet of the gear pump.
With the steering wheel in the neutral position and the Right Turn
engine running, flow enters the steering control valve
and goes through the steering control spool valve, by-- When a right turn is made with the engine running, the
passing the rotary meter (V1) and steering cylinder. turning of the steering wheel positions the spool valve so
Flow leaves the control valve, to the oil filter and returns that flow goes through the bottom of the spool. Flow en-
to the transaxle. tering the steering control valve from the pump goes
through the spool, to the rotary meter (V1) and out the
Left Turn R port. Pressure extends the steering cylinder piston for
a right turn. The rotary meter ensures that the oil flow to
When a left turn is made with the engine running, the the cylinder is proportional to the amount of the turning
turning of the steering wheel positions the spool valve so on the steering wheel. Fluid leaving the cylinder flows
Hydraulic
System
that flow goes through the top of the spool. Flow entering back through the steering control spool valve, then to
the steering control valve from the pump goes through the oil filter and returns to the transaxle.
the spool, to the rotary meter (V1) and out the L port.
Pressure contracts the steering cylinder piston for a left The steering control valve returns to the neutral position
turn. The rotary meter ensures that the oil flow to the cyl- when turning is completed.
STEERING CYLINDER STEERING CYLINDER STEERING CYLINDER

NO PISTON MOVEMENT PISTON MOVEMENT PISTON MOVEMENT
R L L R L
R
T P T P T P
STEERING STEERING STEERING
CONTROL CONTROL CONTROL
NEUTRAL POSITION LEFT TURN RIGHT TURN
Figure 8

Special Tools
Order the following special tools from your Toro Distributor.
Hydraulic Pressure Test Kit

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 the Testing section of this chapter.
Toro Part Number: TOR47009
Figure 9
Hydraulic Tester (Pressure and Flow)

This tester requires O--ring Face Seal (ORFS) adapter
fittings for use on this machine (see Hydraulic Test Fit-
ting Kit -- TOR4079 in this section).
1. INLET HOSE: A hose connected from the system cir-

cuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created

in the circuit by turning the valve to restrict flow.
3. PRESSURE GAUGE: 0 to 5000 PSI gauge to pro-

vide operating circuit pressure.
4. FLOW METER: This meter measures actual oil flow

in the operating circuit with a gauge rated at 15 GPM.
Figure 10
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.

O--Ring Kit
The O--ring kit includes O--rings in a variety of sizes for
face seal and port seal hydraulic connections. It is rec-
ommended that O--rings be replaced whenever a hy-
draulic connection is loosened.
Toro Part Number: 117--2727
Figure 11
Hydraulic Test Fitting Kit

This kit includes a variety of O--ring Face Seal fittings to
Hydraulic
enable the connection of test gauges into the system. TORO TEST FITTING KIT (TOR4079)
System
The kit includes: tee’s, unions, reducers, plugs, caps
and male test fittings.
Figure 12

Troubleshooting
The cause of an improperly functioning hydraulic sys- Continued use of an improperly functioning hydraulic
tem is best diagnosed with the use of proper testing system could lead to extensive internal component
equipment and a thorough understanding of the com- damage.
plete hydraulic system.
The chart that follows contains information to assist in
A hydraulic system with an excessive increase in heat troubleshooting. There may possibly be more than one
or noise has a potential for failure. Should either of these cause for a machine malfunction.
conditions be noticed, immediately stop the machine,
turn off the engine, locate the cause of the trouble and Refer to the Testing section of this chapter for precau-
correct it before allowing the machine to be used again. tions and specific test procedures.
Problem Possible Cause

Hydraulic oil leaks Fitting(s), hose(s) or tube(s) are loose or damaged.
O--ring(s) or seal(s) are missing or damaged.

Foaming hydraulic fluid Oil level in transaxle is incorrect.
Hydraulic system has wrong kind of oil.
Hydraulic oil is contaminated.
The steering pump suction line has an air leak.

Hydraulic system operates hot Oil level in transaxle is incorrect.
Hydraulic hose is kinked.
Hydraulic oil is contaminated or incorrect viscosity.
Suction screen in transaxle is loose or clogged.
Oil constantly forced over relief.
Steering pump is worn or damaged.
Transaxle or drive train problem (see Drive Train -- Chapter 7).

Steering inoperative or sluggish Engine speed is too low.
Oil level in transaxle is incorrect.
Steering pump drive belt is loose.
Steering cylinder is binding.
Steering relief valve is stuck open.
Steering control valve is worn or damaged.
Pulley key (either on engine or pump) is sheared.
Steering cylinder leaks internally.
Steering pump is worn or damaged.

Testing
The most effective method for isolating problems in the 3. The engine must be in good operating condition. Use
hydraulic system is by using hydraulic test equipment a tachometer when making a hydraulic test. Engine
such as pressure gauges and flow meters in the circuits speed will affect the accuracy of the tester readings.
during various operational checks. (See Special Tools
section in this chapter.) 4. Because the hydraulic pump is belt driven, check for
proper pump belt adjustment before performing any hy-
draulic test.
CAUTION 5. When using tester with pressure and flow capabili-

ties, the inlet and the outlet hoses must be properly con-
Failure to use gauges with recommended pres- nected and not reversed to prevent damage to tester or
sure (psi) rating as listed in test procedures components.
could result in damage to gauge and possible
6. When using tester with pressure and flow capabili-
personal injury from leaking hot oil.
ties, completely open load valve in hydraulic tester to
minimize the possibility of damaging components.
Before Performing Hydraulic Tests
7. Install fittings finger tight, far enough to insure that
All obvious areas such as oil supply, filter, binding link- they are not cross--threaded, before tightening with a
age, loose fasteners or improper adjustments must be wrench.
checked before assuming that a hydraulic component is
the source of the problem being experienced. 8. Position the tester hoses so that rotating machine
parts will not make contact with them and result in hose
Hydraulic
Precautions For Hydraulic Testing
System
or tester damage.
9. Check and adjust the oil level in the transaxle after

WARNING connecting hydraulic test equipment.
10.All hydraulic tests should be made with the hydraulic

Before disconnecting components or perform- oil at normal operating temperature.
ing any work on hydraulic system, all pressure
in the system must be relieved by stopping the 11. After testing is completed, check and adjust the oil
engine and rotating the steering wheel in both level in the transaxle before returning the machine to
directions. service.
Keep body and hands away from pin hole leaks

or nozzles that eject hydraulic fluid under high
search for leaks. Hydraulic fluid escaping under
skin and cause serious injury. If fluid is injected
into the skin, it must be surgically removed
within a few hours by a doctor familiar with this
type of injury. Gangrene may result from such
an injury.
1. Thoroughly clean the machine before disconnecting

or disassembling any hydraulic components. Always
keep in mind the need for cleanliness when working on
hydraulic equipment. Contamination will cause exces-
sive wear of hydraulic components.
2. Put caps or plugs on any hydraulic lines left open or

exposed during testing or removal of components.

Steering Pump Flow and Relief Pressure (Using Tester With Pressure Gauges and Flow
Meter)

P T R L
TESTER STEERING
CYLINDER
GEAR
PUMP
RETURN
RELIEF FILTER
VALVE
TRANSAXLE
HOUSING
SUCTION
STRAINER
IN TRANSAXLE
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Figure 13

Procedure for Steering Pump Flow and Relief Pres- 9. To test steering pump relief pressure:
sure Test:
A. Make sure flow control valve on tester is fully
1. Make sure hydraulic oil is at normal operating tem- open.
perature by operating the machine for approximately ten
(10) minutes. B. Start engine and depress accelerator pedal so
engine is running at high idle (3275 to 3425 RPM).
2. Park machine on a level surface with the spray sys-
tem off. Apply parking brake and make sure range selec- IMPORTANT: Hold steering wheel at full lock
tor is in the neutral position. only long enough to get a system pressure read-
ing. Holding the steering wheel against the stop
3. Read Precautions For Hydraulic Testing. for an extended period may damage the steering
control valve.
4. Make sure that steering pump drive belt is adjusted
properly (see Operator’s Manual). C. Watch pressure gauge carefully while turning the
steering wheel completely in one direction (full steer-
ing lock) and holding.
CAUTION D. System pressure should be approximately 1000
PSI (69 bar) as the relief valve lifts. Return steering
Before disconnecting components or perform- wheel to the center position.
ing any work on hydraulic system, all pressure in
the system must be relieved by stopping the en- E. Release accelerator pedal and turn off machine.
gine and rotating the steering wheel in both Record test results.
directions.
10.If relief pressure is incorrect, inspect for:
Hydraulic
System
5. Clean hose fitting and disconnect pressure hose A. Slipping steering pump drive belt.
from the top of the steering pump (Fig. 14).
B. Worn, stuck or out of adjustment relief valve in
IMPORTANT: Make sure oil flow indicator arrow on steering pump.
the flow gauge is showing that the oil will flow from
the pump through the tester and into the hose. 11. After testing is completed, disconnect tester from
steering pump and hose. Reconnect hose to the pump.
6. Install flow tester with pressure gauges in series with
the pump and the disconnected hose. Make sure flow
control valve on tester is fully open. 2
7. To test steering pump flow:
A. Start engine and adjust engine speed with accel-

erator pedal so pump speed is 3450 RPM (engine
speed approximately 3000 RPM). Verify pump
speed with a phototac.
B. Close flow control valve on tester until pressure

gauge reads 800 PSI (55 bar). Observe flow gauge.
TESTER READING: Flow approximately 2.7 GPM.

1
C. Release accelerator pedal and turn off machine.
Record test result. FRONT
8. If pump flow specification is not met, inspect for: 3
A. Slipping steering pump drive belt. Figure 14

1. Steering pump 3. Suction hose
B. Worn, stuck or out of adjustment relief valve. 2. Pressure hose
C. Pump suction line restriction.
D. Steering pump needs to be repaired or replaced.

Steering Control Valve and Steering Cylinder

P T R L
OPEN
FITTING
PLUG
STEERING
CYLINDER
GEAR
PUMP
RETURN
RELIEF FILTER
VALVE
TRANSAXLE
HOUSING
SUCTION
STRAINER
IN TRANSAXLE
Figure 15

Procedure for Steering Control Valve and Steering C. Turn engine off and engage the parking brake.
Cylinder Test:
D. Read Precautions for Hydraulic Testing.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately ten E. Remove hydraulic hose from the fitting on the rod
(10) minutes. end of the steering cylinder. Plug the end of the hose.
2. Perform the Steering Pump Relief Pressure and

Steering Pump Flow tests to make sure that pump and
relief valve are functioning correctly. WARNING
NOTE: This steering test procedure will be affected by Keep body and hands away from disconnected
incorrect tire pressure, binding of the hydraulic steering hose and fitting that might eject hydraulic fluid
cylinder, excessive weight on the vehicle and/or binding under high pressure. Use paper or cardboard,
of the steering assembly (e.g. wheel spindles, tie rods, not hands, to search for leaks. Hydraulic fluid es-
steering pivot). Make sure that these items are checked caping under pressure can have sufficient force
before proceeding with any hydraulic testing procedure. to penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically
3. Drive machine slowly in a figure eight on a flat level removed within a few hours by a doctor familiar
surface. with this type of injury. Gangrene may result from
such an injury.
A. There should be no shaking or vibration in the
steering wheel or front wheels.
IMPORTANT: Do not turn steering wheel to the
B. Steering wheel movements should be followed left (counterclockwise) as system damage may
immediately by a corresponding front wheel move- occur.
Hydraulic
System
ment without the steering wheel continuing to turn.
F. With the engine off, continue turning the steering
4. Stop machine with the engine running. Turn steering wheel to the right (clockwise) with the steering cylin-
wheel with small quick movements in both directions. der fully extended. Observe the open fitting on the
Let go of the steering wheel after each movement. steering cylinder as the wheel is turned. If oil comes
out of the fitting while turning the steering wheel to
A. The steering must immediately return to the neu- the right, the steering cylinder has internal leakage
tral position. and must be repaired or replaced.
B. The steering wheel or front wheels should not G. Remove plug from the hydraulic hose. Recon-
continue to turn. nect hose to the steering cylinder.
5. If either of these performance tests indicate a steer- 6. If steering problem exists and the steering cylinder
ing problem, determine if the steering cylinder is faulty tested acceptably, steering control valve requires ser-
using the following procedure. vice (see Steering Control Valve and Steering Control
Valve Service in the Service and Repairs section of this
A. Park machine on a level surface with the spray chapter).
system turned off.
B. Turn the steering wheel all the way to the right

(clockwise) so the steering cylinder rod is fully ex-
tended.

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 sys- 1. Check oil level in the transaxle and add correct oil if
tem, park machine on a level surface, engage parking necessary. Drain and refill transaxle and change oil filter
brake and stop engine. Remove key from the ignition if component failure was severe or system is contami-
switch. nated (see Flush Hydraulic System in this section).
2. Clean machine before disconnecting, removing or 2. Lubricate O--rings and seals with clean hydraulic oil
disassembling any hydraulic components. Make sure before installing hydraulic components.
hydraulic components, hose connections and fittings
are cleaned thoroughly. Always keep in mind the need 3. Make sure caps or plugs are removed from the hy-
for cleanliness when working on hydraulic equipment. draulic tubes, hydraulic fittings and components before
reconnecting.
4. Use proper tightening methods when installing hy-

CAUTION draulic hoses and fittings (see Hydraulic Fitting Installa-
tion and Hydraulic Hose and Tube Installation in the
Before disconnecting components or perform- General Information section of this chapter).
the system must be relieved by stopping the en- 5. After disconnecting or replacing any hydraulic com-
gine and rotating the steering wheel in both ponents, operate machine functions slowly until air is
directions. out of system (see Hydraulic System Start Up in this sec-
tion).
3. Put caps or plugs on any hydraulic lines, hydraulic fit-
6. Check for hydraulic oil leaks. Shut off engine and cor-
tings and components left open or exposed to prevent
rect leaks if necessary. Check oil level in transaxle and
contamination.
add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially el-

bow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
Check Hydraulic Lines and Hoses

Check hydraulic lines and hoses daily for leaks, kinked
WARNING lines, loose mounting supports, wear, loose fittings or
deterioration. Make all necessary repairs before operat-
ing machine.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
search for leaks. Hydraulic fluid escaping under
the skin and cause serious injury. If fluid is in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.

Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is 1
contaminated. Contaminated oil appears milky,
black or contains metal particles.
1
1. Park machine on a level surface. Stop engine, apply
parking brake and remove key from ignition switch.
2. Clean area around filter mounting area (Fig. 16). Re-

move filter and drain filter into a suitable container. Dis-
card filter.
3. Remove drain plug from transaxle (Fig. 17) and drain

transaxle into a suitable container.
4. Drain hydraulic system. Drain all hoses and compo-

nents while the system is warm. Figure 16
1. Hydraulic filter
5. Make sure filter mounting surface is clean. Apply
Dexron III ATF to gasket on new filter. Screw filter on un-
til gasket contacts mounting plate, then tighten filter 3/4 2
turn further.
1
Hydraulic
System
6. Install all hoses and components.
NOTE: Use only hydraulic fluid specified in Operator’s

Manual. Other fluid could cause system damage.
7. Fill transaxle with new hydraulic fluid (see Operator’s

Manual).
8. Disconnect and ground spark plug wires to prevent

engine from starting.
9. Turn ignition key switch to start; engage starter for

ten (10) seconds to prime hydraulic pump. Repeat this 3
step again.
Figure 17
10.Connect spark plug wires.
1. Transaxle drain plug 3. Strainer
2. Dipstick/filler
11. Start engine and run at idle speed for a minimum of
two (2) minutes.
12.Increase engine speed to high idle for minimum of

one (1) minute under no load.
13.Turn steering wheel in both directions several times.
14.Shut off engine and check for oil leaks. Check oil lev-
el in transaxle and add correct oil if necessary.
15.Operate the machine for two (2) hours under normal

operating conditions.
16.Check condition of hydraulic oil. If the fluid shows any

signs of contamination repeat steps 1 through 15 again.
17.Resume normal operation and follow recommended

maintenance intervals.
Steering Pump Drive Belt
12 9 13
2
14
1 15
8
Loctite #242 10
3 6
4
16
5
Antiseize
Lubricant
11
7
FRONT
LEFT
Figure 18
1. Drive clutch 7. Flange head screw (2 used) 12. Engine
2. Pump drive pulley 8. Flange nut (4 used) 13. CVT drive belt
3. Pump pulley 9. Steering pump drive belt 14. Driven clutch
4. Cap screw (4 used) 10. Set screw (2 used) 15. Pump drive gearbox
5. Steering pump bracket 11. Engine mounting plate 16. Hydraulic fitting (suction)
6. Steering pump
Steering Pump Drive Belt Removal (Fig. 18) Steering Pump Drive Belt Installation (Fig. 18)
1. Park the machine on a level surface, apply parking 1. Install steering pump drive belt to pulleys.
brake and stop engine. Remove key from the ignition
switch. 2. Adjust steering pump belt tension (see Operator’s
Manual).
2. Remove CVT drive belt (see CVT Drive Belt Service
in Service and Repairs Section of Chapter 7 -- Drive 3. Install CVT drive belt (see CVT Drive Belt Service in
Train). Service and Repairs Section of Chapter 7 -- Drive Train).
3. From under left side of machine, locate and loosen

two (2) flange head screws that secure steering pump
bracket to engine mounting plate.
4. Slide pump and pump bracket toward engine crank-

shaft to allow steering pump drive belt to be removed
from pulleys.
Hydraulic
System

Steering Pump
12 9 13
2
14
1 15
8
Loctite #242 10
3 6
4
16
5
Antiseize
Lubricant
11
7
FRONT
LEFT
Figure 19
1. Drive clutch 7. Flange head screw (2 used) 12. Engine
2. Pump drive pulley 8. Flange nut (4 used) 13. CVT drive belt
3. Pump pulley 9. Steering pump drive belt 14. Driven clutch
4. Cap screw (4 used) 10. Set screw (2 used) 15. Pump drive gearbox
5. Steering pump bracket 11. Engine mounting plate 16. Hydraulic fitting (suction)
6. Steering pump

Removal (Figs. 19 and 20) 3. Slide pulley onto shaft with the hub side of the pulley
away from the pump. Align pulley with the end of the
1. Park the machine on a level surface, engage parking pump shaft.
brake and stop engine. Remove key from the ignition
switch. 4. Apply Loctite #242 to two (2) set screws (item 10).
Secure pulley on the pump shaft with set screws.
5. Position hydraulic pump with pulley and bracket to

CAUTION the engine mounting plate. Install two (2) flange head
screws through engine mounting plate into pump brack-
Before disconnecting components or perform- et.
the system must be relieved by stopping the en- 6. Install steering pump belt to the pump pulley.
gine and rotating the steering wheel in both
directions. 7. Adjust steering pump belt tension (see Operator’s
Manual).
2. Label all hydraulic connections for assembly pur-
8. Remove plugs and caps from pump and hoses that
poses. Clean hydraulic hose ends prior to disconnecting
were placed during disassembly. Connect hydraulic
the hoses.
hoses to pump.
3. From under left side of machine, disconnect hydrau-
9. Check fluid level in transaxle and adjust as required.
lic hoses connected to the hydraulic pump. Allow hoses
to drain into a suitable container. Cap or plug openings
of pump and hoses to prevent contamination. Loctite #242
5
4. Loosen two (2) flange head screws that secure
Hydraulic
5
System
steering pump bracket to engine mounting plate. 6
7 12
5. Remove steering pump drive belt from the pump
pulley.
13
6. Remove two (2) flange head screws from the steer-
ing pump bracket. Pull hydraulic pump with pulley and 8
Antiseize
bracket from the machine. Lubricant
4
7. Loosen and remove two (2) set screws (item 10) in
pulley and remove pulley from the pump shaft. Locate 3 9
and remove key from pump shaft.
1 10
8. Loosen and remove four (4) cap screws and flange 2
nuts that secure pump to pump bracket. Remove pump 11
from bracket.
Figure 20
Installation (Figs. 19 and 20) 1. Steering pump 8. Flange nut (4 used)
2. Flange head screw 9. O--ring
1. Position steering pump to pump bracket. Install four 3. Pump bracket 10. O--ring
(4) cap screws and flange nuts to secure pump to brack- 4. Pump pulley 11. Suction fitting
5. Set screw (2 used) 12. Pressure hose
et. 6. Key 13. O--ring
7. Cap screw (4 used)
2. Make sure the pulley bore and pump shaft are clean.
Apply antiseize lubricant to both the pump shaft and the
bore of the pulley. Position key to pump shaft.

Steering Pump Service
8
7
1 6
2 10
5 144 to 180 in--lb
3 9 (16 to 20 N--m)
4 11
12 13
12
15
14 114 to 150 in--lb

12 (13 to 17 N--m)
24
23
20 16
22 19
17
21
15
18
Figure 21
1. Retaining ring 9. Gasket 17. Screw (8 used)
2. Shaft seal 10. Cap 18. Gear housing
3. Spacer 11. Key 19. Idler gear
4. Ball bearing 12. Crescent ring (4 used) 20. Drive gear
5. Check ball 13. Woodruff key 21. Idler shaft
6. Spring 14. Drive shaft 22. Gasket
7. Spring 15. Needle bearing (4 used) 23. Dowel pin (2 used)
8. Adjusting screw 16. Plug 24. Stator
Before performing any service on gear pump, plug 4. Clean and dry relief valve parts. Apply clean Dexron
ports, wash exterior of pump with cleaning solvent and III ATF to valve parts.
dry pump thoroughly.
NOTE: Install adjusting screw same number of turns as
Relief Valve Service (Fig. 21) counted during removal for the same approximate relief
pressure setting.
1. Remove cap (item 10). Remove and discard gasket
(item 9) from cap. 5. Install check ball (item 5), springs (item 6 and 7) and
adjusting screw (item 8). Position small end of springs
NOTE: Count number of turns it takes to unthread ad- against check ball.
justing screw so it can be reinstalled for the same
approximate relief pressure setting. 6. Install new gasket (item 9) and cap (item 10). Torque
cap from 144 to 180 in--lb (16 to 20 N--m).
2. Remove adjusting screw (item 8), springs (items 6
and 7) and check ball (item 5). 7. Check pump relief pressure (see Steering Pump
Flow and Relief Pressure in the Testing section of this
3. Inspect check ball for burrs or roughness. Inspect re- chapter). If adjustment is needed, tighten adjusting
lief valve bore and seat inside pump stator (item 24). In- screw to increase relief pressure or loosen adjusting
spect springs for damage. Replace any worn or screw to reduce relief pressure.
damaged parts.

Shaft Seal Replacement (Fig. 21) 8. Remove drive gear (item 20) and woodruff key (item
13) from drive shaft.
IMPORTANT: Do not attempt to pry seal out of pump
housing. This can damage the shaft seal bore so oil 9. Remove idler shaft assembly (items 12, 19 and 21)
will leak past the seal. from stator. Remove crescent rings and then idler gear
(item 19) from idler shaft.
1. Remove retaining ring (Item 1).
10.Locate and remove dowel pins (item 23) from stator
2. Punch two (2) holes in face of shaft seal (item 2), or gear housing.
180o apart, and install metal screws into seal. Remove
shaft seal from gear pump by grasping and pulling on IMPORTANT: When removing gasket (item 22) from
screws. Discard shaft seal. pump, note gasket color. Use new gasket of same
color for assembly.
3. Remove spacer (item 3).
11. Remove gasket from between gear housing and sta-
4. Thoroughly clean seal bore and drive shaft of pump. tor.
5. Install spacer (item 3) on driveshaft. 12.Press drive shaft and bearing assembly (items 14,
12 and 4) out of stator.
6. Apply grease or petroleum jelly to inside diameter of
new seal. IMPORTANT: When removing bearing and crescent
rings from drive shaft, do not slide bearing or cres-
7. Use a seal sleeve or tape on drive shaft to protect cent rings over seal area of drive shaft.
seal during installation.
13.Remove inner crescent ring, then remove bearing
8. Position new shaft seal (item 2) onto shaft with part and second ring from drive shaft.
Hydraulic
number facing out. Use a seal installation tool to install
System
new seal. Make sure seal is installed square with seal Inspection
bore and that seal is pressed just below retaining ring
groove. 1. Wash all parts in cleaning solvent.
9. Install retaining ring (item 1). 2. Check all parts for burrs, scoring, nicks, etc.
Pump Disassembly (Fig. 21) 3. Clean seal bore and drive shaft of pump so they are
free of any foreign material.
1. Remove shaft seal (see Shaft Seal Replacement
above) and spacer. 4. Check needle bearings in stator and gear housing for
excessive wear or damage. If gears (items 19 and 20),
2. Remove relief valve (see Relief Valve Service needle bearings (item 15), gear housing or stator are ex-
above). cessively worn, scored or damaged, replace pump.
3. Matchmark the gear housing with the stator for prop- 5. Check bearing (item 4) for smooth operation. Re-
er orientation of these parts during assembly. place bearing if loose on shaft or noisy when rotated.
IMPORTANT: Use caution when using a vise to 6. Inspect woodruff key (item 13) and key slots in shaft
avoid distorting any pump components. for wear or damage and replace parts as necessary.
4. Secure flange end of pump in a vise with drive shaft Pump Assembly (Fig. 21)
facing down. Use of a vise with soft jaws is recom-
mended to prevent pump damage. IMPORTANT: When installing bearing and crescent
rings on drive shaft, do not slide bearing or crescent
5. Remove eight (8) screws. rings over seal area of drive shaft.
6. Support gear housing (item 18) and gently tap hous- 1. Install outer crescent ring on drive shaft (item 14),
ing with a soft face hammer to loosen from stator (item then install bearing (item 4) and second crescent ring.
24). Separate gear housing from stator. Be careful to not Slide drive shaft and bearing assembly into stator.
drop any parts or disengage gear mesh.
7. Before removing gears (items 19 and 20), apply

marking dye to mating teeth to retain “timing” and loca-
tion for assembly purposes.

2. Install spacer (item 3) on drive shaft. Then install new 5. Install new gasket (item 22) onto stator. Use same
seal (item 2) (see Shaft Seal Replacement above) and color gasket as the removed gasket.
secure with retaining ring (item 1).
6. Install dowel pins (item 23). Assemble gear housing
3. Install woodruff key (item 13), then apply clean Dex- to stator using the matchmark made during disassem-
ron III ATF to drive gear (item 20) and install to drive bly. Install screws and tighten in a crossing pattern from
shaft. 114 to 150 in--lb (13 to 17 N--m).
4. Install one crescent ring to idler shaft (item 21), then 7. Install relief valve (see Relief Valve Service above).
install idler gear (item 19) and second crescent ring. Ap-
ply clean Dexron III ATF to gear and idler shaft assem- 8. Place a small amount of Dexron III ATF in pump inlet
bly, then install into stator maintaining the original timing and rotate pump one revolution. If binding is noted, dis-
and locations. assemble pump and check for assembly problems.

Hydraulic
System

Steering Control Valve
20 to 26 ft--lb
(28 to 35 N--m) 13
5
10 9
4
15
17 8
18
7
16 6
5
12
15
14 11
2
2
15
15
3
1 UP
15 2
FRONT
Figure 22
1. Steering control valve 7. Dust cover 13. O--ring
2. Hydraulic hose (2 used) 8. Steering wheel 14. Lock washer (4 used)
3. Steering column 9. Hex nut 15. O--ring
4. Hydraulic hose 10. Steering wheel cover 16. Hose cover
5. Hydraulic hose 11. Steering pump 17. Flat washer
6. Steering seal 12. Cap screw (4 used) 18. O--ring

Removal (Fig. 22) 5. Check fluid level in transaxle and adjust as required
1. Park the machine on a level surface, engage parking
brake and stop engine. Remove key from the ignition 6. After assembly is completed, operate steering cylin-
switch. der to verify that hydraulic hoses and fittings are not con-
tacted by anything.
2. Remove screws that secure dash panel to front hood
(Fig. 23). Carefully slide dash panel up steering column
to allow access to steering control valve. 1
2
CAUTION
Before disconnecting components or perform-
the system must be relieved by stopping the en-
gine and rotating the steering wheel in both
directions.
3. Label all hydraulic hoses for assembly purposes

(Fig. 24). Clean hydraulic hose ends prior to disconnect-
ing the hoses from the steering control valve.
4. Disconnect hydraulic hoses connected to the steer-

ing control valve. Allow hoses to drain into a suitable
Hydraulic
System
container. Cap or plug openings of control valve and
hoses to prevent contamination.
Figure 23
5. Support steering control valve to prevent it from fal- 1. Steering wheel 2. Dash panel
ling during removal.
6. Loosen and remove four (4) cap screws and lock

washers that secure steering column and steering con- 1
trol valve to machine frame.
7. Slide steering column from control valve. Remove

control valve from machine.
3
2
1. Position steering control valve to frame. Slide steer-

ing column to control valve. Secure steering column and 4
control valve to frame with four (4) cap screws and lock
washers.
2. Remove caps and plugs from disconnected hoses

and fittings.
3. Using labels placed during removal, connect hydrau-

lic hoses to steering control valve (Fig. 24). Tighten hose
connections (see Hydraulic Hose and Tube Installation Figure 24
in the General Information section of this chapter). 1. T port (hose to oil filter)
2. L port (hose to rod end of steering cylinder)
4. Position dash panel to front hood and secure with re- 3. P port (hose to steering pump)
4. R port (hose to barrel end of steering cylinder)
moved fasteners (Fig. 23).

Steering Control Valve Service
1 3
24
7 6
2 4
5
22 19
19 20
23
150 in--lb 21
(17 N--m)
9
10
11
12
13
14
140 to 160 in--lb
15
(16 to 18 N--m)
16
17
18
Figure 25
1. Steering valve housing 9. Cap screw (7 used) 17. Geroter drive
2. Dust seal 10. End cap 18. Wear plate
3. O--ring 11. O--ring 19. Bearing race
4. Spool 12. Seal ring 20. Thrust bearing
5. Spring retaining ring 13. O--ring 21. Plug
6. Pin 14. Geroter assembly 22. O--ring
7. Sleeve 15. O--ring 23. Check ball
8. Centering springs/spacers 16. Spacer 24. Quad seal
Control Valve Disassembly (Fig. 25) 4. Slide the spool and sleeve assembly from the hous-
ing.
NOTE: Cleanliness is extremely important when
repairing hydraulic components. Work in a clean area. 5. Remove the thrust bearing and two (2) bearing
Before disassembly, drain the oil, then plug the ports races.
and thoroughly clean the exterior. During repairs,
always protect machined surfaces. 6. Remove the quad seal.
1. Remove the seven cap screws from the steering 7. Use a small blade screwdriver to carefully pry the
valve assembly. dust seal from the housing. Be careful to not damage the
dust seal seat in the housing.
2. Remove end cap, geroter, spacer, geroter drive,
wear plate, seal ring and O--rings (items 11, 13 and 15) 8. Remove the pin (item 6) that holds the spool and
from housing. sleeve together.
3. Remove the plug, O--ring and check ball from the 9. Carefully slide the spool out of the sleeve. The cen-
housing. tering springs and spring retaining ring will stay with the
spool as it is removed.

8. Put the thrust bearing and bearing races into the
CAUTION housing. The thrust bearing goes between the two bear-
ing races (Fig. 26).
The centering springs are under tension. Re- IMPORTANT: Do not damage the dust or quad seals
move the retaining ring carefully. when installing the spool and sleeve assembly.
9. Apply a light coating of clean Dexron III ATF to the

10.Remove the spring retaining ring and centering
spool and sleeve assembly. Carefully slide the assem-
springs from the spool.
bly into the housing.
Control Valve Assembly (Fig. 25)
10.Clamp the housing in a vise. Use only enough clamp-
Check all mating surfaces. Replace any parts with ing force to hold the housing securely.
scratches or burrs that could cause leakage. Wash all
11. Lubricate and install a new O-ring (item 3) in the
metal parts in clean solvent. Blow them dry with pressur-
groove in the housing.
ized air. Do not wipe parts dry with paper towels or cloth.
Lint in a hydraulic system will cause damage. 12.Install the wear plate and align screw holes in the
wear plate with threaded holes in the housing.
NOTE: Always use new seals and O--rings when as-
sembling the steering control valve. NOTE: The holes in the wear plate are symmetrical.
IMPORTANT: During assembly, lubricate the new 13.Install the geroter drive, making sure the slot in the
seals with petroleum jelly. Also, lubricate machined drive engages the pin.
surfaces and bearings with clean Dexron III ATF.
14.Lubricate and install new O-ring in wear plate
1. Install the quad seal:
Hydraulic
groove.
System
A. Put one of the bearing races and sleeve into the 15.Install the gerotor and align the screw holes.
housing.
16.Lubricate and install new O-ring in gerotor ring
B. Together, the housing and bearing race create a groove.
groove into which the quad seal will be installed.
17.Lubricate and install new O-ring and seal ring in ger-
C. Hold the bearing race tightly against the input end otor star groove.
of the housing by pushing on the gerotor end of the
sleeve. 18.Install the spacer.
D. Fit the quad seal into its seat through the input 19.Install the end cap and seven (7) cap screws. Tighten
end of the housing. Be sure the seal is not twisted. the cap screws, in a crossing pattern, from 140 to 160
in-lb (16 to 18 N--m).
E. Remove the sleeve and bearing race.
20.Remove the steering control unit from the vise.
2. Lubricate and install the dust seal.
21.Install the check ball and plug with O--ring. Tighten
3. Install the centering springs in the spool. It is best to the plug to 150 in-lb (17 N--m).
install the two flat pieces first. Next, install the curved
pieces, three at a time.
4. Fit the retaining ring over the centering springs.

Thrust Bearing
Dust Seal and Race (2)
5. Apply a light coating of clean Dexron III ATF to the
spool and slide it into the sleeve. Be sure the centering
springs fit into the notches in the sleeve.
6. Install the pin.

Quad Seal
7. Apply a light coating of petroleum jelly to the inner Figure 26
edge of the dust and quad seals.

Steering Cylinder
Antiseize 3
2
Lubricant
1
3
5 11
6 4
10 9
7 1
8 8
9 7
1
10 12
13
14
4 3
5
16 15
10
17
FRONT
RIGHT
Figure 27
1. Cotter pin 7. Thrust washer 13. Steering pivot
2. Slotted hex nut 8. Bearing 14. Tie rod (RH shown)
3. Grease fitting 9. Slotted hex nut 15. Jam nut (LH thread)
4. Jam nut 10. Flat washer 16. Slotted hex nut
5. Tie rod end 11. Steering cylinder 17. Tie rod end (LH thread)
6. Retaining ring 12. Grease fitting

Removal (Fig. 27) 3. Position barrel end of cylinder to the frame. Install
slotted hex nut finger tight to barrel rod end.
1. Park the machine on a level surface, engage the
parking brake and stop the engine. Remove the key 4. Tighten slotted hex nuts to secure cylinder rod ends.
from the ignition switch. Install cotter pins.
2. Lower the engine mounting plate assembly from ma- 5. Remove caps and plugs from disconnected hoses
chine (see Engine Mounting Plate Assembly Removal and fittings.
in the Service and Repairs Section of Chapter 3 -- Kohler
Gasoline Engine). 6. Connect hydraulic hoses to steering cylinder (Fig.
28). Tighten hose connections (see Hydraulic Hose and
3. Label all hydraulic connections for assembly pur- Tube Installation in the General Information section of
poses. Clean hydraulic hose ends prior to disconnecting this chapter).
the hoses from steering cylinder.
7. Check fluid level in transaxle and adjust as required
CAUTION 8. After assembly is completed, operate steering cylin-

der to verify that hydraulic hoses and fittings are not con-
Before disconnecting components or perform- tacted by anything.
the system must be relieved by stopping the en- 9. Raise the engine mounting plate assembly to ma-
gine and rotating the steering wheel in both chine (see Engine Mounting Plate Assembly Installation
directions. in the Service and Repairs Section of Chapter 3 -- Kohler
Gasoline Engine).
4. Disconnect hydraulic hoses from steering cylinder
Hydraulic
System
(Fig. 28). Allow hoses to drain into a suitable container.
5. Put caps or plugs on disconnected hoses and fittings

to prevent contamination. 5
6. Remove cotter pin and hex slotted nut that secure

the barrel end of the steering cylinder to the frame.
7. Remove cotter pin, flat washer and hex slotted nut

that secure the shaft end of the steering cylinder to the 4
steering pivot.
6
8. Remove steering cylinder from machine.
9. If rod end is removed from cylinder shaft, count num- 2

ber of revolutions it takes to remove from shaft so rod
1 3
end can be re--installed without affecting steering.

Figure 28
1. If rod end was removed from cylinder shaft, apply an- 1. Steering cylinder 4. Hyd hose (from pump)
2. Hyd hose (Left turn) 5. Steering control valve
tiseize lubricant to threads of rod end. Install rod end 3. Hyd hose (Right turn) 6. Hyd hose (to filter)
onto shaft the same number of revolutions needed to re-
move rod end. Secure rod end with jam nut.
2. Position shaft end of cylinder to the steering pivot.

Install flat washer and slotted hex nut finger tight to rod
end.

Steering Cylinder Service
11
2 6 14
7
12
3
13
10 8 4 1
5
9
75 ft--lb
(102 N--m)
Figure 29
1. Retaining ring 6. Shaft 11. Barrel
2. O--ring 7. Rod seal 12. Dust seal
3. Head 8. Piston 13. Ball joint
4. Backup ring 9. Uni--ring 14. Jam nut
5. O--ring 10. Lock nut

Disassembly (Fig. 29) Assembly (Fig. 29)
1. Remove oil from the steering cylinder into a drain pan 1. Make sure all parts are clean before assembly.
by slowly pumping the cylinder shaft. Plug both ports
and clean the outside of the cylinder. 2. Coat new O--rings, Uni--ring, rod seal and back--up
ring with with clean Dexron III ATF.
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise. Do not close vise A. Install Uni--ring and O--ring to the piston.
enough to distort the barrel.
B. Install O--ring, back--up ring, rod seal and dust
2. Mount end of steering cylinder in a vise with soft seal to the head.
jaws. Remove retaining ring.
IMPORTANT: Do not clamp vise jaws against the
A. Use a spanner wrench to rotate head clockwise shaft surface. Protect shaft surface before
until the edge of the retaining ring appears in the bar- mounting in a vise.
rel opening.
3. Mount shaft securely in a vise by clamping on the end
B. Insert a screwdriver under the beveled edge of of the shaft.
the retaining ring to start the retaining ring through
the opening. A. Coat shaft with a light coat of clean Dexron III
ATF.
C. Rotate the head counter--clockwise to remove re-
taining ring from barrel and head. B. Slide head assembly onto the shaft. Install piston
and lock nut onto the shaft. Torque lock nut to 75 ft--
3. Remove plugs from ports. Extract shaft, head and lb (102 N--m).
piston by carefully twisting and pulling on the shaft.
Hydraulic
C. Remove shaft from the vise.
System
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mount- IMPORTANT: Prevent damage when clamping
ing in a vise. the hydraulic cylinder into a vise. Do not close
vise enough to distort the barrel.
4. Mount shaft securely in a vise by clamping on the end
of the shaft. Remove lock nut and piston from the shaft. 4. Mount end of the barrel in a vise.
Slide head off the shaft.
5. Coat all internal parts with a light coat of clean Dex-
5. Remove Uni--ring and O--ring from the piston. ron III ATF. Slide piston, shaft and head assembly into
the barrel being careful to not damage the seals.
6. Remove O--ring, back--up ring, rod seal and dust
seal from the head. 6. Secure head into the barrel with retaining ring.
A. Align retaining ring hole in the head with the ac-

cess slot in the barrel.
B. Insert the retaining ring hook into the hole and ro-
tate head clockwise until the retaining ring is com-
pletely pulled into the barrel and the ring ends are
covered.
C. Apply silicone sealer to barrel access slot.


Chapter 5
Electrical System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Traction Speed Sensor . . . . . . . . . . . . . . . . . . . . . . 13
Operator Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pump Drive Electric Clutch . . . . . . . . . . . . . . . . . . 14
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Neutral Engine Speed Control Coil . . . . . . . . . . . 15
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fusible Link Harness . . . . . . . . . . . . . . . . . . . . . . . 15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5 Accessory Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 16
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Spray Pro Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Run Problems . . . . . . . . . . . . . . . . . . . . . . . 6 Boom Actuator and Application Rate (Multi Pro
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 7 1250 only) Switches . . . . . . . . . . . . . . . . . . . . . . 18
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . . 7 Rate Lockout Key Switch (Multi Pro 1250 only) . 19
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . 7 Master Boom (Foot) Switch (Multi Pro 1250 only) 20
Check Operation of Neutral Switch . . . . . . . . . . . . 7 Spray Valve Switch (Multi Pro 1250 only) . . . . . . 21
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 8 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 22
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pump Drive Electric Clutch . . . . . . . . . . . . . . . . . . 22
Start, Neutral Engine Speed Lock, Spray Pump Pump Drive Electric Clutch Service . . . . . . . . . . . 23
Clutch and Spray Valve Relays . . . . . . . . . . . . . . 9 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump Control and Neutral Engine Speed
Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical
System
Multi Pro 1200/1250 Page 5 -- 1 Electrical System

General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Multi Pro machine. Refer to that publi-
cation for additional information when servicing the ma-
chine.
Electrical Drawings
The electrical schematics and wire harness drawings for
the Multi Pro 1200 and Multi Pro 1250 are located in
Chapter 10 -- Electrical Diagrams.
Electrical System Page 5 -- 2 Multi Pro 1200/1250

Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
Multimeter
The multimeter can test electrical components and cir-
cuits for current, resistance or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt--

Ohm--Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital me-
ter in the voltage mode will make sure that excess cur-
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin--Over Grease
Special non--conductive grease which forms a light pro-
tective skin to help waterproof electrical switches and
contacts.
Electrical
System
Figure 2
Dielectric Gel
Dielectric gel should be used to prevent corrosion of
connection terminals. To ensure complete coating of ter-
minals, liberally apply gel to both component and wire
harness connector, plug connector to component, un-
plug connector, reapply gel to both surfaces and Con-
nect harness connector to component. Connectors
should be thoroughly packed with gel for effective re-
sults.

Figure 3

Battery Terminal Protector
Aerosol spray that should be used on battery terminals
to reduce corrosion problems. Apply terminal protector
after the battery cable has been secured to the battery
terminal.
Figure 4
Spray Pro Monitor Tester

Used to test the inputs and power leads to the Spray Pro
Monitor on Multi Pro 1200 and 1250 sprayers. Tests
monitor functions by simulating sprayer operation.
Figure 5

Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
CAUTION components used on this machine (see Chapter 10 --
Electrical Diagrams).
Remove all jewelry, especially rings and
watches, before doing any electrical trouble- If the machine has any interlock switches by--passed,
shooting or testing. Disconnect the battery they must be connected for proper troubleshooting and
cables unless the test requires battery voltage. safety.
Starting Problems
Problem Possible Causes
Starter solenoid clicks, but starter will not crank Battery is discharged.
(if solenoid clicks, problem is not in safety interlock
system). Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Wiring at starter is faulty.
Starter solenoid is faulty.
Starter mounting bolts are loose or not supplying a

sufficient ground for solenoid.
Starter is faulty.
Nothing happens when start attempt is made. Range selector lever is not in the neutral position.
Electrical
System
Battery cables are loose or corroded.
Battery ground cable to frame is loose or corroded.
Battery is discharged or faulty.
Main fuse (30 amp) is faulty.
Wiring to start circuit components is loose, corroded or

damaged (see Chapter 10 -- Electrical Diagrams).
Neutral switch is faulty.
Ignition switch is faulty.
Fuse block is faulty.
Starter solenoid is faulty.

Starting Problems (continued)
Engine cranks, but does not start. Ignition switch is faulty.
Circuit wiring to engine magneto is grounded (see

Chapter 10 -- Electrical Diagrams).
Circuit wiring to carburetor solenoid is loose, corroded

or damaged (see Chapter 10 -- Electrical Diagrams).
Engine or fuel system is malfunctioning (see Chapter

3 -- Kohler Gasoline Engine).
Engine may be too cold.
Engine cranks (but should not) with the range selector Neutral switch wiring is faulty (see Chapter 10 --
lever out of the neutral position. Electrical Diagrams).
Neutral switch is faulty.
General Run Problems
Battery does not charge. Wiring to the charging circuit components is loose,
corroded or damaged (see Chapter 10 -- Electrical
Diagrams).
Alternator components are faulty.
Battery is faulty.
Engine stops during machine operation. Ignition switch is faulty.
Circuit wiring to engine magneto is damaged (see

Chapter 10 -- Electrical Diagrams).
Circuit wiring to carburetor solenoid is loose, corroded

or damaged (see Chapter 10 -- Electrical Diagrams).
Engine or fuel system is malfunctioning (see Chapter

3 -- Kohler Gasoline Engine).

Electrical System Quick Checks
Battery Test (Open Circuit Test)

Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level
battery terminals.
12.68 v (or higher) Fully charged (100%)
Set the multimeter to the DC volts setting. The battery 12.45 v 75% charged
should be at a temperature of 60o to 100o F (16o to 38o
12.24 v 50% charged
C). The ignition key should be in the OFF position and
all accessories turned off. Connect the positive (+) me- 12.06 v 25% charged
ter lead to the positive battery post and the negative (--) 11.89 v 0% charged
meter lead to the negative battery post.
NOTE: This test provides a relative condition of the bat-

tery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test

This is a simple test used to determine if a charging sys- Start the engine and run at high idle (3275 to 3425
tem is functioning. It will tell you if a charging system has RPM). Allow the battery to charge for at least three (3)
an output, but not its capacity. minutes. Record the battery voltage.
Tool required: Digital multimeter set to DC volts. Test results should be at least 0.50 volt over initial bat-
tery voltage. Example:
Test instructions: Connect the positive (+) meter lead to
the positive battery post and the negative (--) meter lead Initial Battery Voltage = 12.30 v
to the negative battery post. Leave the test leads con-
nected and record the battery voltage. Battery Voltage after 3 Minute Charge = 12.95 v
Electrical
System
Difference = +0.65 v
NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running. NOTE: Typical battery voltage while the engine is run-
ning during this test should be 13.5 to 14.5 volts.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
Check Operation of Neutral Switch

Neutral switch operation is described in the Multi Pro
1200 and 1250 Operator’s Manual. Testing of this switch
CAUTION is included in the Component Testing section of this
chapter.
Do not disconnect neutral switch. It is for the op-
erator’s protection. Check the operation of the
neutral switch daily for proper operation. Re-
place a malfunctioning switch before operating
the machine.

Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before CAUTION
doing a continuity check on the ignition switch).
When testing electrical components for continu-
NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure
the Kohler Engine Service Manual at the end of Chapter that power to the circuit has been disconnected.
3 -- Kohler Gasoline Engine.
Ignition Switch
The ignition (key) switch has three positions (OFF, RUN OFF
and START) (Fig. 6). The terminals are marked as o
shown in Figure 7. 45
RUN
Testing
45 o
The circuitry of the ignition switch is shown in the follow-
ing chart. With the use of a multimeter (ohms setting), START
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position.
Unplug wire harness connectors from switch and verify

continuity between switch terminals. Connect the har- Figure 6
ness connectors to the switch after testing.
POSITION CIRCUIT
G B
OFF G+M+A
RUN B+L+A M
START B+L+S
L S
A
Figure 7
HEX NUT
KEY
SWITCH LOCK WASHER
Figure 8

Start, Neutral Engine Speed Lock, Spray Pump Clutch, Boom Actuator and Spray Valve
Relays
The start, neutral engine speed lock, spray pump clutch
and boom actuator relays are used on both the Multi Pro
1200 and Multi Pro 1250. The Multi Pro 1250 uses an
additional three (3) relays for the spray valve system. All
of the relays are located under the operator seat (Fig. 9). 2
The relays are all identical and can be identified by a tag
at the relay wire harness connector.
Testing

gage parking brake and remove key from ignition
switch.
1
2. Raise operator seat and locate the relay to be tested.
Disconnect wire harness connector from relay and re-
move relay from panel. Figure 9
1. Operator seat (raised) 2. Relay location
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 3
1 4
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you 86 87A 87
are testing.
3. Using a multimeter (ohms setting), measure coil re-

sistance between terminals 85 and 86 (Fig. 10). Resist-
Electrical
85 30
ance should be between 70 and 90 ohms.
System
4. Connect multimeter (ohms setting) leads to relay ter- 1 2
minals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay terminals 30 and 87 Figure 10
should have continuity as +12 VDC is applied to terminal 1. Coil terminal 3. Normally closed term.
85. The relay terminals 30 and 87 should not have conti- 2. Common terminal 4. Normally open term.
nuity as +12 VDC is removed from terminal 85.
5. Disconnect voltage from terminal 85 and multimeter

lead from terminal 87.
6. Connect multimeter (ohms setting) leads to relay ter-

minals 30 and 87A. With terminal 86 grounded, apply
+12 VDC to terminal 85. The relay terminals 30 and 87A
should not have continuity as +12 VDC is applied to ter-
minal 85. The relay terminals 30 and 87A should have
continuity as +12 VDC is removed from terminal 85.
7. When testing is completed, disconnect voltage and

multimeter leads from the relay terminals. Replace relay
if necessary.
8. Secure relay to machine panel and connect wire har-

ness to relay. Lower operator seat.

Neutral Switch
The neutral switch is attached to the shift lever assembly
(Fig. 11). The switch is a normally open proximity switch
that is closed when the shift lever is in the neutral posi- 1
tion. The neutral switch allows engine cranking/starting
only when the machine is in neutral.
Testing
2
switch.
2. Locate neutral switch on the shift lever assembly. If 3

needed, remove air cleaner cover to ease access to 4
switch. Disconnect the wire harness connector from the
switch.
3. Check the continuity of the switch by connecting a

multimeter (ohms setting) across the connector termi-
nals.
4. With the shift lever in the neutral position, the neutral

switch should be closed (continuity).
5. Depress the brake pedal to allow the shift lever to

move. While watching the multimeter, move the shift le-
ver out of the neutral position. Continuity of the neutral
switch should be broken as the lever is moved and the Figure 11
interlock switch opens. 1. Shift lever 3. Shifter bracket
2. Sensing tab 4. Neutral switch
6. If necessary, replace switch.
7. Connect the wire harness connector to the switch.
8. If removed, install air cleaner cover.

Hour Meter
The hour meter is located on the control console next to 6. Disconnect voltage source from the hour meter.
the operator seat.
7. Connect yellow/red harness wire to the positive (+)
Testing terminal of the hour meter and black harness wire to the
other meter terminal. Install console panel.
switch.
2. Remove console panel. Disconnect the harness

electrical connectors from the terminals on the hour
meter.
3. Connect the positive (+) terminal of a 12 VDC source

to the positive (+) terminal of the hour meter.
4. Connect the negative (--) terminal of the voltage

source to the other terminal of the hour meter.
Figure 12
5. The hour meter should move a 1/10 of an hour in six
(6) minutes.
Headlight Switch
The headlight switch is located on the control console
next to the operator seat (Fig. 13).
1
Testing
Electrical
System
switch.
2. Remove console panel, locate headlight switch and

unplug wire harness connector from switch.
3. The switch terminals are marked as shown in Figure

14. In the ON position, continuity should exist between
2
the two terminals. In the OFF position, there should be
no continuity between the switch terminals.
4. After testing, connect the harness connector to the Figure 13

switch. Install console panel to machine. 1. Control console 2. Headlight switch
BACK OF SWITCH
Figure 14

Pump Control and Neutral Engine Speed Control Switches
The pump control and neutral engine speed control
switches are identical switches. The pump control MULTI PRO 1200 MULTI PRO 1250
switch is located on the sprayer (right side) console (Fig.
15). The neutral engine speed control switch is posi-
tioned on the control console (Fig. 16).
Testing

switch.
2. Locate switch, remove console panel and unplug

machine wire harness connector from switch. 2
1
17. In the ON position, continuity should exist between
terminals 2 and 3. In the momentary SET position, conti-
nuity should exist between terminals 2 and 3 and also
between terminals 5 and 6. In the OFF position, there Figure 15
should be no continuity between any switch terminals.
1. Pump switch (MP 1200) 2. Pump switch (MP 1250)
NOTE: When the switch is pressed to the momentary
SET position, terminals 5 and 6 are used to initially ener-
gize the controlled component (pump drive clutch or 1
cruise coil) and to set up a latch circuit through terminals
2 and 3. This latch circuit keeps the component ener-
gized through terminals 2 and 3 when the switch returns
to the ON position. Pressing the switch to OFF opens
this latch circuit and de--energizes the component. 2
4. Terminals 7 (--) and 8 (+) are used for the indicator

light in the switch. The light should be illuminated when
the switch is in the ON position while the controlled com-
ponent is energized.
5. Connect the harness connector to the switch after

testing. Install console panel to machine.
Figure 16
1. Control console 2. Engine speed switch
7 5 6
8 2 3
BACK OF SWITCH
Figure 17

Traction Speed Sensor
The traction speed sensor is attached to the upper
transaxle cover (Fig. 18). It uses a magnetically based,
Hall Effect integrated circuit. As the differential in the
transaxle turns, the sensor accurately senses the move-
ment of the differential ring gear teeth passing by the
sensor. The red striped connector wire is the positive
lead, the black wire is the ground lead and the gray 3
striped wire is the signal output. 2
Testing
1. Park machine on a level surface, stop engine, en- 1

switch. Figure 18
1. Transaxle 3. Sensor connector
2. Locate traction speed sensor on the transaxle as- 2. Traction speed sensor
sembly. Disconnect the wire harness connector from the
traction speed sensor.
3. Remove cap screw and lock washer that secure

speed sensor to transaxle. Remove speed sensor from 1K ohm
transaxle. resistor
4. Connect positive multimeter test lead to the sensor

connector gray striped wire terminal and the negative
multimeter lead to the connector black wire terminal
(Fig. 19). Set multimeter to ohms setting. + --
IMPORTANT: Incorrect jumper wire connections 12 VDC

during testing can damage the sensor.
Electrical
System
6
4
5. Using a +12 VDC battery, a multimeter, a 1K ohm re- C B A
sistor and appropriate jumper wires, connect the battery
and multimeter to the speed sensor using Figure 19 as
a guide. 5 3
6. Set multimeter to DC volts setting.

1
7. The multimeter should display very low voltage when
a metal object is held near the sensor tip. The multimeter
should display battery voltage when the metal object is
2
moved away from the sensor tip.
8. After testing is complete, remove jumper wires, re-

sistor and multimeter leads from sensor connector. Figure 19
1. Speed sensor 4. Red striped wire
9. Replace speed sensor if necessary. 2. Sensor tip 5. Gray striped wire
3. Sensor connector 6. Black wire
10.After testing is complete, remove jumper wires and
multimeter leads from sensor connector. Install speed
sensor into transaxle and secure with cap screw and
lock washer. Connect speed sensor to wire harness.

Pump Drive Electric Clutch
An electric clutch is used to engage and drive the spray-
er pump on the Multi Pro. Clutch operation is controlled
by the pump control switch located on the spray console. 2
1
The electric clutch is mounted on the pump drive gear-
box output shaft and is coupled to the spray pump. The
clutch engages when current is applied to the clutch.
Testing

switch.
2. Locate clutch on pump drive gearbox shaft. Unplug

clutch connector from machine wire harness (Fig. 20).

The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal Figure 20
ue from from the measured value of the component you 1. Electric clutch 2. Clutch connector
are testing.
3. Using a multimeter (ohms setting), verify clutch coil

resistance between the two terminals of the connector.
Resistance should be 2.45 ohms.
4. If clutch does not engage when voltage is applied or

coil resistance is incorrect, replace clutch.
5. See Pump Drive Electric Clutch in the Service and

Repairs section of this chapter if clutch removal is nec-
essary.
6. After testing, plug clutch connector into machine wire

harness.

Neutral Engine Speed Control Coil
The neutral engine speed control coil is energized by the
speed control switch and cruise module. The energized 2
coil becomes a magnet to hold the accelerator lever in
position and maintains engine speed for sprayer opera-
tion when the machine is stationary.
Testing

switch.
2. Locate control coil next to accelerator lever under the

floorboard. Unplug coil connector from machine wire
harness (Fig. 21).
3
ue from from the measured value of the component you 1
are testing.
3. Using a multimeter (ohms setting), verify control coil

resistance between the two terminals of the connector.
Figure 21
Resistance should be from 10.2 to 11.2 ohms.
1. Accelerator lever 3. Brake lever
2. Speed control coil
4. If coil does not engage when voltage is applied or coil
resistance is incorrect, replace control coil.
Electrical
System
5. Connect the coil connector to the machine harness
after testing.
Fusible Link Harness

The Multi Pro sprayer uses two (2) fusible links for circuit After fusible link testing is complete, make sure that fus-
protection. These fusible links are located in a harness ible link harness is securely attached to starter B+ termi-
that connects the starter B+ terminal to the wire harness nal and wire harness. Connect positive battery cable to
(Fig. 22). If either of these links should fail, current to the battery terminal first and then connect negative cable to
protected circuit will cease. Refer to wire harness draw- battery.
ings in Chapter 10 -- Electrical Drawings for additional
fusible link information.
Testing
Make sure that ignition switch is OFF. Disconnect nega- P02 P01
TO MAIN HARNESS STARTER B+
tive battery cable from battery terminal and then discon-
nect positive cable from battery (see Battery Service in
the Service and Repairs section of this chapter). Locate FUSIBLE LINK (14 GAUGE)
and unplug fusible link connector from machine wire FUSIBLE LINK (16 GAUGE)
harness. Use a multimeter to make sure that continuity

exists between the fusible link terminals. If either fusible Figure 22
link is open, replace the fusible link harness.

Accessory Solenoid
The accessory solenoid provides a current supply to the
spray system, boom actuators and optional accessories
(e.g. foam markers). The solenoid is energized when
the ignition key switch is in the RUN position. The acces- 4 3 2 1 8
sory solenoid is located under the operator seat (Fig.
23).
7
Testing

switch. 6
2. Disconnect battery cables from battery. Make sure

that negative (--) cable is removed from battery before
positive (+) cable.
Figure 23
3. Raise operator seat and locate accessory solenoid.
Put labels on wires for proper installation after repairs 1. Accessory solenoid 5. Nut (2 used)
2. Lock washer (2 used) 6. Harness connectors
are completed. Disconnect machine wire harness con- 3. Jam nut (2 used) 7. Flange nut (2 used)
nectors from solenoid. 4. Boot 8. Cap screw (2 used)

digital multimeter, short the meter test leads together. 2
1
resistance of the meter and test leads. Subtract this val- 1
ue from the measured value of the component you are
testing.
4. Apply 12 VDC directly across the solenoid coil posts

(steel). The solenoid should click as the solenoid coil is 2
energized. Make sure resistance across the main con-
tact posts (copper) is less than 1 ohm.
5. Remove voltage from solenoid coil posts. The sole-

noid should click as the solenoid coil is de--energized.
Make sure resistance across the main contact posts is
infinite ohms. WIRING
2 DIAGRAM
6. With no voltage to any of the solenoid coil posts,

measure resistance of the coil across the solenoid coil 2
posts (steel). Resistance should be approximately 13.5
ohms. 1
1
7. Replace accessory solenoid if necessary.
Figure 24
8. Using labels placed on wires before removal, con- 1. Main posts (copper) 2. Solenoid posts (steel)
nect electrical connections to solenoid.
9. Connect battery cables to battery. Make sure that

positive (+) cable is secured to battery before negative
(--) cable is attached to battery.
10.Lower operator seat.

Spray Pro Monitor
The Multi Pro 1200 and 1250 are equipped with a Spray 9. If testing results are incorrect, check for wire harness
Pro Monitor (Fig. 25) to provide the machine operator problem between component (flowmeter or speed sen-
with spray system information. Operation, calibration sor) and Spray Pro Monitor. If wire harness is not dam-
and troubleshooting information for the Spray Pro Moni- aged (open or shorted), suspect a faulty monitor.
tor is included in the Operator’s Manual.
10.After testing, connect wire harness connector to
NOTE: Spray monitor operation on Multi Pro 1200 and component. Repeat for second component if necessary.
1250 machines can be checked with special tool
TOR6001 (see Special Tools in this chapter).
Testing Flowmeter and Speed Sensor Input
The following procedure can be used to determine if in-

puts from the flowmeter and speed sensor are reaching SPEED APPLICATION
RATE
the Spray Pro monitor. SPRAY PRO CALIBRATION CALIBRATION
MP120
0
MONITOR DISTANCE VOLUME
1. Park machine on a level surface, stop engine and en- MULTI PRO SPEED FLOWMETER
gage parking brake. 1200

CALIBRATION CALIBRATION
SEL UNITS OF
WIDTH
UNITS MEASURE
2. Locate and disconnect wire harness connector from
component to be tested (flowmeter or speed sensor).
3. Turn ignition switch to RUN (do not start engine).

Make sure that the pump control switch is in the ON posi-
tion. On Multi Pro 1250 machines, turn all spray booms
and master boom (foot) switch ON.
4. Set Spray Pro monitor as follows:
A. If flowmeter input is being tested, turn monitor SPRAY PRO
Electrical
System
knob to the Calibration Volume setting on Multi Pro MONITOR
1200 or Total Volume setting on Multi Pro 1250. MULTI PRO
1250
B. If speed sensor input is being tested, turn monitor
knob to the Calibration Distance setting on Multi Pro
1200 or Distance setting on Multi Pro 1250.
5. At the disconnected wire harness connector, use a

small jumper wire to rapidly short ground terminal and Figure 25
signal terminal several times (Fig. 26). As the jumper
wire makes contact with these two terminals, the Spray
Pro Monitor display value should change. Speed GROUND
6. Use a multimeter (DC volt setting) to measure the DC Sensor SIGNAL
voltage between the disconnected flowmeter wire har- Connector POWER

ness connector terminals (Fig. 26).
GROUND
A. There should be approximately 5 VDC between Multi Pro 1200
connector ground and power terminals. SIGNAL
Flowmeter
B. There should be approximately 5 VDC between Connector POWER
connector ground and signal terminals.
GROUND
7. Turn ignition switch to OFF. Record test results. Multi Pro 1250 POWER
Flowmeter
8. If testing results are correct, consider a faulty compo- Connector SIGNAL
nent (flowmeter or speed sensor).
Figure 26

Boom Actuator and Application Rate (Multi Pro 1250 only) Switches
The right and left boom actuator switches used on both
the Multi Pro 1200 and 1250 are located on the spray MULTI PRO 1200
control console (Fig. 28). Pressing the front of a switch
lowers the appropriate spray boom section. Pressing
the rear of a switch raises the boom section.
The application rate switch on Multi Pro 1250 sprayers 1

is also located on the spray control console (Fig. 28).
Pressing the front of the switch increases spray system
pressure. Pressing the rear of the switch decreases sys-
tem pressure.
2 3
The boom actuator and application rate switches are all
identical.
Testing Figure 27
1. Spray control console 3. RH boom switch
1. Park machine on a level surface, stop engine, en- 2. LH boom switch
switch.
MULTI PRO 1250
2. Locate switch, remove console panel and unplug
wire harness connector from switch. 1
2
29. In the boom raise or pressure decrease position,
continuity should exist between terminals 2 and 3 and
also between terminals 5 and 6. In the neutral, center
position, there should be no continuity between any
switch terminals. In the boom lower or pressure in-
crease position, continuity should exist between termi- 3
nals 2 and 1 and also between terminals 5 and 4.
4
Figure 28
1. Spray control console 3. LH boom switch
2. Application rate switch 4. RH boom switch
4 5 6
1 2 3
BACK OF SWITCH
Figure 29

Rate Lockout Key Switch (Multi Pro 1250 only)
The rate lockout key switch on Multi Pro 1250 sprayers
is located on the spray control console (Fig. 30). When
the rate lockout switch is in the OFF (locked) position,
the application rate switch is disabled. 1
Testing

switch.
2. Locate switch, remove console panel and remove

wire harness connector from switch.
3. With the use of a multimeter (ohms setting), the

switch functions may be tested to determine whether
continuity exists between the various terminals for each Figure 30
switch position. The switch terminals are marked as
1. Spray control console 2. Rate lockout switch
shown in Figure 31. The circuitry of the rate lockout key
switch is shown in the chart below. Verify continuity be-
tween switch terminals.
OFF (LOCKED)
SWITCH NORMAL OTHER 45 o
POSITION CIRCUITS CIRCUITS ON (UNLOCKED)
OFF (LOCKED) NONE B+C

ON (UNLOCKED) A+D B+C
NOTE: Only switch terminals A and D are used on Multi
Electrical
Pro 1250 machines.
System
4. After testing is completed, connect the harness con- FRONT OF SWITCH
nector to the switch. Install console panel to machine.
BACK OF SWITCH
Figure 31

Master Boom (Foot) Switch (Multi Pro 1250 only)
The master boom switch on Multi Pro 1250 sprayers is
located on the floorboard of the machine (Fig. 32). 2
Testing

switch.
2. Locate switch and unplug wire harness connector

from switch.
1
3. The switch terminals are shown in Figure 33. Conti-
nuity should exist between the common terminal and
only one of the side terminals. When the switch is de-
pressed, continuity should exist between the common
terminal and the other side terminal. Regardless of Figure 32
switch position, there should never be continuity be- 1. Operator floorboard 2. Master boom switch
tween the two side terminals.
4. Connect the wire harness connector to the switch af-

ter testing.
2 2
Figure 33
1. Common terminal 2. Side terminal

Spray Valve Switch (Multi Pro 1250 only)
The three (3) spray valve switches for the Multi Pro 1250
sprayers are located on the spray control console (Fig.
34). The switches are identical.
2 4
Testing

gage parking brake and remove key from ignition 3
switch.
2. Locate spray valve switch, remove console panel

and unplug machine wire harness connector from
switch.

35. In the ON position, continuity should exist between 1
terminals 2 and 3 and also between terminals 5 and 6.
In the OFF position, continuity should exist between ter- Figure 34
minals 1 and 2 and also between terminals 4 and 5.
1. Spray control console 3. Center valve switch
2. LH spray valve switch 4. RH spray valve switch
4. Terminals 7 (--) and 8 (+) are used for the indicator
light in the switch. The light should be illuminated when
the switch is in the ON position. 7 4 5 6
8 1 2 3
Electrical
System
BACK OF SWITCH
Figure 35

Service and Repairs
NOTE: For engine component testing information, see
the Kohler Engine Repair Manual at the end of Chapter
3 -- Kohler Gasoline Engine.
Pump Drive Electric Clutch
1
175 to 225 in--lb
Antiseize (20 to 25 N--m)
Lubricant Loctite #242
Loctite #242
27 to 30 ft--lb
(37 to 40 N--m)
Antiseize
Lubricant
19
5 10
4
10
3 21
7 5
22 2 13
12 14
11
6
8 15
6
RIGHT 2 11 12
FRONT 9
175 to 225 in--lb 20
(20 to 25 N--m) 17
16
7 18
Figure 36
1. Spray pump 9. Cap screw (2 used) 16. Spacer (2 used)
2. Lock nut (6 used) 10. Flat washer (4 used) 17. Clutch adapter
3. Key 11. Spacer (4 used) 18. Spacer
4. Cap screw (4 used) 12. Cap screw (4 used) 19. Set screw (2 used)
5. Coupling spacer (4 used) 13. Lock washer 20. Pump drive gearbox shaft
6. Rubber coupling (4 used) 14. Clutch retainer 21. Cap screw
7. Lock nut (4 used) 15. Electric clutch 22. Pump hub
8. Drive coupler
Removal (Fig. 36) 3. Remove lock nuts that secure clutch adapter (item
17) to electric clutch.
gage parking brake and remove key from the ignition 4. Slide drive coupler, rubber couplings and clutch
switch. adapter from machine as an assembly. Locate and re-
trieve two (2) spacers (item 16) from between clutch
2. Remove cap screws, flat washers, lock nuts and adapter and electric clutch.
spacers that secure rubber couplings to pump hub (item
22). 5. Unplug clutch wire connector from machine wire har-
ness.

6. Remove cap screw, lock washer and clutch retainer 9. Secure rubber coupling to pump hub (item 23) with
that secure clutch to pump drive gearbox shaft. spacers, flat washers, cap screws,and lock nuts. Make
sure that cap screw threads extend fully through lock
7. Remove shoulder bolt that secures clutch leg to nuts.
pump drive gearbox (Fig. 37).
8. Slide electric clutch from pump drive gearbox. Lo- 6

cate and remove spacer (item 18) from gearbox shaft.
Note that spacer groove fits around retaining ring on 1
gearbox shaft.
5
4
1. Apply antiseize lubricant to pump drive gearbox

shaft. Make sure that retaining ring on gearbox shaft is
fully seated in shaft groove.
2. Place spacer (item 18) onto gearbox shaft. Make

sure that spacer groove fits around retaining ring on 3 2
shaft.
Figure 37
3. Align key in clutch with key slot in gearbox shaft and
1. Shoulder bolt 4. Retaining ring
align mounting leg of clutch to threaded hole in gearbox. 2. Electric clutch 5. Pump drive gearbox
Slide clutch onto gearbox shaft. 3. Spacer 6. Driven clutch
4. Install shoulder bolt through leg of clutch and into

gearbox (Fig. 37). Tighten shoulder bolt. After shoulder
bolt is tightened, make sure that leg of clutch does not 2
bind on bolt.
5. Install cap screw, lock washer and clutch retainer to

secure clutch to gearbox shaft. Torque screw from 27 to
30 ft--lb (37 to 40 N--m).
Electrical
System
6. Connect clutch wire connector to machine wire har- 1
ness.
IMPORTANT: If pump drive coupler components

were disassembled, make sure that pump hub
flanges and drive coupler are assembled at right
angles (90 degrees) to each other (Fig. 38). Figure 38
1. Drive coupler 2. Pump hub
7. Position drive coupler assembly (with all rubber cou-
plings and clutch adapter) between pump hub and elec-
tric clutch.
8. Make sure that two (2) spacers (item 16) are posi-
tioned between clutch adapter (item 17) and electric
clutch. Secure clutch adapter to clutch with two (2) lock
nuts.
Pump Drive Electric Clutch Service

NOTE: For clutch electrical testing information, see The pump drive electric clutch used on the Multi Pro has
Pump Drive Electric Clutch in the Components section sealed, non--serviceable bearings. If clutch bearing fail-
of this chapter. ure occurs, clutch replacement is necessary.

Headlights
Headlight Removal (Fig. 39)

switch.
2. Reach beneath dash and push headlight out of the

hood.
3. Remove screws attaching the wire harness to the

headlight.
4. Remove rubber seal from around the headlight. Dis- 2

card headlight.
Headlight Installation (Fig. 39) 3

1. Align notch on the inside of the seal with the notch on
the new headlight. Slide seal onto the headlight until the 1
seal is firmly in place.
Figure 39
2. Attach headlight to the wire harness using the pre- 1. Rubber seal 3. Headlight
viously removed screws. 2. Outside notch
NOTE: Applying soapy water to the outside of the seal

will aid in sliding the seal into the hood. Make sure to
thoroughly dry headlights before turning lights on.
3. Align notch on the outside of the seal with the notch

in the hood. Push headlight and seal into the hood until
it is firmly in place.

Battery Storage
If the machine will be stored for more than 30 days: 4. Store battery in a cool atmosphere to avoid quick de-
terioration of the battery charge.
1. Remove the battery and charge it fully (see Battery
Service in this section). 5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service in this section).
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. Battery electrolyte level must be properly main- 3. Battery cables must be tight on terminals to provide
tained. The top of the battery must be kept clean. lf the good electrical contact.
machine is stored in a location where temperatures are
extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temper-
atures are cool. WARNING
Connecting battery cables to the wrong battery
post could result in personal injury and/or dam-
WARNING age to the electrical system.
Wear safety goggles and rubber gloves when 4. If corrosion occurs at terminals, disconnect cables.
working with electrolyte. Charge battery in a well Always disconnect negative (--) cable first. Clean
ventilated place so gases produced while charg- clamps and terminals separately. Connect cables with
ing can dissipate. Since these gases are explo- positive (+) cable first. Coat battery posts and cable con-
sive, keep open flames and electrical sparks nectors with Battery Terminal Protector (see Special
Electrical
away from the battery; do not smoke. Nausea
System
Tools in this chapter) to prevent corrosion.
may result if the gases are inhaled. Unplug char-
ger from electrical outlet before connecting or 5. Check electrolyte level every 25 operating hours and
disconnecting charger leads to or from battery every 30 days if machine is in storage.
posts.
6. Maintain cell level with distilled water. Do not fill cells
IMPORTANT: Do not remove battery fill caps while above the fill line.
cleaning.
2. Check battery condition weekly or after every 50

hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
A. Clean battery by washing entire case with a solu-

tion of baking soda and water. Rinse with clear water.
B. Coat battery posts and cable connectors with

Battery Terminal Protector (see Special Tools in this
chapter) to prevent corrosion.

Battery Service
The battery is the heart of the electrical system. With IMPORTANT: Before cleaning the battery, tape
regular and proper service, battery life can be extended. or block vent holes to the filler caps and make
Additionally, battery and electrical component failure sure the caps are on tightly.
can be prevented.
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or missing
CAUTION filler cap, overcharging, loose terminal post or over-
filling. Also, check battery case for dirt and oil. Clean
the battery with a solution of baking soda and water,
When working with batteries, use extreme cau- then rinse it with clean water.
tion to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or D. Check that the cover seal is not broken away. Re-
eyes. Always wear safety goggles and a face place the battery if the seal is broken or leaking.
shield when working with batteries.
E. Check the electrolyte level in each cell. If the level
Battery Specifications is below the tops of the plates in any cell, fill all cells
with distilled water between the minimum and max-
BCI Group 26 Battery imum fill lines. Charge at 15 to 25 amps for 15 min-
540 Amp Cranking Performance at 0oF (--18oC) utes to allow sufficient mixing of the electrolyte.
80 minute Reserve Capacity at 80oF (27oC)
Electrolyte Specific Gravity (fully charged): from 1.250
to 1.280
Electrolyte Specific Gravity (discharged): 1.240
Battery Removal and Installation (Fig. 40)

1
See Operator’s Manual for battery removal and installa-
tion information.
2
NOTE: Before connecting the negative (ground) cable,
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable 3
connector. The reading should be 0 amps. If the reading
is 0.1 amp or more, the unit’s electrical system should 4
be tested and repaired.
5
Battery Inspection and Maintenance
6
1. Perform following inspections and maintenance: 7
A. Replace battery if cracked or leaking. Figure 40

1. Negative battery cable 5. Flat washer
B. Check battery terminal posts for corrosion. Use 2. Positive battery cable 6. Battery retainer
wire brush to clean corrosion from posts. 3. Battery 7. Flange nut
4. Cap screw

Battery Testing B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
1. Conduct a hydrometer test of the battery electrolyte. Use a battery load tester following the manufactur-
er’s instructions.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps. C. Make sure battery terminals are free of corrosion.
A. Measure the specific gravity of each cell with a D. Measure the temperature of the center cell.
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm-- E. Connect a battery load tester to the battery termi-
up the hydrometer. At the same time take the tem- nals following the manufacturer’s instructions.
perature of the cell. Connect a digital multimeter to the battery terminals.
B. Temperature correct each cell reading. For each F. Apply a test load of one half the Cranking Perfor-
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the mance (see Battery Specifications) rating of the bat-
specific gravity reading. For each 10oF (5.5oC) be- tery for 15 seconds.
low 80oF (26.7oC) subtract 0.004 from the specific
gravity reading. G. Take a voltage reading at 15 seconds, then re-
move the load.
Example: Cell Temperature 100oF
Cell Gravity 1.245 H. Using the table below, determine the minimum
100oF minus 80oF equals 20oF voltage for the cell temperature reading:
(37.7oC minus 26.7oC equals 11.0oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/5.5oC equals 0.008) Minimum Battery Electrolyte
ADD (conversion above) 0.008 Voltage Temperature
Correction to 80oF (27oC) 1.253 9.6 70oF (and up) 21oC (and up)
C. If the difference between the highest and lowest 9.5 60oF 16oC
cell specific gravity is 0.050 or greater or the lowest 9.4 50oF 10oC
cell specific gravity is less than 1.225, charge the bat-
tery. Charge at the recommended rate and time giv- 9.3 40oF 4 oC
en in Charging or until all cells specific gravity is 9.1 30oF --1oC
Electrical
1.225 or greater with the difference in specific gravity 20oF --7oC
System
8.9
between the highest and lowest cell less than 0.050.
If these charging conditions can not be met, replace 8.7 10oF --12oC
the battery. 8.5 0 oF --18oC
2. Perform a high--discharge test with an adjustable

load tester. I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the mini-
This is one of the most reliable means of testing a battery mum, return the battery to service.
as it simulates the cold--cranking test. A commercial bat-
tery load tester is required to perform this test.
CAUTION
Follow the manufacturer’s instructions when us-
ing a battery tester.
A. Check the voltage across the battery terminals

prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.

Battery Charging
To minimize possible damage to the battery and allow CAUTION

the battery to be fully charged, the slow charging meth-
od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex-
complished with a constant current battery charger plode and cause injury. Let the battery warm to
which is available in most shops. 60oF (16oC) before connecting to a charger.
Charge the battery in a well--ventilated place to

CAUTION dissipate gases produced from charging. These
gases are explosive; keep open flame and elec-
trical spark away from the battery. Do not smoke.
Follow the manufacturer’s instructions when us- Nausea may result if the gases are inhaled. Un-
ing a battery charger. plug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
3. Following the manufacturer’s instructions, con-
1. Determine the battery charge level from either its nect the charger cables to the battery. Make sure a good
specific gravity or open circuit voltage. connection is made.
4. Charge the battery following the manufacturer’s

Battery Charge Specific Open Circuit instructions.
Level Gravity Voltage
5. Occasionally check the temperature of the battery
100% 1.265 12.68
electrolyte. If the temperature exceeds 125oF (52oC) or
75% 1.225 12.45 the electrolyte is violently gassing or spewing, the
50% 1.190 12.24 charging rate must be lowered or temporarily stopped.
25% 1.155 12.06 6. Three (3) hours prior to the end of the charging, mea-
0% 1.120 11.89 sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
2. Determine the charging time and rate using the freely at a low charging rate and there is less than a
manufacturer’s battery charger instructions or the 0.003 change in specific gravity for three (3) consecu-
following table. tive readings.
Battery Battery Charge Level

Reserve (Percent of Fully Charged)
Capacity
(Minutes) 75% 50% 25% 0%
80 or 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs
less @ @ @ @
3 amps 3 amps 3 amps 3 amps
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@ @ @ @
126 to 5.5 hrs 11 hrs 16.5 hrs 22 hrs
170 @ @ @ @
171 to 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
250 @ @ @ @
above 6 hrs 12 hrs 18 hrs 24 hrs
250 @ @ @ @

Chapter 6
Spray System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spray Control (Multi Pro 1200) . . . . . . . . . . . . . . . 26
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Flowmeter (Multi Pro 1200) . . . . . . . . . . . . . . . . . . 28
Precautions Concerning Chemicals Used in Master Boom Valve (Multi Pro 1200) . . . . . . . . . . 30
Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pressure Control Valve (Multi Pro 1200) . . . . . . . 32
Precautions for Removing or Adjusting Spray Boom Distribution Valves (Multi Pro 1200) . . . . . 34
System Components . . . . . . . . . . . . . . . . . . . . . . . 2 Spray Control Assembly (Multi Pro 1250) . . . . . . 36
SPRAY SYSTEM OPERATION . . . . . . . . . . . . . . . . . . 3 Flowmeter (Multi Pro 1250) . . . . . . . . . . . . . . . . . . 38
SPRAY SYSTEM FLOW DIAGRAMS . . . . . . . . . . . . 4 Regulating Valve Assembly (Multi Pro 1250) . . . 40
Multi Pro 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Boom Valve Manifold Assembly (Multi Pro 1250) 42
Multi Pro 1250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Regulating and Boom Valve Motor Service . . . . . 44
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Boom Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tank Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 10 Tank Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . 50
Suction Dampener . . . . . . . . . . . . . . . . . . . . . . . . . 10 Spray Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pressure Dampener . . . . . . . . . . . . . . . . . . . . . . . . 11 Turret Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Spray Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Turret Body Service . . . . . . . . . . . . . . . . . . . . . . . . 55
Spray Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 16 Spray Boom Hinge . . . . . . . . . . . . . . . . . . . . . . . . . 56
Agitation Control Valve . . . . . . . . . . . . . . . . . . . . . . 20 Boom Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Agitation Components (Tank Mounted) . . . . . . . . 22 Boom Actuator Service . . . . . . . . . . . . . . . . . . . . . . 60
Pressure Relief Valve (Tank Mounted) . . . . . . . . . 24
System
Spray
Multi Pro 1200/1250 Page 6 -- 1 Spray System

Specifications
Item Description
Spray Pump Diaphragm Pump, 18 GPM @ 220 PSI

(26 GPM @ 0 PSI)
Spray Pressure Relief Valve Poppet Style, 220 PSI Maximum
Sprayer Tank 175 Gallon, Polyethylene
Suction Strainer 50 Mesh, Stainless Steel, Tank Mounted

(30 Mesh and 80 Mesh Optional)
General Information
Precautions Concerning Chemicals Used in Spray System

Chemicals can injure persons, animals, plants, soil and 3. Keep spray material away from skin. If spray material
other property. To eliminate environmental damage and comes in contact with a person, wash it off immediately
personal injury: in accordance with manufacturer’s recommendations
(refer to container labels and Material Safety Data
1. Select the proper chemical for the job. Sheets).
2. Carefully read the directions printed on the chemical 4. Always wear protective clothing, chemical resistant
manufacturer’s labels before handling chemicals. In- gloves, eye protection and other personal protective
structions on chemical manufacturer’s container labels equipment as recommended by the chemical manufac-
regarding mixing proportions should be read and strictly turer.
followed.
5. Properly dispose of chemical containers, unused
chemicals and chemical solution.
Precautions for Removing or Adjusting Spray System Components

1. Stop the vehicle and set the parking brake. 4. Remove chemicals from pump, hoses and other
spray components. Thoroughly neutralize and rinse
2. Shut off the vehicle’s engine and remove the key spray system before loosening or removing any spray
from the ignition switch. system component(s).
3. Disengage all power and wait until all moving parts 5. Make sure system pressure is relieved before loos-
have stopped. ening any system component (e.g. spray valves, spray
system hose).
Spray System Page 6 -- 2 Multi Pro 1200/1250

Spray System Operation
The Multi Pro 1200 and 1250 spray systems use a posi- Multi Pro 1200 Spray Control
tive displacement diaphragm pump to move spray solu-
tion from the spray tank to the boom nozzles. The spray The spray control system on the Multi Pro 1200 consists
pump is self--priming and has a dry crankcase. The of a main on/off valve, a pressure control valve and three
pump is driven by the pump drive gearbox output shaft (3) manual boom control valves. An adjustable boom
at a speed that is proportional to the ground speed of the bypass valve exists in each of the boom control valves
vehicle. The pump is engaged with an electric clutch. to prevent system pressure changes when a boom sec-
tion is shut off. Flow in excess of control valve settings
The downward stroke of the pump’s connecting rods is directed back to the spray tank or used for tank agita-
and diaphragms create suction to allow fluid to be drawn tion.
from the spray tank to the pump through the suction
tube, suction strainer, hoses and connectors. A suction An inline flowmeter in the pressure side of the system di-
dampener placed in the suction line dampens suction rectly before the boom control valves measures flow to
pulses to smooth suction flow. Suction valves positioned the spray booms. The Spray Pro Monitor displays infor-
in the pump valve chamber prevent fluid from being mation regarding application rate based on input from
pumped back into the suction line when the connecting the flowmeter and the transaxle speed sensor.
rods change direction. Leaks in the suction line will
cause system problems and often will be indicated by er- NOTE: On the Multi Pro 1200, make sure that all boom
ratic suction line jumping and pump noise. valves are on when calibrating the Spray Pro Monitor.
The Multi Pro 1200 monitor cannot accurately display
Once to the pump, the fluid is pushed by the upward calibration volume when any of the boom valves are off.
stroke of the pump’s connecting rods and diaphragms
to the pressure side of the spray system through hoses, Multi Pro 1250 Spray Control
connectors, control valves and spray nozzles. A pres-
The spray system on the Multi Pro 1250 is controlled
sure dampener at the pump outlet smooths system
electrically and consists of a main control valve and
pressure pulsation. Pressure valves positioned in the
three (3) boom control valves. An adjustable boom by-
pump head prevent fluid from being drawn back into the
pass valve exists in each of the boom control valves to
pump. Maximum pressure in the system is limited by a
prevent system pressure changes when a boom section
pressure relief valve located in the tank. A pressure
is shut off. Flow in excess of control valve settings is di-
gauge indicates system pressure.
rected back to the spray tank or used for tank agitation.
Flow for tank agitation on both the Multi Pro 1200 and
An inline flowmeter in the pressure side of the system di-
1250 comes from flow that is bypassed by the pressure
rectly before the boom control valves measures flow to
control valve. A manual agitation control valve directs
the spray booms. The Spray Pro Monitor displays infor-
flow to ten (10) agitation nozzles in the spray tank.
mation regarding application rate based on input from
Battery current for spray system fuses, switches, relays the flowmeter and the transaxle speed sensor.
System
Spray
and other components is provided by the accessory so-
lenoid when the machine ignition switch is in the RUN
position. For spray system electrical component infor-
mation and test procedures, see Chapter 5 -- Electrical
System.

Spray System Flow Diagrams
RELIEF VALVE
PRESSURE
SPRAY
TANK
SUCTION
PRESSURE
AGITATION
Multi Pro 1200
BOOM SUPPLY Spray System Flow Diagram
FLOW DIRECTION

PRESSURE
DIAPHRAGM DAMPENER
PUMP
SUCTION
TOP MOUNTED
DAMPENER
SUCTION FILTER
Multi Pro 1200/1250

PRESSURE
GAUGE
BOOM
AGITATION BYPASS
CONTROL
VALVE
SPRAY BOOM
TANK VALVES
Page 6 -- 5
RH BOOM SUPPLY
PRESSURE
RELIEF CENTER BOOM SUPPLY
VALVE
LH BOOM SUPPLY
Multi Pro 1250

REGULATING
VALVE
Spray System Flow Diagram

FLOWMETER
Spray System
Spray
System

Special Tools
Spray Pump Alignment Fixture

The spray pump alignment fixture should be used to en-
sure that the spray pump mounting bracket is positioned
correctly to the machine frame to allow alignment be-
ALIGNMENT
tween the pump drive gearbox output shaft and spray
FIXTURE TUBE
pump input shaft. Proper alignment of the pump pre-
vents damage to the pump drive coupling assembly. In-
structions for alignment fixture are included with the tool.
ALIGNMENT
FIXTURE STOP
Figure 1
O--Ring Seal Kit

The O--Ring Seal Kit includes an assortment of O--rings
used for sealing Multi Pro 1200 spray control valves. It
is recommended that O--rings be replaced every two (2)
years or whenever a valve is loosened.
System
Spray
Figure 2

Troubleshooting

Spray system leaks fluid. Fitting(s), hose(s) or tube(s) are loose or damaged.
O--ring(s) or seal(s) are missing or damaged.

Fluid leaking from bottom of spray Faulty diaphragm(s) exist in spray pump.
pump.
Excessive suction hose vibration. Suction screen in tank is plugged.
Spray pump suction line has an air leak.
Suction tube in spray tank has air leak.
Suction line is restricted.
Suction dampener diaphragm is damaged.

Spray pressure is low. Suction line is restricted.
Suction screen in tank is plugged.
Spray nozzles are worn or damaged.
Pressure line or component is loose or leaking.
Engine speed is low.
Pressure relief valve in tank is not seating.
Pressure control valve is damaged or incorrectly adjusted (Multi

Pro 1200)
CVT drive belt is slipping (Ground speed also affected: see Drive
Train -- Chapter 7).
Spray pump is damaged.
Nozzles on one spray boom leak Diaphragm in turret body is leaking or damaged.
when boom is switched off.
Distribution valve for affected boom not seating (Multi Pro 1200).
Boom valve motor for affected boom not seating (Multi Pro 1250).
All spray boom nozzles leak when Master boom valve is not seating (Multi Pro 1200).
boom is turned off.
Regulating valve is not seating (Multi Pro 1250).
All distribution valves are not seating (Multi Pro 1200).
All boom valve motors are not seating (Multi Pro 1250).

Spray pump doesn’t rotate. Spray pump switch is off or faulty.
Foot switch is off or damaged (Multi Pro 1250).
Key on spray pump shaft is sheared.
Spray pump coupler is damaged.
Pump drive electric clutch is not engaged or is faulty (see Chapter

5 -- Electrical System).
Erratic spray operation from booms. Clogged strainer.
Suction dampener is damaged.
Pressure dampener is damaged.
Leak in suction line exists.
Boom bypass valve on distribution valve is damaged (Multi Pro

1200).
Master boom valve is damaged (Multi Pro 1200).
Console boom switch(es) is dirty, corroded or damaged (Multi Pro

1250).
Regulating valve is worn or sticking (Multi Pro 1250).
Boom valve motor seat is loose or damaged (Multi Pro 1250).
Boom valve motor actuating cam is worn or sticking (Multi Pro

1250).
No spray output from one spray Hoses on boom are pinched or kinked.
boom.
Distribution valve for affected boom is not open (Multi Pro 1200).
Boom valve motor for affected boom is not opening (Multi Pro
1250).
Console boom switch is dirty, corroded or damaged (Multi Pro
System
Spray
1250).
Check for 12 volts at affected boom valve motor (Multi Pro 1250).
Low spray rate from one nozzle. Spray nozzle(s) are clogged or damaged.
Spray nozzles are different sizes.
Distribution valve for affected boom is not seating (Multi Pro 1200).
Boom valve motor for affected boom is not seating (Multi Pro
1250).

Service and Repairs
Suction Dampener
The suction dampener is mounted to the suction line at
the spray pump (Fig. 3) and is used to dampen suction
pulses and smooth suction flow. During pump operation,
the suction dampener diaphragm will move.
2
IMPORTANT: Make sure to neutralize and remove
chemicals from pump and hoses before loosening
and removing spray system components. Wear pro-
tective clothing, chemical resistant gloves, and eye
protection during repair.
A damaged suction dampener diaphragm will allow a

3 1
suction leak and will cause improper pump operation. If
the diaphragm is damaged, remove diaphragm from
dampener housing and replace it (Fig. 4).
Figure 3
1. Spray pump 3. Suction hose
2. Suction dampener
RTV Silicone Thread

Sealent Sealant
2
3
Thread
NOTE: ARROWS SHOW FLUID Sealant
FLOW DIRECTION
Figure 4
1. Spray pump 3. Dampener housing
2. O--ring 4. Diaphragm

Pressure Dampener
The pressure dampener is mounted to the pressure line
at the spray pump (Fig. 5) and is used to smooth system 3
2
pressure pulsation. Adjust air pressure on the pressure
dampener to approximately 1/3 of the spraying pressure
(e.g. if the spraying pressure is 45 PSI (3.1 bar), the
dampener pressure should be 15 PSI (1 bar)). If fluid is
present when pressure in the dampener is checked, the
diaphragm in the pressure dampener is damaged and
should be replaced.
Dampener Service (Fig. 6)

1
protection during repair. Figure 5
1. Spray pump 3. Pressure hose (1”)
1. Loosen and remove cap screws and nuts that secure 2. Pressure dampener
diaphragm between housings.
2. Remove diaphragm from dampener. RTV Silicone

Sealent Thread
Sealant
3. Replace diaphragm and reassemble dampener.
6 3
7 1
2
4
8
5
System
Spray
NOTE: ARROWS SHOW FLUID Thread
FLOW DIRECTION Sealant
Figure 6
1. Spray pump 5. Diaphragm
2. O--ring 6. Front housing
3. Hex nut (12 used) 7. Cap screw (12 used)
4. Rear housing 8. Air valve

Spray Pump
1
175 to 225 in--lb
Antiseize (20 to 25 N--m)
Lubricant Loctite #242
26 Loctite #242
26 27 28
27 to 30 ft--lb
29 (37 to 40 N--m)
Antiseize
Lubricant
25
19
5 10
4
24 10
3 21
23 5
7
22 2 13
12 14
11
6
8 15
6
2 11 12
RIGHT
9
175 to 225 in--lb 20
FRONT (20 to 25 N--m) 17
16
7 18
Figure 7
1. Spray pump 11. Spacer (4 used) 21. Cap screw
2. Lock nut (6 used) 12. Cap screw (4 used) 22. Pump hub
3. Key 13. Lock washer 23. Flange head screw (4 used)
4. Cap screw (4 used) 14. Clutch retainer 24. Flange head screw (4 used)
5. Coupling spacer (4 used) 15. Electric clutch 25. Pump mount bracket
6. Rubber coupling (4 used) 16. Spacer (2 used) 26. Flange nut (8 used)
7. Lock nut (4 used) 17. Clutch adapter 27. Flange head screw
8. Drive coupler 18. Spacer 28. Pump guard
9. Cap screw (2 used) 19. Set screw (2 used) 29. Flange nut
10. Flat washer (4 used) 20. Pump drive gearbox shaft

Removal (Fig. 7)
2 1
protection during repair.

switch.
2. Loosen hose clamps that secure suction and pres-

sure hoses to hose barbs on pump fittings. Pull suction
and pressure hoses from hose barbs.
3. Remove lock nuts, flat washers, cap screws and Figure 8

coupling spacers that secure rubber couplings to pump 1. Elbow (pressure) 2. Suction hose
hub (item 22).
4. Remove flange head screws and flange nuts that se- RTV Silicone
cure pump to pump mount bracket. Sealent Thread
Sealant
5. Remove spray pump from machine. 8 7
6
5 4 3
6. Loosen set screws in pump hub. Pull hub from pump 2
shaft. Locate and remove key from pump shaft.
9
7. For assembly purposes, matchmark fittings at pump
inlet and outlet to make sure that the fittings will be prop- 1
10
erly aligned during pump installation. Also, matchmark 11
position of tee fitting (pressure) (item 4 in Fig. 9) at elbow
(pressure). 13
12
8. Remove pressure dampener, tee fitting (pressure)
and elbow (pressure) from pump outlet (Fig. 9). Discard
14
removed gasket. 15
16
9. Remove suction dampener and tee fitting (suction)
from pump inlet (Fig. 9). Discard removed O--ring and 19
seal.
System
18
Spray
17 Thread
Installation (Fig. 7) Sealant
NOTE: Coat all O--rings with vegetable oil before instal- Figure 9
lation to reduce the chance of damage during assembly. 1. Spray pump 11. O--ring
2. Elbow (pressure) 12. Seal
3. O--ring 13. Hosebarb
1. Apply thread sealant to threads of elbow (pressure) 4. Tee fitting (pressure) 14. Suction hose
and install elbow into pump outlet (Fig. 9). Use match- 5. Gasket 15. Hose clamp
mark made during pump removal to properly orientate 6. Hosebarb 16. Nut
7. Nut 17. Suction dampener
elbow. 8. Hose clamp 18. O--ring
9. Pressure hose 19. Tee fitting (suction)
2. Apply RTV silicone sealant to threads of tee fitting 10. Pressure dampener
(pressure) that will thread into elbow (pressure) and
install fitting into elbow (Fig. 9). Use matchmark made
during pump removal to properly orientate tee fitting.
Install pressure dampener (with new O--ring) and hose-
barb (with new gasket) to tee fitting.

3. Apply thread sealant to threads of tee fitting (suction)
and install fitting into pump inlet (Fig. 9). Use matchmark 2
made during pump removal to properly orientate tee fit-
ting. Install suction dampener (with new O--ring) and ho-
sebarb (with new seal) to tee fitting.
IMPORTANT: If pump drive coupler components

were disassembled, make sure that pump hub
flanges and drive coupler are installed at right
angles (90 degrees) to each other (Fig. 10). 1
4. Remove set screws from pump hub. Clean threads

of set screws and hub.
5. Apply antiseize lubricant to pump shaft. Install key in

shaft and slide pump hub onto shaft.
6. Position pump on pump mounting bracket. Install Figure 10

flange head screws and flange nuts to pump and mount- 1. Drive coupler 2. Pump hub
ing bracket. Leave fasteners loose.
7. Place coupling spacers into rubber coupling. Install

cap screws, flat washers and lock nuts to secure rubber
couplings to pump hub. Make sure that cap screw
threads extend fully through lock nut.
IMPORTANT: Before securing spray pump to

mounting bracket, make sure that the pump shaft,
coupler assembly and electric clutch are properly
aligned. There should not be distortion of the rubber
couplings. Failure to properly align the pump may
result in coupler failure. The spray pump alignment
fixture (see Special Tools in this chapter) can be
used to properly locate pump mounting bracket to
machine frame and ensure coupler alignment.
8. Position pump on mounting bracket so that rubber

couplings are not distorted. Secure pump to mounting
bracket by tightening flange head screws and flange
nuts.
9. Apply Loctite #242 (or equivalent) to threads of pump

hub set screws. Install set screws into pump hub to se-
cure hub to pump shaft.
10.Install pressure and suction hoses to correct barb fit-

tings. Secure hoses with hose clamps.

System
Spray

Spray Pump Service
26 60 ft--lb
1
(81 N--m)
2
27 29
3
55 ft--lb
2 30 (75 N--m)
9 4
16
5 3
60 ft--lb
(81 N--m)
6
25
7 28
8
7 5
18
6
8
24
9
32 ft--lb
(43 N--m) 11
10 13
14 12 12 14
13 20
21
23
15
22
10 21
20
18
19 25 ft--lb
(34 N--m)
17
32 ft--lb
(43 N--m)
Figure 11
1. Valve chamber 11. Hex bolt (M8) 21. Ball bearing (connecting rod)
2. Valve (inlet position) 12. Ball bearing (crankshaft) 22. Grease fitting
3. O--ring 13. Dust plate 23. Crankshaft
4. Diaphragm cover 14. Pump casing 24. Hex nut (5 used)
5. Hex bolt 15. Hex bolt (30 mm long) (3 used) 25. Hex bolt
6. Washer 16. Hex bolt (M12) (4 used per cover) 26. Hex bolt (2 used)
7. Diaphragm 17. Hex bolt (55 mm long) (2 used) 27. Poly O--ring
8. Diaphragm back disc 18. Felt seal 28. Lock washer
9. Nylon washer 19. Hex nut (M8) 29. Valve (outlet position)
10. Lock washer 20. Connecting rod

Disassembly (Fig. 11) IMPORTANT: If connecting rod position is incor-
rect, pump will not operate properly.
IMPORTANT: Make sure to remove and neutralize
chemicals from pump before disassembly. Wear E. Slide crankshaft assembly into pump casing. The
protective clothing, chemical resistant gloves and rear connecting rod should be positioned to the left
eye protection during pump repair. side and the connecting rod closest to you to the right
side (Fig. 12).
1. Remove two (2) hex bolts that retain valve chamber
to pump. Separate valve chamber from pump. 2. Place second pump casing onto assembly. Pump
casing surfaces should mate together.
2. Remove inlet and outlet valves and O--rings from
each diaphragm cover. Note orientation of valves. Dis- 3. Install three (3) shorter (30 mm) and two (2) longer
card valves and O--rings. Clean valve and O--ring seats (55 mm) bolts into pump casing assembly (Fig. 13).
in the valve chambers and diaphragm covers. Thread hex nuts onto bolts but do not fully tighten.
Check that crankshaft turns freely.
3. Remove hex bolts that secure diaphragm covers to
pump. Remove diaphragm covers.
4. Remove hex bolt, washer, nylon washer, diaphragm

and diaphragm back disc from each connecting rod.
Discard diaphragms.
5. Remove five (5) hex bolts and nuts that secure pump
casing halves together. Note location of two (2) longer
hex bolts. Carefully separate pump casing halves. 2
1
6. Clean grease from bottom of housing and check con-
dition of bearings on crankshaft. If bearings require re-
placement, remove and disassemble crankshaft:
A. Remove crankshaft assembly from pump casing.
B. Slide felt seal and dust plate from both ends of Figure 12
crankshaft. 1. Closest connecting rod (to right side)
2. Rear connecting rod (to left side)
C. Loosen bolt and hex nut that secure connecting
rods to crankshaft. Slide connecting rods from crank-
shaft.
1
D. Press ball bearings from crankshaft.
System
Spray
Assembly (Fig. 11)
1. If crankshaft was disassembled, reassemble crank-

shaft: 1
A. Hand pack new bearings with #2 general purpose

lithium base grease. 1
B. Pressing on bearing inner race, install two con- 2

necting rod and two crankshaft ball bearings onto 2
crankshaft.
Figure 13
C. Slide connecting rods onto rod bearings. Offsets
of the connecting rods should face each other. Install 1. Hex bolt (30 mm long) 2. Hex bolt (55 mm long)
hex bolt, flat washers and hex nut to connecting rod.
Torque hex nuts to 25 ft--lb (34 N--m) to secure con-
necting rod to crankshaft.
D. Position dust plate and felt seal on both ends of

crankshaft.

4. Place diaphragm back disc and new diaphragm onto
each connecting rod. The connecting rods should ex-
tend above the diaphragms when correctly installed
(Fig. 14). Position nylon washer and washer on each
connecting rod and then thread hex bolt into connecting
rod. Torque bolt to 60 ft--lb (81 N--m). 2
1
5. Make sure that pump casings align and then secure
pump casing assembly by torquing five (5) bolts to 32 ft--
lb (43 N--m).
6. Secure diaphragm covers to pump with hex bolts (4

per cover). Torque bolts to 55 ft--lb (75 N--m).
7. Place new O--rings and valves into diaphragm cover

openings (Fig. 15). Inlet valves should be installed with
the spring down into the cover. Outlet valves should be Figure 14
installed in with the spring up and away from cover. 1. Diaphragm 2. Connecting rod
8. Place valve chamber over valves noting orientation

of chamber inlet and outlet. Secure valve chamber with
two (2) hex bolts. Torque bolts 60 ft--lb (81 N--m).
1
2 2
Figure 15
1. Inlet (suction) 3. Outlet valve
2. Inlet valve

System
Spray

Agitation Control Valve
13 8 22 NOTE: ARROWS SHOW FLUID

23 9 FLOW DIRECTION
7 2 3
11 10 4 12
3 21
6
1 2
24 5
4 14
2
19
2
15 17
18 16
3
RTV Silicone
Sealent
Thread
Sealent
FRONT
20
RIGHT 14
Thread
Sealent
Figure 16
1. Agitation control valve 9. Hose: control bypass (1”) 17. Tee bracket
2. O--ring 10. Hosebarb 18. Screw (4 used)
3. Fork 11. Hose clamp 19. Connector
4. Hose clamp 12. Hose: tank suction (1 1/2”) 20. Spray pump
5. Hosebarb 13. Hosebarb 21. Spray tank
6. Hose: agitation supply (1”) 14. Suction hose (1 1/2”) 22. Hose clamp
7. Hosebarb 15. Tee 23. O--ring
8. Nut 16. Flange head screw (2 used) 24. Agitation reducer

Removal (Fig. 16)
3
IMPORTANT: Make sure to remove and neutralize 3
chemicals from spray components before disas-
sembly. Wear protective clothing, chemical resist-
ant gloves and eye protection during repair.

switch.
2. Label hoses to allow proper installation after repairs

are completed. Loosen hose clamps and remove hoses 2
from hosebarbs that are to be disassembled. 1
3. Remove agitation control valve using Figures 16 and

17 as guides. If agitation reducer (item 24) is removed, Figure 17
note direction of chamfer on reducer for assembly pur- 1. Agitation control valve 3. Fork
poses. 2. Agitation supply hose
4. Disassemble agitation valve as required (Fig 18).

9
10
Installation (Fig. 16) 11
7
8 4
NOTE: Coat all O--rings with vegetable oil before instal- 12
lation to reduce the chance of damage during assembly. 3
13
1. Assemble agitation control valve (Fig 18). Align ar-
row on valve handle with large hole in valve ball during 14
assembly (Fig. 19). 3 6
2 5
2. Install agitation valve using Figures 16 and 17 as 7 2
guides. 16
1
3. Using labels placed during disassembly, install 15
hoses to hosebarbs and secure with hose clamps. 4
4. Check spray system for leaks. Repair all leaks be- 5

fore returning the sprayer to service. Figure 18
1. Valve housing 9. Screw
System
Spray
2. Ball seat 10. Button
3. O--ring 11. Valve handle
4. O--ring 12. Disc
5. Washer (8 used) 13. O--ring
6. Cap screw (4 used) 14. Spindle
7. End cover 15. Valve ball
8. Screw (4 used) 16. Lock nut (4 used)
Figure 19
1. Valve handle arrow 2. Valve ball large hole

Agitation Components (Tank mounted)
4 4
7 16
13 7
13
11
6 4
16
13
15
7 7 13
3 11
4 8
7 10 14
8 9
13 15
9 9
16 10
13 3 5
11 4 4
15
6 10
16
15 14 13 16
16 7 17 3
3 2
12 8
9 10
16
5
8 4
2
17
2
FRONT 1
12 17
RIGHT 12
12
2
17
Figure 20
1. Spray Tank 7. Agitation nozzle 13. Elbow
2. Bulkhead nut 8. Bulkhead gasket 14. Tee
3. O--ring 9. Fork 15. Adapter
4. Nut 10. Bulkhead fitting 16. Nipple
5. Agitation nozzle 11. Nipple 17. O--ring
6. Cross 12. Hosebarb

IMPORTANT: Make sure to remove and neutralize NOTE: Coat all O--rings with vegetable oil before instal-
chemicals from tank and other components before lation to reduce the chance of damage during assembly.
disassembly. Wear protective clothing, chemical re-
sistant gloves and eye protection during repair. 1. Install agitation components using Figure 20 as a
guide. Replace all removed O--rings and gaskets.
gage parking brake and remove key from the ignition 2. Using labels placed during disassembly, install
switch. hoses to hosebarbs and secure with hose clamps.
2. Drain spray tank (see Operator’s Manual). 3. Check spray system for leaks. Repair all leaks be-
fore returning the sprayer to service.
are completed. Loosen hose clamps and remove hoses
from all hosebarbs that are to be disassembled.
4. Remove agitation components as required using

Figure 20 as a guide. Discard all removed O--rings and
gaskets.
System
Spray

Pressure Relief Valve (Tank Mounted)
9 8 6
7 5
3 FRONT
4
RIGHT
11
22
11 21
2
10 17
20
12 15
19
13
18
14
10 15 16 10
12 17
13
NOTE: ARROWS SHOW FLUID
FLOW DIRECTION
Figure 21
1. Spray tank 9. Hosebarb 16. Hosebarb
2. Spray pump 10. Hose clamp 17. Pressure supply hose (1”)
3. Ring nut 11. Hose: pressure relief valve (1”) 18. Suction hose (1 1/2”)
4. Hose clamp 12. Hosebarb 19. Flange head screw (2 used)
5. Relief valve assembly 13. Fork 20. Tee bracket
6. Gasket 14. Hose: control supply (1”) 21. Phillips head screw (4 used)
7. Ringnut 15. O--ring 22. Coupler (MP 1200)
8. O--ring

Removal (Fig. 21)

chemicals from tank and other components before
sistant gloves and eye protection during repair.
1 2
switch.
2. Drain spray tank (see Operator’s Manual).

3
from hosebarbs that are to be disassembled. Figure 22
1. Hose to pressure relief 3. Control supply hose
4. Remove pressure relief valve from spray tank using 2. Hose from spray pump
Figures 21 and 22 as guides. Discard all removed O--
rings and gaskets.
1
5. Disassemble relief valve using Fig. 23 as a guide. 2
Assembly (Fig. 21) 3

5
1. Assemble relief valve using Fig. 23 as a guide. 4
NOTE: Coat all O--rings with vegetable oil before instal-

lation to reduce the chance of damage during assembly.
2. Install pressure relief valve using Figures 21 and 22

as guides. Replace all removed O--rings and gaskets.
3. Using labels placed during disassembly, install

hoses to hosebarbs and secure with hose clamps. Figure 23
1. Housing 4. Relief valve seat
4. Check spray system for leaks. Repair all leaks be- 2. Relief valve cone 5. Nut
fore returning the sprayer to service. 3. Spring
System
Spray

Spray Control (Multi Pro 1200)
2 1
4
10
3 5 14
3
4
15
11
4
7
8 9
8
12 2
4
FRONT
3
RIGHT
6
13
Figure 24
1. Boom distribution valves 6. Flange head screw 11. Valve mount
2. Screw 7. Flowmeter 12. Pressure control valve
3. Hex nut 8. Flange nut 13. Pressure control valve bracket
4. Washer 9. Hex bolt 14. Pressure hose
5. Bracket 10. Master boom valve 15. Hose clamp

Removal (Fig. 24)
3

switch.
2. Remove master boom valve handle, spray console

panel and spray console from machine (Fig. 25).
1
from hosebarbs that are to be disassembled.
Figure 25
4. Remove spray control components as required us-
1. Boom valve handle 3. Spray console
ing Figures 24 and 26 as guides. 2. Spray console panel
Assembly (Fig. 24)
1. Install spray control components using Figures 24 3

and 26 as guides. 4
2
hoses to hosebarbs and secure with hose clamps.
3. Operate spray system and check for leaks. Repair all

leaks before returning the sprayer to service.
4. Install spray console, spray control panel and master 1

boom valve handle to machine (Fig. 25).
System
Spray
FRONT
Figure 26
1. Flowmeter 3. Master boom valve
2. Pressure control valve 4. Boom distribution valves

Flowmeter (Multi Pro 1200)
10
3
11
4
8
5
7
UP

FLOW DIRECTION
Figure 27
1. Flow sensor with nut 5. Flowmeter housing 9. Hose: from master boom valve (1”)
2. Flowmeter rotor shaft 6. O--ring 10. O--ring
3. Flowmeter rotor 7. Hosebarb 11. Hose: to distribution valves (1”)
4. Fork 8. Hose clamp

Removal and Inspection (Fig. 27)
3

switch.
2. Remove master boom valve handle, spray control 1

panel and spray console from machine (Fig. 28). 2
3. Loosen and remove nut that secures flow sensor to
housing (Fig. 29). Carefully remove flow sensor from Figure 28
flowmeter housing. 1. Boom valve handle 3. Spray console
2. Spray console panel
4. Clean rotor, rotor shaft and flowmeter sensor if re-
quired (see Operator’s Manual).
5. With the flow sensor harness connected to the ma-

chine and the ignition key in the ON position, slowly spin
the flowmeter rotor. The LED on the flowmeter should il-
luminate as a rotor magnet passes the flow sensor and
should go out as the next rotor magnet passes the sen-
sor.
2
NOTE: When using a magnet to check the flowmeter, 1
make sure to alternately use both north and south poles
of the magnet.
6. If the flowmeter LED does not flash, remove rotor

and rotor shaft from sensor. With the flowmeter harness
connected to the machine and the ignition key in the ON
position, slowly pass alternate poles of a magnet past
the flow sensor. If the flowmeter LED flashes as the
magnet poles pass the sensor, replace the rotor and ro- FRONT
tor shaft. If the flowmeter LED does not flash as the mag-
net poles pass the sensor, replace the flow sensor. Figure 29
System
Spray
1. Flowmeter assembly 2. Hose to boom valves
7. If necessary, remove flowmeter housing using Fig-
ures 27 and 29 as guides (also see Spray Control (Multi
Pro 1200) in this section). Discard all removed O--rings
and gaskets. 3 1
Assembly (Fig. 27)
NOTE: Coat all O--rings with vegetable oil before instal- 2

lation to reduce the chance of damage during assembly. 3
NOTE: When installing flow sensor into housing, make

sure to align locating pin on sensor with hole in housing.
1. Assemble flowmeter using Figures 27 and 29 as

guides. Replace all removed O--rings and gaskets.
2. Operate spray system and check for leaks. Repair all

leaks before returning the sprayer to service. Figure 30
1. Rotor shaft 3. Rotor magnet
3. Install spray console, spray control panel and master 2. Rotor
boom valve handle to machine (Fig. 28).
Master Boom Valve (Multi Pro 1200)
31
32
33
9 30
29
28
27
1
2 26
3
25 16
4
24
15
23
5
14
20
11 7
6 22
7 21 10
20
19
8
18
12 17
16
15
14
7
RIGHT
FRONT 13

FLOW DIRECTION
Figure 31
1. Housing 12. Screw (4 used) 23. O--ring
2. Ball 13. Hose: pressure supply (1”) 24. Seat
3. Seat 14. Nut 25. Valve assembly
4. O--ring 15. Hose barb 26. Pressure valve housing
5. Hosebarb 16. Seal 27. Pin
6. Nut 17. Retaining ring 28. O--ring
7. Hose clamp 18. O--ring 29. Fitting
8. Hose: to flowmeter (1”) 19. Adapter 30. Nut
9. Handle 20. O--ring 31. Screw (4 used)
10. Hose: control bypass (1”) 21. Stem 32. Hex nut
11. Plate 22. Roll pin 33. Washer

Disassembly (Fig. 31)

chemicals from spray components before disas- 1
1. Remove master boom valve from machine (see

Spray Control (Multi Pro 1200) in this section).
2. Disassemble master boom valve using Figure 31 as

a guide. Discard all removed O--rings.
Assembly (Fig. 31)

1. Assemble master boom valve using Figure 31 as a

guide. Replace all removed O--rings.
2. Install master boom valve to machine (see Spray

Control (Multi Pro 1200) in this section). FRONT
Figure 32
1. Master boom valve
System
Spray

Pressure Control Valve (Multi Pro 1200)
8
1
7
17
2
6
16
3
4
5
3 3
5
15 6
7
14
13 8
9
12
10
9
11

FLOW DIRECTION
Figure 33
1. Pressure control valve 7. Washer 13. Hosebarb
2. O--ring 8. Hex nut 14. Seal
3. O--ring 9. Hose clamp 15. Pressure control housing
4. Tee piece 10. Hose: pressure supply (1”) 16. Threaded rod
5. Cap 11. Hose: control bypass (1”) 17. Bushing
6. O--ring 12. Nut

1
1. Remove pressure control valve from machine (see

Spray Control (Multi Pro 1200) in this section).
2. Disassemble pressure control valve using Figure 33

as a guide. Discard all removed O--rings.
Assembly (Fig. 33)

1. Assemble pressure control valve using Figure 33 as

a guide. Replace all removed O--rings.
2. Install pressure control valve to machine (see Spray

Control (Multi Pro 1200) in this section).
FRONT
Figure 34
1. Pressure control valve
System
Spray

Boom Distribution Valves (Multi Pro 1200)

FLOW DIRECTION
6
7
4
1
4 5
1
4 3
25
3 14
12
15
3 9
2 11
9
8
3 17
9
18
8
8
9 19
10
17
11 9
18 20
12
13
19 21
14
24
20
6 21 23
15 FRONT
16 22
RIGHT
Figure 35
1. Distribution valve (center/LH boom) 10. Tee fitting 18. Seal
2. Distribution valve (RH boom) 11. Cover 19. Hosebarb
3. O--ring 12. Washer 20. Nut
4. Fork 13. Threaded rod 21. Hose clamp
5. Elbow 14. Hex nut 22. Hose: RH boom (3/4”)
6. Hose clamp 15. O--ring 23. Hose: Center boom (3/4”)
7. Hose: boom bypass (1”) 16. Hose: from flowmeter (1”) 24. Hose: LH boom (3/4”)
8. Fork 17. Housing 25. Bushing
9. O--ring
IMPORTANT: Make sure to remove and neutralize Disassembly (Fig. 35)

sembly. Wear protective clothing, chemical resist- 1. Remove boom distribution valve assembly (see
ant gloves and eye protection during repair. Spray Control (Multi Pro 1200) in this section).

2. Separate boom distribution valves:
1
A. Remove forks (item 4) that secure distribution
valves together.
2
B. Remove hex nut from one end of threaded rod.
C. Pull threaded rod from assembly and separate

components.
3. Remove fork (item 8) to separate individual distribu-

tion valves from housings.
3
4. Remove and discard O--rings and seals.
Distribution Valve Service (Figs. 37 and 38)
1. Remove cap screw and washer to allow seat assem-

blies to be removed from shaft. Each seat assembly in-
cludes two (2) O--rings.
2. The seat assemblies allow the spindle to shut off flow FRONT
to the spray boom. If boom nozzles leak when the boom
is shut off, the seat and seat O--rings should be in- Figure 36
spected carefully. The seats should be free of nicks or 1. Boom distribution valves 3. Boom bypass hose
worn spots. 2. Boom bypass valve
3. Press pin from handle to remove handle from shaft.

1 5
4. Take note of washer, spring, retaining ring (not pic-
tured) and O--ring locations as shaft is removed from
housing.
5. Assemble valve in reverse order of disassembly. Ap-

ply Loctite #243 (or equivalent) to threads of cap screw 2
and torque cap screw to 45 in--lb (5 N--m). 3
4
Assembly (Fig. 35)
Figure 37
NOTE: Coat all O--rings with vegetable oil before instal- 1. Distribution valve 4. Handle
lation to reduce the chance of damage during assembly. 2. Bypass valve 5. Pin
System
Spray
3. O--ring
1. Replace O--rings and seals that were removed dur-
ing disassembly.
4
2. Secure distribution valves to housings with fork (item
8).
3
3. Position distribution valves, tee fitting, O--rings and
covers together. Slide threaded rod with O--rings, bush-
ing and washers through distribution valves and secure
with hex nuts.
4. Install forks (item 4) to secure distribution valves to-

gether.
45 in--lb
5. Install boom distribution valve assembly to machine (5 N--m) 1 2
(see Spray Control (Multi Pro 1200) in this section).
Figure 38
1. Cap screw and washer 3. Seat components
2. Seat assembly (2 used) 4. Retaining ring location

Spray Control Assembly (Multi Pro 1250)
11
16
LEFT 13
15
FRONT 13
23 19
16 17
22 17
18
8
7
12
17
4 6
1 20
14
10
9 5
21

FLOW DIRECTION
Figure 39
1. Boom bypass hose 9. LH boom supply hose 17. Hose clamp
2. RH boom mount 10. RH boom supply hose 18. Tee controls hose
3. LH boom mount 11. Regulating valve assembly 19. Boom valve manifold assembly
4. Cap screw (4 used) 12. Valve mount 20. Flat washer (8 used)
5. Flange nut (4 used) 13. Worm clamp (2 used) 21. Center boom supply hose
6. Hose clamp (3 used) 14. Flange head screw (8 used) 22. Coupler
7. Agitation bypass hose 15. Flowmeter assembly 23. Pressure gauge tube
8. Flange nut (8 used) 16. Gasket (2 used)
IMPORTANT: The regulating valve and all boom

valve motors each have a 5 amp fuse for circuit
protection. Make sure that the correct fuse is
installed in the in--line fuse holder located near the
spray control motors.

IMPORTANT: Make sure to remove and neutralize 4. Install pressure gauge tube to coupler on pressure
chemicals from spray components before disas- gauge port on right side of boom valve manifold assem-
sembly. Wear protective clothing, chemical resist- bly (Fig. 40).
5. Using labels placed during disassembly, secure wire
Removal (Fig. 39) harness connectors to regulating valve, flowmeter and
three (3) boom valve motors.
gage parking brake and remove key from the ignition 6. Operate spray system and check for leaks. Repair all
switch. leaks before returning the sprayer to service.
2. Label all spray control assembly hoses for proper

installation after repairs are completed. Loosen hose
clamps and disconnect hoses from spray control. 3 2 1
3. Label all wire harness leads for assembly purposes.

Disconnect wire harness connectors from regulating
valve, flowmeter and three (3) boom valve motors.
4. Remove pressure gauge tube from coupler on pres-

sure gauge port on right side of boom valve manifold as-
sembly (Fig. 40).
4
5. Support spray control assembly to prevent it from fal-
ling.
6. Remove eight (8) flange head screws, flat washers

and flange nuts that secure spray control assembly to
valve mount. Remove spray control assembly from ma-
chine.
Figure 40
IMPORTANT: Before removing flowmeter from 1. Boom valve manifold 3. Regulating valve
2. Flowmeter 4. Pressure gauge port
spray control assembly, note direction of arrow on
top of flowmeter (Fig. 41). The arrow should point to-
ward boom valve manifold assembly. NOTE ARROW
DIRECTION
7. Separate spray control assembly as required using
Figure 39 as a guide. Discard all removed gaskets. TO BOOM
VALVE
Installation (Fig. 39) MANIFOLD
System
Spray
NOTE: Coat gaskets with vegetable oil before installa-
tion to reduce the chance of damage during assembly.
1. Assemble spray control using Figure 39 as a guide.

Replace all removed gaskets. Make sure that arrow on
flowmeter body points toward boom valve manifold as-
sembly (Fig. 41).
FROM
2. Position spray control assembly to valve mounting REGULATING
bar and secure with eight (8) flange head screws, flat VALVE
washers and flange nuts.
Figure 41
hoses to correct locations on spray control assembly.
Secure hoses with hose clamps.

Flowmeter (Multi Pro 1250)
Note Arrow
Direction Notch
7
Notch
8
6 Thread
Sealent
Figure 42
1. Flowmeter body 4. Downstream hub 7. Sensor assembly
2. Rotor/magnet assembly 5. Retaining ring (2 used) 8. Cable clamp
3. Upstream hub with bearing 6. Turbine stud with bearing 9. Screw

3 2 1
1. Remove spray control assembly from machine and

separate flowmeter from spray control (see Spray Con-
trol Assembly (Multi Pro 1250) Removal in this section).
2. Disassemble flowmeter as required using Figures 42

and 44 as guides.
3. Clean rotor (item 2), both hubs (items 3 and 4) and

flowmeter body to remove any metal filings, spray
chemicals or other materials.
Figure 43
Assembly (Fig. 42)
1. Boom valve manifold 3. Regulating valve
2. Flowmeter
1. Assemble flowmeter using Figures 42 and 44 as
guides. Check the following items during flowmeter as-
sembly.
6
A. If turbine stud was removed from upstream hub,
apply thread sealant to threads of stud before instal- 1
lation.
B. Check that rotor spins freely with very little drag. If

necessary, loosen the turbine stud 1/16 of a turn and 2 5 3 2
check rotor drag. Continue the process of loosening
stud until rotor spins freely.
C. When installing hubs (items 3 and 4) into hous-

ing, make sure to align locating notch on each hub
with boss in housing bore. 4
D. If sensor (item 7) was removed from flowmeter
Figure 44
body, thread sensor into housing so it lightly bottoms
1. Flowmeter body 4. Rotor
in housing. Secure sensor in position by tightening 2. Retaining ring 5. Downstream hub
jam nut.
System
3. Upstream hub 6. Sensor
Spray
E. Make sure that retaining rings are fully seated in
grooves of flowmeter housing.
2. Attach flowmeter assembly to spray control and then

install spray control assembly to machine (see Spray
Control Assembly (Multi Pro 1250) Installation in this
section).

Regulating Valve Assembly (Multi Pro 1250)

FLOW DIRECTION 10
7
1
3
12
4
11
7
10
9
5
12
6 8
13
2
9
14 11
Figure 45
1. Regulating valve motor 6. Elbow fitting (supply) 11. Lock nut (4 used)
2. Hose barb (agitation supply) 7. Mounting bracket (2 used) 12. O--ring (2 used)
3. Flange 8. Fork 13. O--ring
4. Adaptor 9. Washer (4 used) 14. O--ring
5. Flynut 10. Cap screw (4 used)
The regulating valve allows the operator to vary the NOTE: The regulating valve affects flow to all spray
spray application rate. The pressure increase/decrease booms so a problem with the regulating valve will affect
switch on the spray console energizes the regulating all booms and nozzles.
valve motor which adjusts the valve opening and allows
some flow to bypass the spray booms.

3 2 1

separate regulating valve assembly from spray control
(see Spray Control Assembly (Multi Pro 1250) Removal
in this section).
2. Disassemble regulating valve assembly as needed

using Figure 45 as a guide. Discard all removed O--rings
and gaskets.
3. See Boom and Agitation Valve Motor Service in this

section for disassembly and assembly information of the
agitation valve motor. Figure 46
1. Boom valve manifold 3. Regulating valve
2. Flowmeter
Assembly (Fig. 45)

1. Assemble regulating valve assembly using Figure

45 as a guide.
2. Attach regulating valve assembly to spray control

and then install spray control assembly to machine (see
Spray Control Assembly (Multi Pro 1250) Installation in
this section).
System
Spray

Boom Valve Manifold Assembly (Multi Pro 1250)

FLOW DIRECTION 3
1 17
7
1
9
1
12
16
12 10 13
12 5
7
11
12 6
14
13 8
18
2 11
16 15
4 18
19
Figure 47
1. Boom valve motor (3 used) 8. Balancing valve assembly 14. O--ring (3 used)
2. Hose barb (boom supply) (3 used) 9. Flange 15. Balancing valve assembly (2 used)
3. Pressure gauge port 10. Fork (3 used) 16. Washer (4 used)
4. Flange 11. Fork (6 used) 17. Cap screw (4 used)
5. Flynut 12. O--ring (4 used) 18. Lock nut (4 used)
6. Elbow fitting (boom bypass) 13. O--ring (4 used) 19. Cap
7. Mounting bracket (2 used)
The Multi Pro 1250 uses three (3) boom valve motor as- The boom control switches on the operator spray con-
semblies to control the spray booms. Each boom valve sole are used to energize the boom valve motors and
motor assembly includes a motor section and a balanc- open the boom valves. The open boom valves allow sys-
ing valve assembly. tem flow to reach the appropriate boom section (right,
center or left).

4
1 2 5

separate boom valve manifold assembly from spray
control (see Spray Control Assembly (Multi Pro 1250)
Removal in this section).
2. Disassemble boom valve manifold assembly as

needed using Figure 47 as a guide. Discard all removed
O--rings and gaskets.
3. See Boom and Agitation Valve Motor Service in this

section for disassembly and assembly information of the
agitation valve motor. Figure 48
1. Regulating valve 4. Center boom valve motor
Assembly (Fig. 47) 2. Flowmeter 5. RH boom valve motor
3. LH boom valve motor
1. Assemble boom valve manifold assembly using Fig-

ure 47 as a guide.
2. Attach boom valve manifold assembly to spray con-

trol and then install spray control assembly to machine
(see Spray Control Assembly (Multi Pro 1250) Installa-
tion in this section).
System
Spray

Regulating and Boom Valve Motor Service
IMPORTANT: Make sure to remove and neutralize 5. Apply silicone grease to seals on piston valve as-
chemicals from spray components before valve mo- sembly.
tor disassembly. Wear protective clothing, chemical
resistant gloves and eye protection during repair. 6. Position spring into valve motor housing. Use 3mm
allen wrench to secure piston valve assembly to valve
NOTE: There are limited replacement parts available motor.
for agitation and boom valve motor assemblies. Check
your parts catalog for parts that are available. 7. Secure hosebarb to bottom of valve motor.
Valve Motor Cover Removal (Fig. 49)
1. Loosen three (3) screws that secure valve motor 5

cover to valve motor assembly. 3
2. Carefully lift and rotate cover from valve motor.
3. Unplug wire connections and remove cover.
4. Make sure that all screws that secure valve motor are
tight. 3
Valve Motor Cover Installation (Fig. 49) 4
1
1. Connect cover wires to motor wires. Make sure that 2
cover wire color is the same as the motor wire color
when connecting wires. Figure 49
1. Valve motor assembly 4. Socket screw (4 used)
2. Carefully rotate cover onto valve motor taking care 2. Valve motor cover 5. Phillips screw (2 used)
to not damage wires. 3. Wire connector
3. Tighten screws to secure cover to valve motor.
Piston Valve Service (Fig. 50)
1. Remove hosebarb from bottom of valve motor to al- 5

low access to piston valve.
2. Make sure that valve is closed. If valve is not closed,

spring above piston valve will be under compression
and may damage valve motor or piston valve during dis- 4
assembly. End of piston valve will extend into bottom of
valve motor housing when valve is closed. If necessary, 3
reconnect motor to machine wire harness and close
valve before removing piston valve.
3. Use 3mm allen wrench to loosen and remove piston

valve assembly from valve motor. Locate and retrieve 1 2
spring from above piston valve.
4. Inspect seals on piston valve assembly. O--ring in top Figure 50

groove of piston valve assembly is available separately. 1. Valve motor assembly 4. Spring
If lower two (2) seals in piston valve are worn or dam- 2. Piston valve assembly 5. Valve motor cover
aged, replace piston valve assembly. The piston valve 3. Valve seal
is not designed to be disassembled.

System
Spray

Boom Bypass
11 12
10
9
2
8
7
5
14
6 FRONT
4 RIGHT
3
13
Figure 51
1. Spray tank 6. Bulkhead nut 11. Union
2. O--ring 7. Bulkhead gasket 12. Elbow
3. Hosebarb 8. Bulkhead fitting 13. Hose clamp
4. O--ring 9. Adapter 14. Boom bypass hose
5. Fork 10. Nipple

IMPORTANT: Make sure to remove and neutralize NOTE: Coat all O--rings with vegetable oil before instal-
chemicals from tank and spray components before lation to reduce the chance of damage during assembly.
sistant gloves and eye protection during repair. 1. Assemble boom bypass using Figure 51 as a guide.
Replace all removed O--rings and gaskets.
gage parking brake and remove key from the ignition 2. Using labels placed during disassembly, install
switch. hoses to hosebarbs and secure with hose clamps.
2. Drain spray tank (see Operator’s Manual). 3. Check spray tank for leaks. Repair all leaks before
returning the sprayer to service.
NOTE: The boom bypass hose on the Multi Pro 1200
is routed between the spray tank hosebarb (item 3) and
the boom distribution valves. On the Multi Pro 1250, the
boom bypass hose is routed between the spray tank ho-
sebarb (item 3) and the spray control assembly.

4. Disassemble boom bypass using Figure 51 as a

guide. Discard all removed O--rings and gaskets.
System
Spray

Tank Suction
12
27
25
4
13 8 22
23 9
28
7 2 3 26
11 10 4 12
3
6
1
2 21
24 5
4 14
2
19
2
15
17
3 18 16
RTV Silicone
Sealent
Thread
Sealent
FRONT
20
RIGHT 14
Thread
Sealent
Figure 52
1. Agitation control valve 11. Hose clamp 20. Spray pump
2. O--ring 12. Hose: tank suction (1 1/2”) 21. Spray tank
3. Fork 13. Hosebarb 22. Hose clamp
4. Hose clamp 14. Suction hose (1 1/2”) 23. O--ring
5. Hosebarb 15. Tee 24. Agitation reducer
6. Hose: agitation supply (1”) 16. Flange head screw (2 used) 25. Hosebarb
7. Hosebarb 17. Tee bracket 26. Suction assembly
8. Nut 18. Screw (4 used) 27. Fork
9. Hose: control bypass (1”) 19. Connector 28. O--ring
10. Hosebarb

NOTE: If suction tube in tank develops an air leak,
1
spray performance will diminish when tank level reach-
es the leak point. 3
Removal (Fig. 52) 4

chemicals from tank and spray components before 6
sistant gloves and eye protection during repair. 8

gage parking brake and remove key from the ignition 9
switch.
10
7 2
3. Remove suction strainer from spray tank (see Oper-

ator’s Manual). 13
11
4. Raise tank lid and remove strainer basket to gain ac-
cess to suction tube inside spray tank.
15
5. Remove suction tube assembly from spray tank us-
ing Figure 52 as a guide. Discard all removed O--rings
and gaskets.
14
6. For assembly purposes, measure and record length
of suction tube from filter housing flange to foot (Fig. 54). Figure 53
7. Disassemble suction tube as needed using Figure 1. Hosebarb 9. Bulkhead nut
2. O--ring (2 used) 10. Hosebarb
53 as a guide. 3. Screen vane 11. Hose clamp (2 used)
4. Filter 12. Suction hose
Installation (Fig. 52) 5. Fork 13. Suction tube
6. Filter housing 14. Screw
7. Expansion pin (2 used) 15. Foot
NOTE: Coat all O--rings with vegetable oil before instal- 8. Bulkhead gasket
1. Assemble suction tube assembly using Figure 53 as
System
Spray
a guide. Make sure that assembled length is the same
as the length measured before disassembly (Fig. 54).
2. Install suction tube assembly into spray tank using

Figure 52 as a guide. Replace all removed O--rings and
gaskets. The foot of the suction tube foot should be less
MEASURE AND RECORD LENGTH
than 1/2 inch (12.7 mm) from floor of spray tank after as-
sembly.
3. Using labels placed during disassembly, install Figure 54

4. Check spray tank for leaks. Repair all leaks before

returning the sprayer to service.

Tank Drain Assembly
13
14 15 10
16
2
17
12
3 18 9
4 5
6 FRONT
7 8 9
10 4 RIGHT
11
Figure 55
1. Spray tank 7. Drain valve 13. Drain outlet
2. Cap screw 8. Barbed fitting 14. Plastic seal
3. Lynch pin assembly 9. Hose clamp (2 used) 15. Ring nut
4. Flange nut (2 used) 10. Hose 16. O--ring
5. Peg mount (2 used) 11. R--clamp 17. Bulkhead nut
6. Rubber washer (2 used) 12. Carriage bolt 18. Elbow fitting


1
chemicals from tank and spray components before

gage parking brake and remove key from the ignition 2
switch.
2. Drain spray tank (see Operator’s Manual and Fig.

56).

4. Disassemble drain assembly using Figure 55 as a

guide. Discard all removed O--rings and gaskets.
2

1. Assemble drain assembly using Figure 55 as a

guide. Replace all removed O--rings and gaskets.

2
3. Make sure that drain valve is closed and secured to
3
sprayer with lynch pin.
4. Check spray tank for leaks. Repair all leaks before

returning the sprayer to service. Figure 56
1. Drain valve (closed) 3. Drain valve (open)
2. Lynch pin
System
Spray

Spray Tank
25
13 27
14 2 26
28
11 15
7
4
10 3
8
5
9
17
18
RIGHT
FRONT
12
20
23
1 16
22
24
19 21
Figure 57
1. Front saddle foam (2 used) 11. Elbow 20. Rear saddle
2. Hose fill 12. Rubber spacer (RH rear position) 21. Flange nut (4 used)
3. Rear tank band 13. Mounting bracket 22. Front saddle
4. Front tank band 14. Grommet 23. Flange nut (4 used)
5. Carriage bolt (2 used) 15. Pressure gauge tubing 24. Flange head screw (4 used)
6. Anti--siphon bracket 16. Spray tank assembly 25. Pressure gauge
7. Flange nut (2 used) 17. Cap screw (4 used) 26. Reducer
8. Flange head screw 18. Hardened washer (4 used) 27. Nut
9. Adapter 19. Rear saddle foam (3 used) 28. Coupler
10. Female coupling
NOTE: For easiest service access to the engine, drive

clutch, driven clutch and spray pump drive gearbox, re-
moval of the spray tank is recommended using the fol-
lowing procedure.

Removal (Fig. 57) 4. Position tank bands to front and rear of tank.
IMPORTANT: Make sure to remove and neutralize NOTE: A rubber spacer (item 12) is used between the
chemicals from tank and spray components before rear tank band and saddle on the right side of the ma-
disassembly. Wear protective clothing, chemical re- chine.
5. Install cap screws (item 17), hardened washers (item
1. Park machine on a level surface, stop engine, en- 18) and flange nuts (item 21) to secure front and rear
gage parking brake and remove key from the ignition tank bands (items 4 and 3) to saddle. On RH rear tank
switch. band, make sure that rubber spacer is placed between
the tank band and saddle.
2. Drain spray tank (see Operator’s Manual).
6. Using labels placed during tank removal, correctly
3. Label all hoses that are connected to spray tank fit- connect hoses to spray tank fittings. Secure hoses with
tings to allow proper installation after repairs are com- hose clamps.
pleted. Loosen hose clamps and disconnect all hoses
from spray tank hosebarbs. 7. Make sure that drain valve is closed and secured to
sprayer with lynch pin.
NOTE: A rubber spacer (item 12) is used between the
rear tank band and saddle on the right side of the ma- 8. After spray tank installation, make sure that spray
chine. hoses do not contact any moving parts on machine.
4. Remove cap screws (item 17), hardened washers 9. Check spray tank for leaks. Repair all leaks before
(item 18) and flange nuts (item 21) that secure front and returning the sprayer to service.
rear tank bands (items 4 and 3) to saddles.
5. Remove front tank band from machine. 3

5
6. Carefully position rear tank band with attached
6 4
mounting bracket (item 13) and spray components
away from spray tank.
7. Raise spray tank assembly from machine.
8. Remove tank saddles from machine frame if neces-

sary.
2
1. Make sure that foam cushions on front and rear 7 1

saddles are in good condition. Install new cushions if
System
Spray
needed.
2. If tank saddles were removed from frame, position Figure 58

saddles to frame and secure with flange head screws 1. Spray tank 5. Cap
and flange nuts. 2. Spigot assembly 6. Rinse tank
3. Cap 7. Rubber pad
4. Fresh water tank
3. Carefully lower spray tank assembly onto machine.

Turret Bodies
12
11
FRONT
RIGHT
10 3
7
2 6
3
1
8
5
4 3
LEFT CENTER RIGHT

BOOM BOOM BOOM
SUPPLY SUPPLY SUPPLY
1 4 4 5 1 4 5 1 4 4 5
Figure 59
1. Turret body (single LH barb) 5. Turret body (single RH barb) 9. Flange nut
2. Tee fitting (1 used per boom section) 6. Hose 10. Mount bracket
3. Hose clamp 7. Hose 11. Boom frame
4. Turret body (double hose barb) 8. Hose 12. Pop rivet (2 used per bracket)
IMPORTANT: Make sure to remove and neutralize NOTE: The type of hose barb on turret body deter-
chemicals from spray components before disas- mines turret location on spray boom. Refer to Figure 59
sembly. Wear protective clothing, chemical resist- for turret position on booms.
1. Position turret body clamp halves to spray boom and
1. Park machine on a level surface, stop engine, en- turret body. Slide clamp halves together. Level turret and
gage parking brake and remove key from the ignition tighten flange nut to secure turret body.
switch.
2. Install supply hose(s) to turret body. Tighten hose
2. Loosen hose clamp(s) and remove supply hose(s) clamp(s).
from turret body.
3. Remove flange nut that secures turret body to mount

bracket. Remove turret body from machine.

Turret Body Service
1
1. Pull e--clip from body and slide plug with O--ring from 19
body.
18 7
2 5
2. Disassemble turret body using Figure 60 as a guide.
3 6
3. Discard all removed seals, gaskets, O--rings and dia- 17 4
phragms.
8 9

6
16 13
1. Replace all removed seals, gaskets, O--rings and di- 11
14
aphragms. 15 20
2. Assemble turret body using Figure 60 as a guide. 12
A. The turret (item 8) end with slightly larger bore Figure 60

and detent grooves needs to be orientated toward 1. Upper clamp 11. Nozzle
2. O--ring 12. Nozzle cap
detent posts on body (item 4) (Fig. 61). 3. Pivot pin 13. O--ring
4. Body 14. Seal
B. Make sure to align notch on plug (item 10) with 5. E--clip 15. Screw
6. Gasket (3 used) 16. End cap
groove in body (item 4) as plug is installed. 7. Dust cap (2 used) 17. Diaphragm
8. Turret 18. Hose barb
C. Install e--clip (item 5) into body to secure assem- 9. O--ring 19. Cap screw
bly. 10. Plug 20. O--ring
1 3
2
System
Spray
2
Figure 61
1. Body 3. Detent groove
2. Detent post

Spray Boom Hinge
16 8
15 19
18 9
14 17 10 FRONT
20 RIGHT
3
1
4
12 2
13
7
11
10
9
5
8
Figure 62
1. Hinge (2 used per boom) 8. Lock nut 15. Flange nut
2. Rubber boot (2 used per hinge) 9. Cap screw 16. Boom frame
3. Backing plate (4 used per hinge) 10. Flat washer 17. Tube (2 used per boom)
4. Flange nut (4 used per hinge) 11. Pivot bracket 18. Spring retainer (2 used per boom)
5. Boom (RH shown) 12. Bushing (2 used per pivot bracket) 19. Breakaway spring (2 used per boom)
6. Tee fitting 13. Flange head screw 20. Grease fitting (2 used per hinge)
7. Flange hd screw (4 used per hinge) 14. Pivot pin
Disassembly (Fig. 62) 4. Loosen two (2) cap screws (item 9) and lock nuts
(item 8) to allow breakaway springs (item 19) to fully ex-
IMPORTANT: Make sure to remove and neutralize tend.
sembly. Wear protective clothing, chemical resist- 5. Complete boom hinge disassembly as required us-
ant gloves and eye protection during repair. ing Figure 62 as a guide. If pivot bracket (item 11) is to
be removed from machine, disconnect boom actuator
1. Park machine on a level surface, lower spray booms, (not shown) from pivot bracket (see Boom Actuator Re-
stop engine, engage parking brake and remove key moval) in this section).
from the ignition switch.
6. Clean all removed components. If pivot bracket was
2. Loosen hose clamp and remove supply hose from removed, inspect bushings and pivot pin for damage or
tee fitting (item 6) on spray boom. wear.
3. Support spray boom to prevent it from falling.

Assembly (Fig. 62)
1. If pivot bracket (item 11) was removed from machine, 2

lightly lubricate bushings (item 12) with motor oil before
assembly. Connect boom actuator (not shown) to pivot
bracket (see Boom Actuator Installation in this section).
1
2. Make sure that hinges (item 1) are securely fastened UP
to pivot bracket (item 11) and boom (item 5). The boom
hinge uses four (4) backing plates between the boom
and flange nuts.
Figure 63
1. Rubber boot 2. Rib
3. Position boom hinge to pivot bracket hinge. Make
sure that rubber boots (item 2) are placed at hinge junc-
tions and that rib on boots are toward the top of the boom
(Fig. 63).
4. Insert two (2) cap screws (item 9) through flat wash-

ers (item 10) and hinges. Place tube (item 17), break-
away spring (item 19), spring retainer (item 18) and lock
nut (item 8) on each cap screw. Make sure that shoulder
on spring retainer fits into breakaway spring.
1.560”
5. Tighten lock nuts so there is 1.560” (39.6 mm) be- (39.6 mm)
tween the face of the spring retainer and the hinge cast-
ing (Fig. 64).
6. Connect supply hose to tee fitting on spray boom and

secure with hose clamp.
7. Lubricate grease fittings on boom hinge.
Figure 64
System
Spray

Boom Actuator
12 11
FRONT
1
RIGHT
10
7
3
6
Figure 65
1. Boom actuator (2 used) 5. Lock nut (4 used) 9. Clevis strap (2 used)
2. Carriage screw (4 used) 6. Flange nut (2 used) 10. Boom pivot bracket
3. Boom frame 7. Flange head screw (2 used) 11. Clevis pin (2 used)
4. Washer plate 8. Pivot pin (2 used) 12. Cotter pin (2 used)

1. Park machine on a level surface, place spray booms 1. Position boom actuator to boom frame and boom
in the transport (raised) position, stop engine, engage pivot bracket.
parking brake and remove key from the ignition switch.
2. Secure actuator to boom pivot bracket with clevis pin
2. Disconnect boom actuator from machine wire har- and cotter pin.
ness.
3. Secure actuator to clevis strap on boom frame with
3. Remove pivot pin (item 8) that secures actuator to pivot pin.
clevis strap (item 9) on boom frame.
4. Connect boom actuator to machine wire harness.
4. Remove cotter pin (item 12) from clevis pin (item 11).
Support boom actuator and slide clevis pin from boom
pivot bracket. Remove actuator from machine.
System
Spray

Boom Actuator Service
IMPORTANT: Do not dismantle, repair or modify the Actuator Air Bleeding
boom actuator. Internal components are not avail-
able for the actuator. If an actuator is damaged or If actuator freeplay is excessive, air bleeding of the ac-
worn, replace actuator. tuator should be performed using the following proce-
dure:
CAUTION 1. Make sure that the exterior of the actuator is thor-

oughly clean to prevent contaminates from entering the
actuator.
During and after operation, the actuator may be
very hot. To avoid possible burns, allow the ac- 2. Make sure that the actuator cylinder is fully retracted.
tuator to cool before working on it.
IMPORTANT: To prevent actuator damage, use vise
Actuator Circuit Protection with protective jaws when clamping actuator.
Each boom actuator is protected internally by a thermal 3. Place the actuator in a vise making sure that actuator
circuit breaker. In case of actuator overheating, the ther- is clamped in the area identified in Figure 66. Use just
mal breaker will trip, causing the actuator to cease func- enough clamping force to hold the housing securely.
tioning. Once the actuator cools to appropriate Make sure that the reservoir plug is orientated up.
operating temperature, the actuator thermal breaker will
reset to allow actuator operation to resume.
CAUTION
A separate 30 amp thermal breaker also protects each
boom actuator circuit. These thermal breakers are lo- The actuator reservoir is pressurized. If the res-
cated at the machine fuse panel and will prevent circuit ervoir plug is removed too quickly, oil under
operation if overloaded. The thermal breakers reset au- pressure can be ejected from the actuator.
tomatically.
Actuator Freeplay Inspection 4. Slowly loosen and remove the reservoir plug at the
top of the reservoir.
Over time, actuator operation may be affected by air
captured in the reservoir oil. An excessive amount of air 5. Using a light through the plug hole, confirm that the
in the actuator oil will allow excessive actuator freeplay. reservoir oil is clear. If the oil appears milky, air is en-
Excessive freeplay will allow spray boom bouncing trained in the reservoir oil. Keep the actuator vertical
when driving over severe terrain. with the plug removed for approximately fifteen (15)
minutes to allow the air to separate from the oil.
Measure actuator freeplay using the following proce-
dure: 6. When oil appears clear, use a 12 volt DC power sup-
ply to power the actuator and extend the cylinder com-
1. Move the vehicle to an open area and lower the spray pletely.
booms to the spray position.
IMPORTANT: To ensure proper reservoir pressure,
2. Lift up on the boom at the last triangular gusset with make sure that cylinder is extended before instal-
a 25 pound (11.4 kg) force. Support boom in that posi- ling reservoir plug.
tion.
7. Install the reservoir plug and torque from 45 to 60 in--
3. Using a non--permanent felt tipped marker, mark the lb (5.1 to 6.8 N--m).
cylinder rod at the outside of the cylinder seal.
8. If reservoir oil was milky, use power supply to con-
4. Release the spray boom and allow it to return to the tract and extend the actuator cylinder three (3) times.
spray (fully lowered) position. Repeat steps 2 through 7 until oil is clear.
5. Determine the actuator freeplay by measuring the 9. When actuator oil is clear and plug has been
distance from the mark on the cylinder rod to the cylinder installed, use power supply to fully contract the actuator
seal. The freeplay should be less than 0.100” (2.5 mm). cylinder. Remove actuator from vise and install on ma-
If excessive freeplay is found, bleed air from actuator. chine.

Actuator Oil Level
RESERVOIR UP
Under normal conditions, actuator oil level should re- PLUG
main constant. If any oil is spilled from the reservoir dur-
ing air bleeding, the oil level in the actuator should be
RESERVOIR
checked and adjusted. CYLINDER
1. Make sure that the exterior of actuator is thoroughly

clean to prevent contaminates from entering the actua-
tor. VISE
CLAMPING
AREA
2. Make sure that the actuator cylinder is fully retracted.
IMPORTANT: To prevent actuator damage, use vise

with protective jaws when clamping actuator.
ELECTRIC
MOTOR
3. Place the actuator in a vise making sure that actuator DOWN
is clamped in the area identified in Figure 66. Use just
enough clamping force to hold the housing securely.
Make sure that the reservoir plug is orientated up. Figure 66
CAUTION
The actuator reservoir is pressurized. If the res-
ervoir plug is removed too quickly, oil under
pressure can be ejected from the actuator. 0.984”
(25 mm)
4. Slowly loosen and remove the reservoir plug at the
top of the reservoir.
5. Using a light through the plug hole, confirm that the

reservoir oil is clear. If the oil appears milky, perform ac-
tuator air bleeding procedure.
6. Use a clean rod to identify the level of oil in reservoir.

Distance from plug fitting to oil level should be 0.984” (25
mm). If necessary, add ISO VG 32 mineral oil to actuator
reservoir to adjust oil level.
Figure 67
System
Spray
7. When oil level is correct, use a 12 volt DC power sup-
ply to power the actuator and extend the cylinder com-
pletely.
IMPORTANT: To ensure proper reservoir pressure,

make sure that cylinder is extended before instal-
ling reservoir plug.
8. Install the reservoir plug and torque from 45 to 60 in--

lb (5.1 to 6.8 N--m).
Actuator Disposal
If actuator disposal is necessary, remove hydraulic oil

from actuator before disposal.
1. Open actuator reservoir (see Steps 1 through 4 in

Actuator Air Bleeding above).
2. Drain oil from actuator.


Chapter 7
Drive Train
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Driven Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Clutch System Operation . . . . . . . . . . . . . . . . . . . . . 3 Pump Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . 18
Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump Drive Gearbox Service . . . . . . . . . . . . . . . . 20
Driven Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Stub Axle and Driveshaft . . . . . . . . . . . . . . . . . . . . 24
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Driveshaft Universal Joint Service . . . . . . . . . . . . 27
Clutch Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8 Transaxle Removal . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Transaxle Installation . . . . . . . . . . . . . . . . . . . . . 30
Shift Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . 10 Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 11 Transaxle Disassembly . . . . . . . . . . . . . . . . . . . 31
CVT Drive Belt Service . . . . . . . . . . . . . . . . . . . . . . 11 Transaxle Inspection . . . . . . . . . . . . . . . . . . . . . 40
Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . 44
Drive Train
Multi Pro 1200/1250 Page 7 -- 1 Drive Train

Specifications
Item Description
Transmission Integrated Transaxle with 3 Forward Speed Ranges and Reverse

Fluid Capacity 7.5 quarts (7.1 liters)
Fluid Type Dexron III ATF
Clutch System Centrifugally Engaged Variable Belt Drive

Drive Clutch Speed Sensing With Mechanical Fly--Weights
Driven Clutch Torque Sensing With Spring Loaded Cam
Pump Drive Gearbox Reducing Worm Gear for Pump Drive and Through
Shaft for Transaxle Drive
Fluid Capacity 0.6 quarts (0.57 liters)
Fluid Type Mobil SHC 634 Synthetic Lubricant (Toro Part No. 104--8772)
Drive Train Page 7 -- 2 Multi Pro 1200/1250

General Information
Clutch System Operation
FULL ENGINE SPEED

LOW ENGINE SPEED DECREASING LOAD 1 FULL ENGINE SPEED
LIGHT LOAD
INCREASING LOAD
3 4
2
7 8 5
Figure 1
1. Drive clutch 4. Fixed sheave (drive clutch) 7. Fixed sheave (driven clutch)
2. Driven clutch 5. Moveable sheave (driven clutch) 8. CVT drive belt
3. Moveable sheave (drive clutch) 6. Spring
Two Clutch System (Fig. 1)

Drive Train
Power is transferred from the engine to the transaxle The two clutches work together to automatically up--shift
and spray pump by a variable clutch system that con- and back--shift as changes in load and speed occur. This
sists of two clutches connected by a drive belt. The drive shifting changes the turning ratio between the drive and
clutch responds to engine speed and is mounted to the driven clutches and allows the engine to operate at opti-
engine driveshaft. The driven clutch responds to mum efficiency.
changes in load from the transaxle and spray pump and
is mounted to the pump drive gearbox input shaft.

Drive Clutch
Principles of Operation (Fig. 2)
The operation of the drive clutch is affected by engine

shaft speed. With the engine not turning, the CVT drive 1 2 3 4
belt rests low within the drive clutch sheaves as the pres-
sure of the spring holds the sheaves apart. As the en-
gine increases in speed, the clutch weights attached to
the moveable sheave move outward as they spin about
the engine driveshaft. The outward movement of the
clutch weights presses against the rollers and overcom- 7
es spring pressure through the spider assembly, which
forces the moveable sheave closer to the fixed sheave.
This inward movement of the sheave engages the drive
belt to drive the driven clutch.
With increasing engine speed, the moveable sheave

continues to move inward, which forces the drive belt to
ride towards the outer diameter of the clutch sheaves.
When engine speed is decreased, the clutch weights

exert less force on the rollers and thus the spring. The
spring pressure overcomes the force of the clutch 6
weights and shifts the moveable sheave away from the 5
fixed sheave. The drive belt disengages from the clutch Figure 2
sheaves at a point where the force of the spring is great-
1. Fixed sheave 5. Clutch weight (3 used)
er than that of the clutch weights. 2. Moveable sheave 6. Roller (3 used)
3. Spider assembly 7. Spring
4. Cover
1
2
3
Figure 3
1. Pump drive clutch 4. Steering pump
2. Driven clutch 5. Drive clutch
3. Engine 6. Pump drive gearbox

Driven Clutch
Principles of Operation (Fig. 4)
The operation of the driven clutch is affected by load.

When the vehicle is stopped, the CVT drive belt is held
at the outer diameter of the driven clutch sheaves from 2 3
the pressure of the spring pushing the moveable sheave
against the fixed sheave and away from the fixed cam.
A fixed cam on the moveable sheave rotates on a pair
of rollers in the fixed sheave base to allow a low friction
movement of the moveable sheave.
Once the drive clutch (engine mounted) starts rotating,

the drive belt also starts to rotate. With increasing speed
of the drive clutch, the belt begins to climb to the outer
diameter of the drive clutch sheaves. This increases the
tension on the drive belt and forces the driven clutch 1
moveable sheave to move away from the fixed sheave
against the pressure of the spring. As the belt tightens
and the driven clutch sheaves open up, the drive belt
rides lower in the driven clutch sheaves.
With increased load from the transaxle and/or spray Figure 4

pump, the cam resists forward movement relative to the 1. Moveable sheave 3. Spring
moveable sheave and drive belt. Torque from the drive 2. Fixed sheave
belt and spring pressure moves the movable sheave up
the ramp of the fixed cam. The drive belt becomes posi-
tioned closer to the outer diameter of the driven clutch 1
sheaves to respond to the load increase. 2
3
Drive Train
Figure 5
1. Pump drive clutch 4. Steering pump
2. Driven clutch 5. Drive clutch


Special Tools
Order special tools from your Toro distributor. Some
tools may also be available from a local supplier.
Drive Clutch Removal Tool

This tool is required to remove the drive clutch from the
tapered crankshaft of the engine. It is placed in the
threaded hole of the fixed clutch sheave after the clutch
retaining cap screw has been removed.
Figure 6
Drive Train

Troubleshooting
Transaxle
Symptom Possible Causes
Noisy operation. Low oil level in transaxle.
Damaged or worn transaxle bearings.
Transaxle gears worn, scuffed or broken.
Excessive end play in transaxle countershaft.
Gears loose on transaxle shaft.
Excessive wear of differential side gear liners and

pinion liners.
Excessive wear of splined slider on axle drive joints.
Difficult shifting. Shift cable out of adjustment.
Shift cable damaged.
Shifter cap screw loose (at operator position).
Loose shift lever on transaxle.
Cable clamp securing cables near shifter is loose.
Sliding gear tight on transaxle shaft or splines.
Transaxle synchronizing unit damaged.
Transaxle sliding gear teeth damaged.
Transaxle synchro keys damaged.

Transaxle (continued)
Symptom Possible Causes
Gears make clashing noise when shifting. Shifting too fast.
Excessive wear of transaxle synchro rings.
Excessive wear of differential side gear thrust wash-

ers and/or pinion gear washers.
Damaged transaxle synchro springs and/or keys.
Transaxle main gear needle bearings worn or dam-

aged.
Excessive wear of driveshaft(s).
Transaxle sticks in gear. Transaxle shift fork detent ball stuck.
Shift linkage damaged, loose or out of adjustment.
Transaxle sliding gears tight on shaft splines.
Transaxle synchro shift keys damaged.
Transaxle slips out of gear. Shift linkage out of adjustment.
Gear loose on transaxle shaft.
Transaxle gear teeth worn.
Excessive end play in transaxle gears.
Lack of spring pressure on transaxle shift fork det-

ent ball.
Badly worn transaxle bearings.
Overheating of transaxle. Oil level too high in transaxle.
Excessive hydraulic load (see Chapter 8 -- Hydraulic

System).
Drive Train

Adjustments
Shift Cable Adjustment (Fig. 7)

gage parking brake and remove key from the ignition 2 2
switch. Place the shift lever in the neutral position. 3
2. Remove cotter pins and clevis pins that secure cable

1
clevis to shift levers.
3. Check that the threads of the shift cables are cen-

tered in the mounting brackets. If needed, readjust shift 3 4
cable jam nuts.
1
4. Adjust cable clevis with clevis jam nuts so that for-
ward and backward free play of clevis is equal relative
to the hole in the transaxle shift lever. Tighten clevis jam
nuts. 5
5. Secure cable clevis to shift levers with clevis pins and Figure 7
cotter pins. 1. Shift cable jam nut 4. Shift cable (1/reverse)
2. Clevis pin 5. Shift cable (2/3)
6. Check shift lever for proper operation. 3. Clevis jam nut

Service and Repairs
CVT Drive Belt Service

CVT Drive Belt Inspection
1
NOTE: Perform this maintenance procedure at the in-
terval specified in the Operator’s Manual. 2

switch.
2. Put vehicle transmission in neutral.
3. Rotate and inspect CVT drive belt for excessive wear

or damage. Replace belt as necessary.
CVT Drive Belt Replacement (Fig. 8) 3
1. To remove CVT drive belt:
A. While rotating the driven clutch, route belt over

the clutch.
Figure 8
B. Remove belt from the drive clutch. 1. CVT drive belt 3. Drive clutch
2. Driven clutch
2. To install CVT drive belt:
A. Place new belt around drive clutch.
B. Position belt to driven clutch. While rotating the

driven clutch, route belt into position on driven clutch.
Drive Train

Drive Clutch
5 13
8 11
1
Loctite #242
6 10 4 12
9 14
2
40 to 45 ft--lb
(55 to 61 N--m)
FRONT
LEFT
Figure 9
1. Drive clutch 6. Pump pulley 11. Pump drive gearbox
2. Engine mounting plate 7. CVT drive belt 12. Pump drive electric clutch
3. Stepped washer 8. Engine 13. Driven clutch
4. Cap screw 9. Steering pump belt 14. Transaxle driveshaft
5. Pump drive pulley 10. Steering pump
NOTE: For easiest service access to the drive clutch,

removal of the spray tank is recommended in the follow-
ing procedure. As an alternative, the engine mounting
CAUTION
plate can be lowered from the machine to access the
clutch (see Engine Mounting Plate Assembly in the Ser- The engine, exhaust system and drive compo-
vice and Repairs section of Chapter 3 -- Kohler Gasoline nents may be hot. To avoid possible burns, allow
Engine).
drive clutch.

Removal (Fig. 9)
1
1. Park machine on a level surface, stop engine, set 2
parking brake and remove key from the ignition switch. 3
2. Remove the spray tank from machine to access

drive clutch (see Spray Tank Removal in the Service and
Repairs section of Chapter 6 -- Spray System).
3. Remove CVT drive belt from the drive clutch (see

CVT Drive Belt Service in this section). 6
4. Remove cap screw and stepped washer securing

the drive clutch to the engine tapered crankshaft. 5
IMPORTANT: Lightly grease end of clutch removal

tool to prevent damage to removal tool. To prevent
clutch damage, thread tool into clutch threads only 4
enough to remove the clutch.
5. Use clutch removal tool (see Special Tools in this Figure 10

chapter) to remove drive clutch from the engine tapered 1. Pump drive clutch 4. Steering pump
shaft. 2. Driven clutch 5. Drive clutch
1. Make sure that tapers of engine crankshaft and drive

clutch bore are thoroughly clean.
2. Slide drive clutch onto engine shaft.
3. Apply Loctite #242 (or equivalent) to the threads of

the cap screw used to secure clutch to crankshaft. Install
cap screw and stepped washer to crankshaft. Torque
cap screw 40 to 45 ft--lb (55 to 61 N--m) to secure drive
clutch.
4. Install CVT drive belt to the drive clutch (see CVT

Drive Belt Service in this section).
5. Install the spray tank to the machine (see Spray Tank

Installation in the Service and Repairs section of Chap-
ter 6 -- Spray System).
Drive Train

Drive Clutch Service
1 8
105 to 120 in--lb

(11.9 to 13.5 N--m)
4 7
5
10 3
40 to 50 in--lb 9
(4.6 to 5.6 N--m) 2
v
Figure 11
1. Fixed sheave 5. Flange head screw (6 used) 8. Moveable sheave
2. Compression spring 6. Lock nut (3 used) 9. Shoulder screw (3 used)
3. Shim 7. Cover 10. Clutch weight (3 used)
4. Spider assembly
Disassembly (Fig. 11) 6. Clean all dust and debris from clutch components. If
necessary, use contact or brake cleaner to remove any
1. Make note of the “X” mark cast into the cover and spi- oil or other lubricants from clutch components.
der before clutch disassembly (Fig. 12). These marks
must be aligned during assembly for proper clutch op-
eration.
CAUTION
2
Loosen flange screws that secure cover slowly.
The cover is under pressure from the compres-
sion spring.
2. Using a crossing pattern, loosen and remove six (6)

flange head screws (item 5) that secure the cover to the
movable sheave.
3. Carefully remove cover and compression spring 1

from clutch.
4. Remove lock nut (item 6) from each of the shoulder

screws (item 9). Discard lock nuts after removal.
5. Slide shoulder screw from each of the clutch weights Figure 12

(item 10) and then remove weights from clutch. 1. Spider 2. Cover

Inspection
2
NOTE: If drive clutch wear or damage occurs, clutch re-
placement may be necessary. Refer to your parts cata-
1
log to identify individual drive clutch components that
are available.
1. Inspect the tapered ends of the engine crankshaft

and fixed sheave of drive clutch. If either is severely
damaged, replace component as damage to the taper
will allow loosening of the clutch during machine opera- Figure 13
tion.
1. Clutch weight 2. Contact surface
2. Inspect the compression spring (item 2) and replace

if damaged or fatigued.
3. Clean and inspect shoulder screws (item 9). If the 2 3

shoulder area of the screws is worn or if the threads are
damaged, replace the screws.
4. Check the contact surface of the clutch weights (Fig.

13). If surface is worn or damaged, replace all three (3)
clutch weights as a set.
5. Check the rollers in the spider assembly for binding 1

or wear (Fig. 14). If binding or uneven wear is found, re-
place clutch assembly.
Figure 14
6. Check the contact surface of the movable sheave for 1. Roller 3. Roller uneven wear
wear and/or fraying. If surface is worn/frayed, replace 2. Weight contact surface
clutch assembly.
Assembly (Fig. 11) 2 1

IMPORTANT: For proper drive clutch operation, DO
NOT lubricate drive clutch components.
IMPORTANT: To maintain the balance of the clutch, 2

all shoulder screws must be installed with their
threads pointing in a clockwise direction (Fig. 15).
1
1. Position clutch weights to moveable sheave and
slide shoulder screw into sheave and weight. Make sure
that shoulder screw threads are pointing in a clockwise
direction.
2. Install new lock nuts on the shoulder screws. DO 2 1

Drive Train
NOT reuse removed lock nuts. Tighten nuts until they
contact screw shoulder and then torque nuts from 40 to Figure 15
50 in--lb (4.6 to 5.6 N--m).
1. Shoulder screw 2. Lock nut
3. Position compression spring and cover to clutch.
Make sure that the “X” mark cast into the cover and spi-
der are aligned.
4. Secure cover to the movable sheave with six (6)

flange head screws in a crossing pattern and in three (3)
steps. Final torque on screws should be from 105 to 120
in--lb (11.9 to 13.5 N--m).

Driven Clutch
2 Antiseize
Lubricant
4 3 1
7 5
6
11
9
10
12
FRONT
LEFT
Figure 16
1. Driven clutch 5. Washer 9. Engine mounting plate
2. CVT drive belt 6. Spacer 10. Pump drive gearbox
3. Flat washer 7. Engine 11. Pump drive electric clutch
4. Lock nut (LH thread) 8. Drive clutch 12. Transaxle driveshaft
NOTE: For easiest service access to the driven clutch, Driven Clutch Removal (Fig. 16)
removal of the spray tank is recommended in the follow-
ing procedure. As an alternative, the engine mounting 1. Park machine on a level surface, stop engine, set
plate can be lowered from the machine to access the parking brake and remove key from the ignition switch.
clutch (see Engine Mounting Plate Assembly in the Ser-
vice and Repairs section of Chapter 3 -- Kohler Gasoline 2. Remove the spray tank from machine to access
Engine). drive clutch (see Spray Tank Removal in the Service and
Repairs section of Chapter 6 -- Spray System).
3. Remove CVT drive belt from the driven clutch (see

CAUTION CVT Drive Belt Service in this section).
The engine, exhaust system and drive compo- IMPORTANT: The gearbox input shaft and lock nut
nents may be hot. To avoid possible burns, allow that secures the driven clutch have left hand
all components to cool before working on the threads.
driven clutch.
4. Remove lock nut and flat washer securing the driven
clutch to the input shaft of the pump drive gearbox.
IMPORTANT: When removing driven clutch, note Driven Clutch Installation (Fig. 16)
quantity of washers (item 5) that exist on gearbox
shaft. Washers are used to align drive and driven IMPORTANT: For proper driven clutch operation,
clutch pulleys. DO NOT lubricate driven clutch components.
5. Pull driven clutch from the pump drive gearbox input 1. Apply antiseize lubricant to gearbox input shaft.
shaft. Locate and retrieve washer(s) (item 5) and spacer
(item 6) from input shaft. 2. Place spacer (item 6) and then washer(s) (item 5)
onto input shaft. Make sure that number of washers
Driven Clutch Service (Fig. 17) used during clutch installation is the same as number of
washers that were removed.
1. Use a suitable press to compress the clutch spring
enough to allow removal of the retaining ring. 3. Position driven clutch to the gearbox input shaft.
Make sure pulley side of the clutch faces away from the
2. Remove retaining ring. gearbox case.
3. Carefully, allow the spring to extend fully. IMPORTANT: The gearbox input shaft and lock nut
that secures the driven clutch have left hand
4. Remove outer spring retainer, spring and inner threads.
spring retainer from clutch.
4. Secure driven clutch to the gearbox input shaft with
5. Make note of the “X” mark cast into the fixed sheave lock nut and flat washer.
and moveable sheave before removing the moveable
sheave. These marks must be aligned during assembly 5. Install CVT drive belt to the driven clutch (see CVT
for proper clutch operation. Drive Belt Service in this section).
6. Separate the clutch sheaves. Locate and retrieve 6. Install the spray tank to the machine (see Spray Tank
thrust washer. Installation in the Service and Repairs section of Chap-
ter 6 -- Spray System).
7. Clean and inspect driven clutch components:
A. Clean all dust and debris from clutch compo-

2
nents. If necessary, use contact or brake cleaner to 3
remove any oil or other lubricants from clutch com-
ponents.
B. Inspect the spring and replace if damaged or fa- 4

tigued. 6
7
C. Check the rollers in the fixed sheave for binding or
wear. If binding or uneven wear is found, replace
driven clutch assembly. 1
D. Check the contact surface of the sheaves for

5
wear and/or fraying. If wear or damage is found, re-
place driven clutch assembly.
Figure 17
Drive Train
8. Assemble the driven clutch in the reverse order of 1. Fixed sheave 5. Spring
disassembly. Make sure that the “X” mark cast into the 2. Thrust washer 6. Outer spring retainer
fixed and moveable sheaves are aligned. Also, make 3. Moveable sheave 7. Retaining ring
4. Inner spring retainer
sure that the retaining ring is fully seated in groove after
installation.

Pump Drive Gearbox
14 Antiseize
Lubricant 27 to 30 ft--lb
11 37 to 40 N--m
13 7
12 6
10 Loctite #242
24
25 5
3 20
15
9
26
21
22
8 2 4
Loctite #242
19
27
18
16
23
17
FRONT
LEFT
Figure 18
1. Pump drive gearbox 10. Driven clutch 19. Cap screw (2 used)
2. Key 11. CVT drive belt 20. Cap screw
3. Spacer 12. Flat washer 21. Lock washer
4. Pump drive electric clutch 13. Lock nut (LH thread) 22. Clutch retainer
5. Shoulder bolt 14. Engine 23. Engine mounting plate
6. Coupling 15. Drive clutch 24. Pipe nipple
7. Breather 16. Flange nut (4 used) 25. Washer (as needed for alignment)
8. Flange head screw (4 used) 17. Transaxle driveshaft 26. Retaining ring
9. Spacer 18. Lock nut (2 used) 27. Socket head screw
NOTE: For easiest service access to the pump drive

gearbox, removal of the spray tank is recommended in
the following procedure. As an alternative, the engine
CAUTION
mounting plate can be lowered from the machine to ac-
cess the gearbox (see Engine Mounting Plate Assembly The engine, exhaust system and drive compo-
in the Service and Repairs section of Chapter 3 -- Kohler nents may be hot. To avoid possible burns, allow
Gasoline Engine).
pump drive gearbox.

Removal (Fig. 18) 4. Connect transaxle driveshaft to pump drive gearbox
shaft:
1. Park vehicle on a level surface, stop engine, set
parking brake and remove key from the ignition switch. A. Slide transaxle driveshaft yoke onto pump drive
gearbox shaft.
2. Remove the spray tank from machine to access
drive clutch (see Spray Tank Removal in the Service and B. Align mounting holes in driveshaft with relief in
Repairs section of Chapter 6 -- Spray System). gearbox shaft.
3. Disconnect transaxle driveshaft from pump drive C. Install and tighten two (2) cap screws and lock
gearbox shaft: nuts to secure driveshaft to transaxle shaft.
A. Remove two (2) cap screws and lock nuts that se- D. Remove socket head screw (item 27) from drive-
cure transaxle driveshaft yoke to pump drive gear- shaft yoke. Clean threads of screw and yoke. Apply
box shaft. Loctite #242 (or equivalent) to threads of screw.
Install and tighten screw into yoke.
B. Loosen socket head screw (item 27) in driveshaft
yoke. IMPORTANT: Make sure that correct gearbox lubri-
cant is used when filling gearbox. Recommended
C. Slide transaxle driveshaft yoke from pump drive gearbox lubricant is Mobil SHC 634 Synthetic Lubri-
gearbox shaft. cant (Toro Part No. 104--8772).
IMPORTANT: When removing driven clutch, note 5. Check and adjust gearbox lubricant level (see Oper-
quantity of washers (item 25) that exist on gearbox ator’s Manual). The oil level should be checked using
shaft. Washers are used to align drive and driven the plug on the side of the gearbox.
clutch pulleys.
6. Install the spray tank to the machine (see Spray Tank
4. Remove driven clutch from pump drive gearbox (see Installation in the Service and Repairs section of Chap-
Driven Clutch in this section). ter 6 -- Spray System).
5. Remove electric clutch from pump drive gearbox
(see Electric Clutch (Pump Drive) in the Service and Re- 1
pairs Section of Chapter 6 -- Spray System). Locate and 2
remove spacer from gearbox input shaft. 3
6. Remove four (4) flange head screws and lock nuts

that secure gearbox to engine mounting plate. Remove
gearbox from machine.

6
1. Position gearbox to engine mounting plate. Secure
gearbox to mounting plate with four (4) flange head
screws and lock nuts. 5
2. Install electric clutch to gearbox shaft (see Electric

Clutch (Pump Drive) in the Service and Repairs Section
Drive Train
of Chapter 6 -- Spray System). Make sure that spacer is 4
installed so that spacer groove is positioned over the re-
taining ring in gearbox shaft.
Figure 19
3. Install driven clutch to gearbox (see Driven Clutch in 1. Pump drive clutch 4. Steering pump
this section). Make sure that spacer (item 3) and wash- 2. Driven clutch 5. Drive clutch
er(s) (item 25) are installed on gearbox input shaft.

Pump Drive Gearbox Service
8 9
6
5 2
4
3 7
2
1 8 ft--lb
(10.8 N--m)
1 Loctite #242
11 10
12
8 ft--lb 13
(10.8 N--m) 14 Thread Sealant
15
Loctite #271
18 21
23
7 20
19
22
16 15 14
Loctite #242 17 26
13
18
25
17 16
10 24 Loctite #242
8 ft--lb 11
5
(10.8 N--m) 7 7
8 ft--lb
Loctite #242 (10.8 N--m)
Figure 20
1. Bearing cup 10. O--ring 19. Oil level plug
2. Bearing cone 11. Blue shim (0.005”) 20. Coupling
3. Worm gear 12. Output shaft 21. Breather
4. Key 13. Input shaft seal 22. Nipple
5. Red shim (0.002”) 14. Open input cap 23. Gearbox housing
6. Open output cap 15. Ball bearing 24. Drain plug
7. Cap screw (4 per cap) 16. O--ring 25. Closed output cap
8. Output shaft seal 17. Red shim (0.002”) 26. Worm (input) shaft
9. Retaining ring 18. Blue shim (0.005”)
Disassembly (Fig. 20) 4. Carefully remove output shaft (item 12) with worm
gear and bearing cones from housing.
1. Drain lubricant from gearbox.
5. Loosen and remove cap screws that secure both
2. Remove retaining ring (item 9) from output shaft. open input caps (item 14) to gearbox housing. Remove
caps and O--rings from housing. Remove shims. Note
3. Loosen and remove cap screws that secure output shim location for assembly purposes.
caps (item 6 and 25) to gearbox housing. Remove caps
with bearing cups and O--rings. Remove shims. Note 6. Carefully pull worm (input) shaft (item 26) with bear-
shim location for assembly purposes. ings from housing.

7. Remove seals from open caps taking care not to
damage seal bores. Clean seal bore in caps. Remove 1
and discard O--rings from caps.
3 2
8. If required, press bearings from worm (input) shaft
(item 26).
9. If necessary, remove bearing cups from output caps.

Make sure to remove bearing cups evenly to prevent
damage to output caps.
IMPORTANT: Do not attempt to remove both bear-

ing cones and gear from output shaft at the same 4
time. The key (item 4) will cause severe damage to 3
gear, shaft and bearings.
10.If worm gear (item 3) and bearing cones (item 2) are

to be removed from output shaft, support bottom side of Figure 21
gear and press shaft down through one bearing cone 1. Press 3. Bearing cone
and gear (Fig. 21). Remove key from shaft. Second 2. Output shaft 4. Worm gear
bearing cone can then be pressed from shaft.
11. Thoroughly clean all gearbox components and in-

spect for evidence of wear or damage. Replace internal 1
components as needed.

3
1. If removed, install bearings onto worm (input) shaft.
Press on the inner bearing race until the bearing is tight
against the shaft shoulder.
2. If removed, press bearing cups into output caps. 4

3. If worm gear and bearing cones were removed from
output shaft, fit key into output shaft and position gear to
shaft. Press gear onto shaft until the gear is centered on
the key (Fig. 22). Pressing on the inner bearing race,
install bearing cones until they are tight against the gear.
4. Slide worm (input) shaft with bearings into housing Figure 22

noting correct orientation of shaft ends. 1. Press 3. Worm gear
2. Output shaft 4. Bearing cone
5. Adjust worm (input) shaft end play.
6. Once correct quantity of shims has been deter-
A. Position new shims to gearbox housing. mined, make final assembly of input caps to gearbox
housing.
Drive Train
B. Install both open caps (item 14) (O--ring and seal
not installed on cap) to gearbox housing. Torque cap A. Remove open input caps from housing.
screws 8 ft--lb (10.8 N--m) while checking for binding
of shaft. If shaft binds as screws are tightened, add B. Install new O--ring into groove of input cap. Apply
additional shims. light coat of grease on O--ring and gearbox housing
bore.
C. After both input caps are installed, check end play
of worm (input) shaft. Shaft end play should be from C. Taking care to not damage O--ring or shims,
0.001” to 0.003” (0.025 to 0.076 mm). End play can install input cap over input shaft and into housing.
be adjusted by adding or removing shims from be-
tween input caps and gearbox housing. Total shim D. Apply Loctite #242 to cap screw threads. Install
thickness at one input cap should be within 0.005” and torque cap screws 8 ft--lb (10.8 N--m).
(0.13 mm) of the total shim thickness of the other
cap.

7. Slide output shaft with worm gear and bearing cones 10.Install seals into input and output caps.
into housing. Align output shaft worm gear with input
shaft gear. A. Apply a light coat of Permatex to outside diameter
of new shaft seal.
8. Adjust output shaft end play.
B. To prevent seal damage, cover shaft keyway with
A. Position one red (0.002”) and one blue (0.005”) seal protector, cellophane tape or other thin material.
shim to both openings of gearbox housing. Apply light coat of grease on seal lip and place seal
on the shaft with the seal lip facing in.
B. Install both output caps (items 6 and 25) (O--rings
and seals not installed on caps) to gearbox housing. C. Press seal evenly into cap bore. Seal in output
Torque cap screws 8 ft--lb (10.8 N--m) while check- cap should be flush to the cap face. Seals in input
ing for binding of shaft. If shaft binds as screws are caps should be recessed 0.040” (1.0 mm) into cap.
tightened, add additional shims.
11. Install retaining ring to output shaft. Make sure that
C. After both output caps are installed, check end retaining ring is fully seated in shaft groove.
play of output shaft. Shaft end play should be from
0.001” to 0.003” (0.025 to 0.076 mm). End play can 12.If breather assembly was removed from gearbox,
be adjusted by adding or removing shims from be- apply Loctite #271 (or equivalent) to threads on each
tween output caps and gearbox housing. Total shim end of nipple. Install nipple into gearbox housing and
thickness at one output cap should be within 0.005” then thread coupling onto nipple. Apply thread sealant
(0.13 mm) of the total shim thickness of the other onto threads of breather and install breather onto cou-
cap. pling.
D. Check gear contact by applying bluing compound

to worm gear (item 3) teeth. Turn worm (input) shaft
while putting a slight load on output shaft. Inspect
contact on gear by viewing through drain plug open- 2
ing in gear housing. Worm contact should be cen-
tered on both sides of the gear (Fig. 23). To adjust
gear contact while maintaining shaft end play, move
shim(s) from one side of the gear housing to the oth-
er.
1
9. Once correct quantity of shims has been determined
and gear contact has been adjusted, make final assem-
bly of output caps to gearbox housing.
A. Remove output caps from gearbox housing. Figure 23

1. Worm gear (output shaft) 2. Gear pattern
B. Install new O--rings into groove of output caps.
Apply light coat of grease on O--rings and gearbox
housing bores.
C. Taking care not to damage O--rings or shims,

install caps over output shaft and into housing.
D. Apply Loctite #242 to cap screw threads. Install

and torque cap screws 8 ft--lb (10.8 N--m).

Drive Train

Stub Axle and Driveshaft
200 to 250 in--lb

21 Loctite #271
22 18 (22.6 to 28.2 N--m)
20 17
40 to 60 ft--lb
(55 to 81 N--m)
13 220 to 225 ft--lb
19 12 Loctite #271 (299 to 305 N--m)
2 10
7
15
55 to 65 ft--lb
14
(75 to 88 N--m)
6 16
4
1
23
11
9 5
8
RIGHT
3
Loctite #271
FRONT
Figure 24
1. Lug nut (5 used per wheel) 9. Lock washer (4 used per wheel) 17. Yoke strap (2 used per yoke)
2. Flange head screw 10. Brake assembly 18. Bolt (4 used per yoke)
3. Wheel assembly 11. Brake cable clip 19. Driveshaft assembly
4. Brake drum 12. Axle housing assembly 20. Lock nut (2 used per driveshaft)
5. Stub axle 13. Flange head screw (3 used per wheel) 21. Cap screw (2 used per driveshaft)
6. Lock washer (5 used per wheel) 14. End yoke 22. Hardened washer (2 per driveshaft)
7. Drive stud (5 used per wheel) 15. Flat washer 23. Parking brake cable
8. Cap screw (4 used per wheel) 16. Flange lock nut
Removal (Fig. 24) 4. Remove the straps securing driveshaft bearing

cross to the end yoke, then disconnect driveshaft from
1. Park machine on a level surface, stop engine and re- the end yoke.
move key from the ignition switch.
5. Loosen flange lock nut that secures end yoke to stub
2. Chock front wheels. Raise rear wheel using a jack or axle. Remove flange lock nut, flat washer and flange
hoist (see Jacking Instructions in Chapter 1 -- Safety). head screw. Pull end yoke from stub axle.
Support rear of machine with jack stands.
6. Carefully slide stub axle from axle housing.
3. Loosen and remove lug nuts. Remove rear wheel.
Remove brake drum (see Rear Wheels and Brakes in 7. To remove driveshaft from transaxle, loosen and re-
the Service and Repairs Section of Chapter 8 -- Chas- move lock nuts, cap screws and hardened washers se-
sis). curing driveshaft to splined axle shaft of transaxle. Slide
driveshaft outward and remove from transaxle.
NOTE: Loosening driveshaft at transaxle will allow eas-
ier driveshaft removal from end yoke.

8. To remove axle housing from machine:
8
A. Remove brake assembly from axle housing (see
Rear Wheels and Brakes in the Service and Repairs 6
Section of Chapter 8 -- Chassis). Spacer
Step
B. Remove three (3) flange head screws that secure
axle housing to machine frame. Remove axle hous- 2
ing.
7
Bearing Service (Fig. 25)
1. Inspect bearings and replace if necessary. If outer

bearing cone is removed from stub axle, bearing set 5
must be replaced. 4
3
IMPORTANT: Bearings, with bearing cups and thin
1
bearing spacer, are a MATCHED SET. Use one bear-
ing set for each axle housing. Bearing set compo- Figure 25
nents are NOT INTERCHANGEABLE. 1. Outer bearing cone 5. Axle housing
2. Outer bearing cup 6. Inner bearing cup
2. Remove seal from back of axle housing. 3. Thin bearing spacer 7. Inner bearing cone
4. Large bearing spacer 8. Seal
3. Remove inner bearing cone. Slide bearing spacers
from axle housing noting orientation of step in large Installation (Fig. 24)
bearing spacer (toward seal location).
1. If removed, install axle housing to frame:
4. Press inner and outer bearing cups from housing.
Press outer bearing cone from stub axle. A. Apply Loctite #271 (or equivalent) to the threads
of three (3) flange head screws that mount axle
5. Clean all parts thoroughly before reassembly. housing to machine.
6. Position inner and outer bearing cups to axle hous- B. Position axle housing to frame and install three
ing. Press bearing cups into housing until they seat (3) flange head screws to secure axle housing to ma-
against the housing shoulder. chine frame.
7. Pack bearings with lithium based grease. C. Install brake assembly to axle housing (see Rear
Wheels and Brakes in the Service and Repairs Sec-
8. Position larger bearing cone (item 1), wide end first, tion of Chapter 8 -- Chassis).
onto stub axle. Press bearing onto stub axle putting
pressure on inner race of bearing. Slide thin bearing 2. If driveshaft was removed from transaxle:
spacer onto stub axle.
A. Apply antiseize lubricant to transaxle shaft. Slide
9. Insert stub axle with bearing and thin spacer into axle driveshaft clamp end onto splined transaxle shaft.
housing.
B. Apply Loctite #242 (or equivalent) to threads of
10.Fill axle housing with grease. cap screws that secure driveshaft to transaxle shaft.
11. Insert large bearing spacer onto stub axle inside C. Align mounting holes in driveshaft with relief in Drive Train
housing. Orientate the stepped end of the spacer toward transaxle shaft.
the seal location.
D. Install cap screws, hardened washers and lock
12.Insert smaller, greased bearing cone, small end first, nuts to secure driveshaft to transaxle shaft.
onto stub axle inside housing.
3. If wheel studs were removed from stub axle, apply
IMPORTANT: The seal must be pressed in so it is Loctite #271 (or equivalent) to threads near head of
flush with the end of the axle housing. The lip of the stud. Install stud with lock washer into stub axle and
seal must be toward the bearing. torque from 40 to 60 ft--lb (55 to 81 N--m).
13.Install new seal over shaft and into housing. Be care- 4. Insert stub axle with greased bearing and thin spacer
ful to not damage the seal during installation. into axle housing. Be careful to not damage the bearing
seal during installation.
5. Apply antiseize lubricant to splines of stub axle. 9. Lubricate driveshaft grease fittings.
6. Slide end yoke onto stub axle shaft. 10.Install brake drum and wheel. Tighten wheel nuts to
a torque of 55 to 65 ft--lb (75 to 88 N--m) (see Rear
7. Insert cap screw through flat washer, end yoke and Wheels and Brakes in the Service and Repairs Section
stub axle. Install flange nut onto cap screw. Torque of Chapter 8 -- Chassis).
flange nut from 220 to 225 ft--lb (299 to 305 N--m).
11. Lower machine to ground.
8. Position driveshaft cross to the end yoke. Install the
straps to secure driveshaft bearing cross to the end
yoke. Torque bolts from 200 to 250 in--lb (22.6 to 28.2
N--m).

Driveshaft Universal Joint Service
1. Remove driveshaft from machine:

TRANSAXLE
A. For transaxle driveshaft (Fig. 26) removal, see 3
DRIVESHAFT 2
Pump Drive Gearbox Removal in this section. 4
5
B. For rear axle driveshaft (Fig. 27) removal, see 6 1
Stub Axle and Driveshaft Removal in this section.
7
2. Remove snap rings that secure bearings.
8
IMPORTANT: Yokes must be supported when re-
7
moving and installing bearings to prevent damage.
3. Use a press to remove cross and bearings from 10

yokes.
4. To install new cross and bearings: 3 4

9
1
A. Apply a coating of grease to all bearing bores.
Figure 26
B. Press one bearing partially into yoke.
1. Cap screw (2 per yoke) 6. Yoke and tube
C. Insert cross into yoke and bearing. 2. Splined yoke 7. Cross and bearing kit
3. Lock nut (2 per yoke) 8. Keyed yoke
4. Grease fitting 9. Set screw
D. Hold cross in alignment and press bearing in until 5. Grease fitting 10. Yoke and shaft
it hits the yoke.
E. Install snap ring into yoke groove to secure instal-

led bearing.
REAR AXLE
10 DRIVESHAFT
9
F. Place second bearing into yoke bore and onto 8
cross shaft. Press bearing into yoke and secure with 11
snap ring. 2
G. Repeat procedure for other yoke. 1
H. Grease cross until grease comes out of all four (4) 3

7
cups. 4
5. Install driveshaft to machine:

6
A. For transaxle driveshaft installation, see Pump
Drive Gearbox Installation in this section. 5
Drive Train
B. For rear axle driveshaft installation, see Stub 3
Axle and Driveshaft Installation in this section.
Figure 27
1. Grease fitting 6. Shaft and tube yoke
2. Seal 7. Lock nut (2 per yoke)
3. Snap ring 8. Clamp yoke
4. Cross and bearing kit 9. Hardened washer
5. Yoke and hub 10. Cap screw (2 per yoke)

Transaxle
8
8
9
10
11
38 12
22 21
38 39 13
20
40 23
24 19 14
37 22
26 23
24 21
2 20 15
Antiseize 1 18
Loctite #242 Lubricant 16
26 19 17
13
18
32 6 7
3
33 4 5
30 Loctite #242
Antiseize 29
RIGHT Lubricant
31 28
32 27
FRONT 33
34 25
35 80 to 90 ft--lb
34 36 (108 to 122 N--m)
Figure 28
1. Transaxle assembly 15. O--ring 28. O--ring
2. O--ring 16. Oil filter head 29. Strainer
3. Input shaft cover plate 17. Oil filter 30. O--ring
4. Cap screw (3 used) 18. Shift cable 31. Front transaxle mount
5. Lock nut 19. Jam nut 32. R--clamp (2 used)
6. Hardened washer 20. Cable clevis 33. Flange head screw (2 used)
7. Cap screw (2 used per driveshaft) 21. Cotter pin 34. Flange head screw (10 used)
8. Flange head screw (4 used) 22. Clevis pin 35. Shift cable mount
9. Flange head screw (2 used) 23. Lock nut 36. Lock washer
10. Flange head screw (2 used) 24. Hardened washer 37. Cap screw (2 used per yoke)
11. Lock washer (2 used) 25. Driveshaft assembly (2 used) 38. Lock nut
12. Transaxle strap mount (2 used) 26. Shift lever 39. Transaxle driveshaft
13. Flange nut (4 used) 27. Suction hose 40. Socket head screw
14. Hydraulic return hose

Transaxle Removal (Fig. 28)

switch. 2
2. Drain oil from transaxle into a suitable container.
3. Disconnect negative (--) cable from battery first and

then positive (+) cable.
4. Block front wheels. Raise rear of machine and se- Figure 29

cure machine with jack stands so transaxle can be re-
1. Speed sensor connector 2. Suction hose
moved by sliding out under rear of machine (see Jacking
Instructions in Chapter 1 -- Safety).
5. Unplug speed sensor connector from machine wire 3

harness (Fig. 29). 2
6. Label shift cables to ease reassembly. Loosen shift

cable jam nuts at cable mount (Fig. 30). Remove cotter
pin and clevis pin that attach shift cable ends to trans- 1
axle shift arm levers. Pull shift cables free from mount.
2
7. Disconnect hydraulic return hose from top of trans-
axle (Fig. 30). Locate, remove and discard hose O--ring.
8. Disconnect suction hose from transaxle (Fig. 29).

Locate, remove and discard suction hose O--ring. Posi- 1
tion suction hose away from transaxle.
9. Put caps or plugs on all open hoses and fittings to

prevent contamination. Figure 30
1. Shift cable jam nut 3. Hydraulic return hose
10.Remove two (2) R--clamps that secure LH parking 2. Clevis pin
brake cable to front transaxle mount.
11. Remove the straps securing driveshaft bearing 200 to 250 in--lb
Loctite #242 (22.6 to 28.2 N--m)
cross to the end yoke at both rear wheel hubs (Fig. 31).
4
12.Loosen and remove cap screws, hardened washers 5
3
and lock nuts that secure driveshafts (both right and left
sides) to transaxle axle shafts (Fig. 32). Remove both 2
driveshafts from machine.
6
13.Loosen and remove cap screws and lock nuts that
secure universal joint of transaxle driveshaft to input 7
Drive Train
shaft of transaxle (Fig. 33). Disconnect driveshaft from
transaxle input shaft.
14.Support transaxle to prevent it from shifting or falling. 1

Remove four (4) flange nuts that secure transaxle
mounts to machine frame. Lower transaxle with mounts
from machine. Figure 31
1. Driveshaft assembly 5. Bolt (2 per strap)
15.If required, remove front transaxle mount, shift cable 2. Lock nut 6. Yoke strap (2 per yoke)
mount and transaxle strap mounts from transaxle. 3. Hardened washer 7. End yoke
4. Cap screw (2 per shaft)
16.Remove oil strainer from transaxle. Locate, remove
and discard strainer O--ring.

Transaxle Installation (Fig. 28)
1. Lubricate new oil strainer O--ring with Dexron III ATF

oil and position on strainer. Install strainer into transaxle
and torque from 80 to 90 ft--lb (108 to 122 N--m).
2. If removed, install front transaxle mount, shift cable

mount and transaxle strap mounts to transaxle.
1
3. Apply antiseize lubricant to transaxle shafts.
4. Position transaxle to machine. Slide universal joint of

transaxle driveshaft onto input shaft of transaxle. Slide 2 3
both driveshafts onto transaxle axle shafts. Position dri-
veshaft bearing cross to the end yoke at both rear wheel
hubs and loosely install straps.
Figure 32
5. Secure transaxle to machine by installing and tight-
1. Cap screw w/washer 3. Driveshaft (RH)
ening four (4) flange nuts onto cap screws. 2. Driveshaft (LH)
6. Secure driveshafts to transaxle:
A. Tighten the strap bolts to secure driveshaft bear-

ing cross to the end yoke at wheel hubs (Fig. 31).
Torque bolts from 200 to 250 in--lb (22.6 to 28.2
N--m).
B. Align mounting holes in driveshafts with reliefs in

transaxle shafts.
C. Apply Loctite #242 (or equivalent) to threads of

cap screws used to secure driveshafts to transaxle 2 1
shafts.
D. Install cap screws and lock nuts to secure drive-

shaft to transaxle input shaft (Fig. 33).
E. Install cap screws, hardened washers and lock

nuts to secure driveshafts to transaxle axle shafts Figure 33
(Fig. 32). 1. Cap screw 2. Driveshaft
7. Secure LH parking brake cable to front transaxle 13.Plug speed sensor connector into wire harness (Fig.
mount with two (2) R--clamps. 29).
8. Remove all caps or plugs placed on hydraulic hoses 14.Lower machine to ground.
and fittings during disassembly.
9. Lubricate new suction and return hose O--rings with

Dexron III ATF oil. Install suction and return hoses to WARNING
transaxle.
Connecting battery cables to the wrong post
10.Position shift cables to cable mount noting cable could result in personal injury and/or damage to
identification made during disassembly. Center the the electrical system.
cable threads to the cable mounts and secure cables
with jam nuts (Fig. 30). 15.Connect positive (+) cable to battery first and then
negative (--) cable.
11. Check and adjust shift cables as needed (see Shift
Cable Adjustment in the Adjustments section of this 16.Fill transaxle with Dexron III ATF oil (see Operator’s
chapter). Manual).
12.Secure shift cable ends to shift arm levers of trans-
axle with clevis pins and cotter pins.
Transaxle Service
Transaxle Disassembly
1. Thoroughly clean outside surface of transaxle.
NOTE: Item numbers in figures are shown in order of 2

disassembly; for example, remove item 1 first, then item
2, etc. Assemble in reverse order; for example, install
item 1 last.
2. Loosen four (4) cap screws (items 1 and 2) and re- 1

move fork shaft cap (item 3) from center plate. Note
1
location of longer cap screw. Be careful when removing
cap as steel balls inside are spring loaded.
3
3. Inspect fork shaft cap for cracks or damage and re-
place if necessary.
Figure 34
1. Cap screw 3. Fork shaft cap
2. Longer cap screw
4. Hold hand over the area and shift R--1 and 2--3 levers
to move shafts outward so two (2) balls (item 3), two (2)
springs (item 2) and spindle lock (item 1) can be re-
moved from center plate.
2
5. Remove three (3) cap screws that secure input shaft
cover plate to transaxle. Remove cover plate. 4
3
Figure 35
IMPORTANT: The center plate has one (1) tabbed

shim (item 4) with three (3) tabless shims (item 2)
(Fig. 36).
3
6. Loosen cap screws and separate center plate from 4
transaxle case. Note dowel pin locations in transaxle 1
case. Remove seal cap (item 1), shims (items 2 and 4)
2
Drive Train
and snap ring (item 3) from center plate.
Figure 36

7. Remove reverse shaft (item 1) from transaxle case.
Figure 37
8. Remove main shaft assembly (item 1) together with

2nd--3rd fork shaft assembly (item 2) from transaxle 2
case.
NOTE: This shaft not

used on Multi Pro
Figure 38
9. Remove, all at the same time, reduction shaft as-

sembly (item 1), 1st--reverse fork shaft assembly (item NOTE: This shaft not
used on Multi Pro
2) and countershaft assembly (item 3) 2
Figure 39

10.Loosen five (5) cap screws (item 1) and remove dif- 3
ferential carrier with L.H. axle shaft assembly (item 2)
and shims (item 3) from side cover (item 4).
2
1
4
Figure 40
11. Loosen cap screws (item 1) and remove side cover

(item 2) from transaxle case. Note locations of two (2) 3
dowel pins (item 3) in transaxle case. 1
12.Inspect side cover for cracks or damage and replace
if necessary.
Figure 41
13.Loosen cap screws (item 1) and remove R.H. axle

shaft assembly (item 2) from transaxle case.
1
Figure 42
14.Slide differential gear assembly (item 1) from trans-

axle case. 1
Drive Train
Figure 43

15.To remove shift arms:
3
A. Loosen and remove lock nuts (item 3) that secure
shift arms (items 1 and 4). Remove flat washers (item 2
2) and shift arms.
1 3
B. Loosen and remove cap screws (item 5). Re- 5
move lock washers (item 6) and keeper plates (item 6 2
7).
7 4
8
C. Remove oil seals (item 8) from transaxle case.
8 5
D. Inspect shift arms and keeper plates for bending
or damage and replace if necessary. 6
Figure 44
1. Shift arm (2--3) 5. Cap screw
2. Flat washer 6. Lock washer
3. Lock nut 7. Keeper plate
4. Shift arm lever (1--R) 8. Oil seal
16.Loosen five (5) cap screws (item 1) and remove nut

with washer (item 2). Separate P.T.O. cover (item 3) and 2
O--ring from transaxle case. Inspect P.T.O. cover for
5
cracks or damage and replace if necessary.
3
17.If necessary, remove oil cap (item 4) with O--ring from
transaxle case.
18.If necessary, remove air breather (item 5) from trans-

axle case.
4 1
Figure 45
19.If necessary, remove cap screw with lock washer

(item 1) and slide speed sensor (item 2) from upper cov-
er (item 4).
4
20.Loosen and remove cap screws (item 3) that secure
upper cover to transaxle case. Remove upper cover
(item 4) from case.
2 3
Figure 46

21.Disassemble main shaft assembly: 7
4 8 10 13
3 16 14
A. Use a bearing puller to remove bearing (item 1)
from main shaft.
B. Remove snap ring (item 2) and thrust washer

(item 3). Measure thickness of thrust washer. Re-
place washer if it is less than 0.0709” (1.8 mm) thick.
C. Remove 36T gear (item 4) and two (2) needle

bearings (item 5). Inspect needle bearings and re-
9
place if necessary.
18 1 12 17 15
D. Remove synchro ring (item 6). 2 5 6 11
E. Remove retaining ring (item 7). Figure 47

F. Remove synchro shifter (item 8) together with
springs, hub and three (3) keys. 8
4
G. Remove key (item 9). 3 14

2 5
16
H. Remove retaining ring (item 10). 1
17
6
I. Remove synchro ring (item 6), 22T gear (item 11), 9
two (2) needle bearings (item 12) and thrust washer 18
(item 13). Inspect needle bearings and replace if
12 15
necessary.
6
10
J. Use a bearing puller to remove bearing (item 14).
7
K. Remove 14T gear (item 15), retaining ring (item 13
16) and 20T gear (item 17).
11
Figure 48
Drive Train

22.Disassemble reduction shaft assembly:
1 5 14 13 12 7
from reduction shaft.
B. Remove 25T gear (item 2), collar (item 4) and

32T gear (item 5).
C. Use a bearing puller to remove bearing (item 6).
D. Remove thrust washer (item 7), 40T gear (item 8)

and needle bearing (item 9).
E. Remove retaining ring (item 10).

3 2 4
16 15 11 10
F. Remove synchro shifter (item 11) together with 8 6
springs, hub and three (3) keys. 9
G. Remove key (item 12) from reduction shaft. Figure 49
H. Remove synchro ring (item 13) from 47T gear

(item 14). 6
9
I. Remove 47T gear (item 14), needle bearings 8
(item 15) and thrust washer (item 16). Inspect needle 10
bearings and replace if necessary. Measure thick- 11
ness of thrust washer. Replace thrust washer if thick- 14
7
ness is less than 0.0709” (1.8 mm).
15 13
12
3
5 13
4
2
1 16
Figure 50

23.Disassemble reverse shaft assembly:
4
from reverse shaft.
B. Remove 33T gear (item 2).
C. Use a bearing puller to remove bearing (item 3)

from reverse shaft.
3
2 1
Figure 51
24.Disassemble countershaft assembly:

8
from countershaft. 7
4
B. Remove collar (item 2) and retaining ring (item 5). 3
C. Remove countershaft gear (item 3).

2
D. Remove retaining ring (item 6) and collar (item 4)
1
from shaft.
E. Use a bearing puller to remove two (2) bearings

(item 8) from shaft.
6
Figure 52
Drive Train

25.Disassemble fork shaft assemblies:
3 6
1 4
A. Remove spring pin (item 1) from 2nd--3rd fork
shaft assembly.
B. Remove shift fork (item 2) from fork shaft (item 3).
C. Remove spring pin (item 4) from 1st--Reverse

fork shaft assembly. 5
2
D. Remove fork (item 5) from fork shaft (item 5).
Figure 53
26.Disassemble differential gear assembly:

1 4 10 7
A. Use a bearing puller to remove bearing (item 1) 2
from differential case.
B. Remove retaining ring (item 2).
C. Use a bearing puller to remove bearing (item 3).
D. Loosen and remove twelve (12) flange head

screws (item 4) that secure ring gear (item 5) to dif-
ferential case.
E. Remove ring gear (item 5) from differential case

and remove two (2) alignment pins (item 6).
6
F. Drive spring pin (item 7) out of pinion shaft (item 11 5 8 9 13 12 3
8).
Figure 54
G. Remove pinion shaft (item 8) from differential
case.
10
H. Remove two (2) differential pinion gears (item 9) 2 9
and two (2) washers (item 10). 3
5 8
7 11
I. Remove L.H. side gear (item 11), R.H. side gear 6 13
13
(item 12) and two (2) thrust washers (item 13).
12
9
10
4 1
Figure 55

27.Disassemble differential carrier (L.H. axle shaft) as-
sembly: 1
L.H. AXLE SHAFT
A. Remove O--ring (item 1) from differential carrier 4 6
(item 8).
8
B. Remove retaining ring (item 2) from carrier.
C. Remove L.H. axle shaft assembly (item 3) from

carrier.
D. Remove retaining ring (item 4) and washer (item 2

5) from axle shaft. 5
7
E. Use a bearing puller to remove bearing (item 6) 3
from axle shaft.
Figure 56
F. Remove oil seal (item 7) from carrier (item 8).
28.Disassemble R.H. axle shaft assembly:

1
A. Remove R.H. axle shaft assembly (item 1) from
6
seal cover (item 7). 3
B. Remove retaining ring (item 2) and washer (item

3) from axle shaft.
C. Use a bearing puller to remove bearing (item 4)

from axle shaft. Locate and remove washer (item 6). 7
5
D. Remove oil seal (item 5) from seal cover. R.H. AXLE SHAFT 4
2
Figure 57
Drive Train

Transaxle Inspection
1. Thoroughly clean and dry all parts.
2. Use emery cloth to remove nicks and burrs from all

parts.
3. Inspect synchronizer ring:
A. Inspect the chamfer for excessive wear or dam-

age.
B. Inspect inner tapered area for excessive wear or

damage.
C. Measure the clearance between synchronizer

ring and synchro gear in three equally spaced points.
If clearance is less than 0.0197” (0.5 mm) replace the
synchronizer ring.
Figure 58
4. Inspect synchro gears:

36T
A. Inspect the cone surface for roughness, material
transfer (brass color material) or damage.
B. Inspect the spline chamfer for excessive chipping

or damage.
C. Inspect I.D. of synchro gears on main shaft for ex-

cessive wear or scoring (Fig. 59). If synchro gear has
the following I.D., replace the synchro gear:
22T I.D. exceeds 1.027” (26.08 mm) 22T

36T I.D. exceeds 1.027” (26.08 mm)
D. Inspect I.D. of synchro gears on reduction shaft Figure 59

for excessive wear or scoring (Fig. 60). If synchro
gear has the following I.D., replace the synchro gear:
40T I.D. exceeds 1.027” (26.08 mm)

47T I.D. exceeds 1.145” (29.08 mm)
47T
40T
Figure 60

5. Inspect hub, shifter, synchro keys and synchro
springs:
A. Inspect hub for worn or damaged spline.
B. Inspect shifter for chipping or damaged chamfer.
C. Inspect synchro keys for wear or damage.
D. Inspect synchro springs for wear or damage.
E. The shifter should move freely on the hub.
F. Measure the clearance between shifter groove

and fork. Replace shift fork if the clearance exceeds
0.039” (1.0 mm).
Figure 61
6. Inspect main shaft:
A. Inspect main shaft for worn or damaged surfaces.

If O.D. of needle bearing surface is less than 0.864”
(21.95 mm), replace the main shaft.
B. Inspect lip portion of oil seal for wear or damage. NEEDLE BEARINGS
C. Inspect main shaft input spline for wear or dam- OIL SEAL AREA
age. INPUT SPLINE
Figure 62
IMPORTANT: The center plate has one (1) tabbed

(Fig. 63).
3
7. Inspect retaining ring (item 3) and shims (items 2 and 4
4) for damage (Fig. 63). Replace all parts if any compo- 1
nent is cracked or broken.
2
Figure 63
Drive Train

8. Inspect center plate for cracks and damage. Replace
center plate if the retaining ring groove has more than
15% of its edges damaged due to nicks, rounding,
cracks or dents (Fig. 64 and 65).
UNDAMAGED
GROOVE EDGES
Figure 64
DAMAGED
GROOVE EDGES
Figure 65
9. Inspect reduction shaft:

STD. O.D. 0.984” (25 mm)
A. Inspect reduction shaft for wear or damage. If Reject O.D. 0.982” (24.95 mm)
O.D. of needle bearing area is less than reject size
specified in Figure 66, replace the reduction shaft.
STD. O.D. 0.866” (22 mm)

Reject O.D. 0.864” (21.95 mm)
Figure 66

10.Inspect countershaft:
A. Inspect countershaft for wear or damage. If O.D.

of inner portion is less than 1.100” (27.95 mm) or 71T
gear portion is less than 1.179” (29.95 mm), replace
the countershaft.
B. Inspect the gear contact condition of the bevel 71 TOOTH GEAR

gear. INNER PORTION
Figure 67
11. Inspect differential:

WASHERS (2)
A. Inspect pinion shaft for excessive wear or dam-
age. If O.D. is less than 0.707” (17.95 mm), replace
the pinion shaft.
PINION SHAFT
B. Measure thickness of pinion shaft washers. If
thickness is less than 0.035” (0.9 mm), replace the
washers. THRUST
WASHERS (2)
C. Measure thickness of side gear thrust washers. If
thickness is less than 0.043” (1.1 mm), replace the
thrust washers.
D. Inspect the gear contact condition of the ring

gear.
Figure 68
E. Inspect differential case for wear in side gears
and pinion shaft mating area. Replace the case if ma-
chined surfaces are scored or if the pinion shaft fits
loosely in the bore.
Drive Train

Transaxle Assembly
NOTE: Item numbers in figures are shown in reverse

order of assembly; for example, when reassembling,
install item 1 last.
IMPORTANT: Be careful not to damage mating sur-

faces when removing gasket material.
1. Clean gasket material from all transaxle mating sur-

faces before reassembling. Make sure all parts are
clean and free of dirt and dust.
2. Assemble differential carrier (L.H. axle shaft) assem-

bly (Fig. 69): 1 L.H. AXLE SHAFT
A. Apply multi--purpose grease on new oil seal (item 4 6

7) and install seal into differential carrier (item 8). 8
B. Use a press to install bearing (item 6) onto L.H.

axle shaft (item 3).
C. Install washer (item 5) and retaining ring (item 4)

onto L.H. axle shaft. Make sure that retaining ring is
2
fully seated in axle groove.
5
D. Install L.H. axle shaft assembly into carrier. 7
3
E. Install retaining ring (item 2) into groove in carrier.
Make sure that retaining ring is fully seated in carrier Figure 69
groove.
F. Apply multi--purpose grease onto O--ring (item 1)

and install O--ring onto carrier.
3. Assemble R.H. axle shaft (Fig. 69):

1
A. Apply multi--purpose grease on oil seal (item 5)
6
and install seal into seal cover (item 7). 3
B. Use a press to install bearing (item 4) onto R.H.

axle shaft.
C. Install washer (item 3) and retaining ring (item 2)

onto R.H. axle shaft. Make sure that retaining ring is 7
fully seated in axle groove. 5
R.H. AXLE SHAFT 4
D. Insert washer (item 6) into seal cover. 2
E. Install R.H. axle shaft assembly into seal cover. Figure 70

4. Assemble differential gears:
1 4 10 7
A. Apply moly disulfide grease on washers (item 2
10), holes of pinion gears (item 9), side gear thrust
washers (item 13) and hubs of side gears (item 11
and 12).
B. Install side gear thrust washers (item 13), side

gears (item 11 and 12), washers (item 10) and differ-
ential pinion gears (item 9) into differential case.
C. Rotate side gears until holes of pinion gears and

washers line up with holes of differential case.
D. Grease the pinion shaft (item 8) and insert it into

the differential case. 6
11 5 8 9 13 12 3
E. Assemble lock pin (item 7). Drive the pin to the
approximate center location of the pinion shaft. Pay Figure 71
attention to direction of slit in lock pin (Fig. 73).
10
F. Check for smooth revolution of pinion gears and 2 9
side gears. 3
5 8
7 11
G. Completely clean oil from fastener threads in ring 6 13
gear (item 5). 13
12
NOTE: Ring gear and countershaft are supplied in
matched sets only.
9
H. Insert two (2) dowel pins (item 6) onto ring gear Thread locking 10
(item 5). compound
I. Completely clean oil from threads of cap screws 18 to 22 ft--lb 4 1

(item 4). (24.5 to 29.5 N--m)
J. Clean oil from contact surface of differential case Figure 72

and ring gear.
K. Drive ring gear onto differential case.
NOTE: It is recommended that whenever the ring

gear screws are removed that they be replaced with NOTE: This
new screws. collar not
used on
L. Apply thread locking compound (e.g. Loctite) to Multi Pro
threads of cap screws (item 4).
M. Install cap screws into ring gear. Torque cap Drive Train
screws from 18 to 22 ft--lb (24.5 to 29.5 N--m).
Figure 73
N. Use a press to install bearing (item 1) onto differ-
ential case.
O. Use a press to install bearing (item 3) onto differ-

ential case.
P. Install retaining ring (item 2) to secure bearing.

5. Assemble 1st--reverse and 2nd--3rd fork shaft:
3 6
1 4
A. Insert 1st--reverse fork shaft (item 3) into 1st--re-
verse fork (item 2).
B. Drive spring pin (item 1) into fork and fork shaft.

Pay attention to direction of slit in spring pin.
C. Insert 2nd--3rd fork shaft (item 6) into 2nd--3rd 5

fork (item 5). 2
D. Drive spring pin (item 4) into fork and fork shaft. Figure 74
Pay attention to direction of slit in spring pin.
6. Assemble countershaft:
8
A. Use a press to install two (2) new bearings (item
8) onto countershaft. 7
4
B. Install collar (item 4) and retaining ring (item 6). 3
C. Install countershaft gear (item 3) onto shaft.

2
D. Install retaining ring (item 5).
1
E. Slide collar (item 2) onto shaft.
F. Use a press to install new bearing (item 1).

6
Figure 75

7. Assemble synchro hub:
A. Install three (3) keys (item 1) into grooves of hub

(item 2).
1 2
Figure 76
B. Install shifter (item 1) onto hub assembly (item 2).
Figure 77
C. Insert two (2) springs (item 1) into hub to secure

hub assembly. Pay attention to direction of spring.
Figure 78
Drive Train
Figure 79

8. Assemble reduction shaft:
1 5 14 13 12 7
A. Apply moly disulfide grease to thrust washer
(item 16) and two (2) needle bearings (item 15).
Install washer, needle bearings and 47T gear (item
14) onto reduction shaft (item 3). Oil groove on wash-
er must face the gear.
B. Apply Dexron III ATF oil on cone face of gear

(item 14). Install synchro ring (item 13) onto gear.
C. Insert key (item 12) into reduction shaft slot.
D. Install synchro hub sub--assembly (item 11).

3 2 4
16 15 11 10 8 6
E. Install retaining ring (item 10).
9
F. Insert needle bearing (item 9) into 40T gear (item
8). Slide gear and bearing assembly onto shaft. Figure 80
G. Install thrust washer (item 7). Oil groove on wash-

er must face the gear. 6
9
H. Use a press to install bearing (item 6) onto shaft. 8
10
11
I. Install 32T gear (item 5), collar (item 4) and 25T 14
gear (item 2) onto shaft. 7
15 13
J. Use a press to install bearing (item 1) onto shaft. 12
3
5 13
4
2
1 16
Figure 81
9. Assemble reverse shaft:
A. Install 33T gear (item 2) onto reverse shaft (item 4

4).
B. Use a press to install bearings (item 3 and 1).
3
2 1
Figure 82

10.Assemble main shaft: 7
4 8 10 13
3 16 14
A. Install 20T gear (item 17) and retaining ring (item
16).
B. Install 14T gear (item 15).
C. Use a press to install bearing (item 14) onto shaft.
D. Apply moly disulfide grease onto thrust washer

(item 13) and two (2) needle bearings (item 12).
Install washer and needle bearings onto main shaft. 9
Oil groove on washer must face the gear.
18 1 12 17 15
2 5 6 11
E. Install 22T gear (item 11) and retaining ring (item
10). Figure 83
F. Apply Dexron III ATF oil on cone face of gear
(item 11). Install synchro ring (item 6) onto gear. 8
4
G. Insert key (item 9) into main shaft slot. 3 14

2 5
16
H. Install synchro hub sub--assembly (item 8). 1
17
6
I. Install retaining ring (item 7). 9
18
J. Apply Dexron III ATF oil to cone face of 36T gear
(item 4). Install synchro ring (item 6) onto gear. 12 15
6
10
K. Apply moly disulfide grease onto two (2) needle
bearings (item 5). Insert needle bearings into gear 7
(item 4). 13
L. Install gear (item 4) with synchro ring and needle 11

bearings onto main shaft.
Figure 84
M. Apply moly disulfide grease to thrust washer
(item 3). Install washer and snap ring (item 2) to
shaft. Oil groove on washer must face the gear.
N. Use a press to install bearing (item 1) onto shaft.
Drive Train

11. Assemble shift arms:
18 to 22 ft--lb
3
A. Apply multi--purpose grease on lips of new oil 11 to 13 ft--lb (24.5 to 29.5 N--m)
seals (item 14). Install oil seals into transaxle case. (15 to 17 N--m)
2
B. Position keeper plates (item 13) and secure with
cap screws (item 12). Torque cap screws from 11 to 1
5 3
13 ft--lb (15 to 17 N--m).
6 2
8
C. Apply Loctite #680 (or equivalent) to threads and
7 4
tapers of shift fork shafts.
Loctite #680
D. Install 1st--reverse shift arm lever (item 9). 8 5
6
E. Install 2nd--3rd shift arm lever (item 1).
F. Install flat washers (item 2) and lock nuts (item 3) 7

to secure shift arms. Torque shift arm retaining lock
nuts from 18 to 22 ft--lb (24.5 to 29.5 N--m).
Figure 85
1. Shift arm (2--3) 5. Cap screw
2. Flat washer 6. Lock washer
3. Lock nut 7. Keeper plate
4. Shift arm lever (1--R) 8. Oil seal

12.Install reduction shaft and countershaft together with
1st--reverse fork shaft. Insert head of shift arm into
groove of fork (item 1) when installing assembly.
NOTE: This
shaft not
used on
Multi Pro
Figure 86
NOTE: Not
used on
Multi Pro
Figure 87
13.Install main shaft together with 2nd--3rd fork shaft.

Insert head of shift arm into groove of fork (item 1) while
installing.
Figure 88
Drive Train
Figure 89

14.Install reverse shaft (item 1) into transaxle case. Ro-
tate main shaft and reverse shaft gears to mesh gears
when installing.
Figure 90
15.Install center plate onto transaxle: 18 to 22 ft--lb

(24.5 to 29.5 N--m)
A. Thoroughly clean mating surfaces of transaxle
case and center plate. Insert two (2) dowel pins into
transaxle case.
B. Apply silicone sealant onto mating surface of

center plate. Carefully install center plate onto trans-
axle case.
C. Install and tighten cap screws to a torque of 18 to

22 ft--lb (24.5 to 29.5 N--m) to secure center plate.
D. Apply multi--purpose grease onto lips of main

shaft oil seal. Insert oil seal into center plate flush
Figure 91
with face of housing.

IMPORTANT: The center plate uses one (1) tabbed
(Fig. 92).
2
NOTE: The thickest shim of the shim set (item 3) should 4
be positioned against the retaining ring (Fig. 92). 1
3
16.Insert tabbed shim (item 4) against the bearing. In-
sert shim set (item 3) against the tabbed shim. Use thick-
est shims in set possible, that will permit installation of
the snap ring (Fig. 92 and 93).
Figure 92
5
3 1
4 2
Figure 93
1. Countershaft 4. Retaining ring
2. Bearing 5. Center plate
3. Shims 6. Sealing cap
17.Install retaining ring into the groove of the center

plate (Fig. 93 and 94).
Drive Train
Figure 94

18.Measure countershaft end play. Rotate one of the
axle shafts back and forth to take up all back lash. Rotat-
ing the shaft in one direction will pull the shaft and bear-
ing away from the snap ring. Rotate axle shaft in this
direction, then measure space between the retaining
ring and shim (set) with a feeler gauge. Make sure shim
set is pressed against the bearing during the measure-
ment. End play should be 0.000” to 0.0039” (0.0 to 0.10
mm) (Fig. 95).
IMPORTANT: If end play is too great, replace shim/

shim set (item 2) with thicker shims to allow correct
end play.
Figure 95
19.Insert sealing cap (item 1) flush with face of center

plate. Make sure not to insert sealing cap too far. Pay
attention to direction of sealing cap.
Figure 96

20.Install fork shaft case:
A. Thoroughly clean mating surface of transaxle

case and fork shaft case.
B. Insert spindle lock (item 1) between fork shafts.
Figure 97
C. Insert two (2) steel balls (item 2) and two (2)

springs (item 1) into the grooves of the center plate. 1
2
2
Figure 98
D. Apply silicone sealant to mating surface of fork

shaft case. Install fork shaft case (item 3). Install cap
screws (items 2 and 1) noting location of longer 1 18 to 22 ft--lb
(24.5 to 29.5 N--m)
screw (item 1). Tighten cap screws to a torque of 18
to 22 ft--lb (24.5 to 29.5 N--m). Check operation of
2
shifters and detent.
Figure 99
Drive Train

21.Install differential gear assembly (item 2) into trans-
axle case. 2
22.Insert two (2) dowel pins (item 1) into transaxle case.
Figure 100
23.Install side cover:

18 to 22 ft--lb
A. Thoroughly clean mating surfaces of transaxle (24.5 to 29.5 N--m)
case and side cover. Apply silicone sealant onto mat-
ing surface of side cover.
B. Install side cover and secure with cap screws.

Torque cap screws from 18 to 22 ft--lb (24.5 to 29.5
N--m).
NOTE: This
shaft not
used on
Multi Pro
Figure 101
24.Install R.H. axle shaft assembly: 18 to 22 ft--lb

(24.5 to 29.5 N--m)
A. Thoroughly clean mating surface of transaxle 1
case and seal cover of R.H. axle shaft assembly. Ap-
ply silicone sealant onto mating surface of seal cov-
er.
B. Install axle shaft assembly (item 2) and secure 2

with cap screws. Torque cap screws (item 1) from 18
to 22 ft--lb (24.5 to 29.5 N--m).
Figure 102

25.Install L.H. axle shaft assembly:
A. Thoroughly clean mating surface of differential

2
carrier and side cover (item 2).
B. Insert selected shims (item 1) into housing of side

cover.
NOTE: The thickest shim should be installed

against the bearing.
1
Figure 103
C. Install axle shaft assembly and secure with cap

18 to 22 ft--lb
screws (item 1). Torque cap screws from 18 to 22 ft-- (24.5 to 29.5 N--m)
lb (24.5 to 29.5 N--m).
Figure 104
26.Measure backlash of ring gear through P.T.O. cover

opening on top of transaxle. Using a dial indicator, check
ring gear backlash in three equally spaced points. Back-
lash should be 0.0031” to 0.0071” (0.08 to 0.18 mm) and
must not vary more than 0.002” (0.05 mm) at the points
checked. If backlash is not in this range, replace shim
set in end of differential carrier:
A. If backlash is less than target range, decrease to-

tal thickness of shim set until correct backlash is
achieved.
B. If backlash exceeds the target range, increase to-

tal thickness of shim set until correct backlash is
achieved. Figure 105
NOTE: The thickest shim should be installed
against the bearing.
Drive Train

27.Apply multi--purpose grease to P.T.O. cover O--ring
and insert O--ring into groove of transaxle case. Position 3
P.T.O. cover (item 5) to transaxle case. Install five (5)
cap screws (item 4) and nut with lock washer (item 3).
1
Tighten cap screws and nut to a torque of 11 to 13 ft--lb 11 to 13 ft--lb
(15 to 17 N--m). (15 to 17 N--m)
28.If removed, install oil cap (item 2) with O--ring to

transaxle case.
29.If removed, apply sealing tape to threads of air

2
breather (item 1) and install air breather.
5 4
Figure 106
30.Apply silicone sealant to mating surface of upper

cover (item 4). Pay attention to direction of cover and
install. Torque cap screws (item 3) from 18 to 22 ft--lb
(24.5 to 29.5 N--m). 18 to 22 ft--lb
4 (24.5 to 29.5 N--m)
31.If removed, slide speed sensor (item 2) into upper
cover (item 4). Install cap screw (item 1) with lock wash-
er to secure sensor.
1
2 3
Figure 107
32.Position input shaft cover plate (item 2) to transaxle

and secure it with three (3) cap screws (item 1).
Figure 108

Chapter 8
Chassis
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parking Brake Cables . . . . . . . . . . . . . . . . . . . . . . . 15
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Master Cylinder Service . . . . . . . . . . . . . . . 16
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bleed Brake System . . . . . . . . . . . . . . . . . . . . . . . . 17
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front Wheels and Brakes . . . . . . . . . . . . . . . . . . . . 4 Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tie Rod End Replacement . . . . . . . . . . . . . . . . . . . 22
Rear Wheels and Brakes . . . . . . . . . . . . . . . . . . . . 10 Ball Joint Replacement . . . . . . . . . . . . . . . . . . . . . . 23
Rear Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . 12 Seat Base (Multi Pro 1200) . . . . . . . . . . . . . . . . . . 24
Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Seat Base (Multi Pro 1250) . . . . . . . . . . . . . . . . . . 26
Chassis
Multi Pro 1200/1250 Page 8 -- 1 Chassis

Specifications
Item Description
Front tire pressure 18 PSI (124 kPa) Maximum

(18 x 9.5 -- 8, 4 ply, tubeless)
Rear tire pressure 18 PSI (124 kPa) Maximum

(24 x 13 -- 12, 4 ply, tubeless)
Front wheel lug nut torque 55 to 65 ft--lb (75 to 88 N--m)
Rear wheel lug nut torque 55 to 65 ft--lb (75 to 88 N--m)
Front wheel toe--in 0 to 1/4 inch (0 to 6 mm)
Chassis Page 8 -- 2 Multi Pro 1200/1250

Adjustments
Front Suspension
Any time the front wheel toe--in is checked, the front sus-
pension should be checked as well. Incorrect suspen-
sion setting can affect steering and can cause
accelerated tire wear and scuffing.
IMPORTANT: When checking suspension, vehicle

spray tank should be approximately half full and op-
erator should be in seat.
IMPORTANT: Prior to checking front suspension,

drive the machine straight forward at least fifteen 2 1
(15) feet to allow the suspension to relax. Do not
turn steering wheel. Figure 1
1. LH A--arm 2. RH A--arm
1. Drive machine straight ahead at least fifteen (15) feet
and stop on a level surface. Stop engine and remove key
from ignition switch.
2. Check attitude of both right and left A--arms (Fig. 1).

Both A--arms should be level and parallel to the ground.
2
3. If either A--arm is not level, check all suspension and 1
steering components for wear or damage. If no compo-
nent wear or damage is detected, adjust suspension:
A. Chock rear wheels to prevent vehicle from shift-

ing. Lift front of machine using a jack or hoist to allow 4
front suspension to relax (see Jacking Instructions in 3
Chapter 1 -- Safety). Support raised machine with 130 to 150 ft--lb
(176 to 203 N--m)
jack stands.
Figure 2
B. Loosen and remove lock nut and cap screw that
secure axle assembly position to the frame (Fig. 2). 1. Axle assembly (RH) 3. Cap screw
2. Frame 4. Lock nut
C. Rotate axle assembly to allow different cap screw
position. Rotating axle toward ground increases ten-
sion on suspension.
D. Reinstall cap screw in new position and secure

with lock nut. Torque from 130 to 150 ft--lb (176 to
203 N--m).
E. Lower machine to ground and repeat steps 1 to 3

as needed.
Chassis

Service and Repairs
Front Wheels and Brakes
10
12
5
6
55 to 65 ft--lb
(75 to 88 N--m)
9
8
13
Loctite #242
6
11 5
4
3
2 See text for

tightening
1
procedure
Figure 3
1. Dust cap 6. Wheel bearing cup 10. Front spindle
2. Slotted hex nut 7. Wheel hub/drum 11. Cotter pin
3. Washer 8. Socket head screw (4 per wheel) 12. Seal
4. Wheel and tire assembly 9. Front brake assembly 13. Lug nut (5 per wheel)
5. Wheel bearing cone

Removal (Fig. 3) 2. If removed, inspect wheel bearings. Make sure bear-
ing cones are in good operating condition. Check the
1. Park machine on a level surface, stop engine and re- bearing cups for wear, pitting or other noticeable dam-
move key from the ignition switch. age. Replace worn or damaged parts.
2. Jack front wheel off the ground (see Jacking Instruc-
tions in Chapter 1 -- Safety). Chock front and rear of oth-
er wheels. Support raised machine with jack stands. 2
4
3. Remove lug nuts and wheel assembly.
4. Carefully pry dust cap from wheel hub.
5. Remove cotter pin from front spindle.

3
6. Remove slotted hex nut and washer that secures
wheel hub/drum to spindle. Slide wheel hub with bear-
1
ings from spindle.
7. If required, disassemble wheel hub/drum:
A. Pull seal out of the wheel hub.
B. Remove bearings from both sides of wheel hub.

Clean bearings in solvent. Clean inside of the hub. Figure 4
1. Brake assembly 3. Banjo bolt
8. Inspection and service of front brakes can be com- 2. Brake line 4. Banjo washer (2 used)
pleted with brake assembly on machine (see Front
Brake Service in this section). If required, brake assem- Installation (Fig. 3)
bly can be removed from machine as follows:
1. Clean all parts thoroughly before assembly.
A. Clean hydraulic brake line area of brake assem-
bly to prevent contamination. 2. If removed, position brake assembly to the front
spindle.
B. Loosen and remove banjo bolt from wheel cylin-
der and brake line. Locate and retrieve two (2) wash- A. Apply Loctite #242 (or equivalent) to threads of
ers from brake line fitting. Cap brake line and position socket head screws that secure brake assembly to
it away from brake assembly. spindle.
C. Remove four (4) socket head screws that secure B. Secure backing plate of the brake assembly to
the brake assembly to the front spindle. the spindle with four (4) socket head screws.
D. Remove brake assembly from spindle. C. Position two (2) new banjo washers on sides of
brake line fitting.
Inspection
D. Secure brake line to wheel cylinder with banjo
1. Inspect brake drums. bolt.
IMPORTANT:Brake drum machining is not re- 3. If wheel bearings were removed from wheel hub/
commended. Replace front brake drums as a set drum, assemble wheel hub:
to maintain equal braking forces.
A. If bearing cups were removed from the wheel
A. Clean drums with denatured alcohol. hub, press inner and outer cups into the hub until
they seat against the hub shoulder.
B. Replace drums that are cracked, deeply grooved,
Chassis
tapered, significantly out--of--round, scored, heat B. Pack both bearings with grease. Install greased
spotted or excessively rusted. Minor scoring in brake inner bearing into the cup on inboard side of the
drum can be removed with sandpaper. wheel hub.

IMPORTANT: The lip seal must be pressed in so 12.Align steering, adjust toe--in (see Operator’s Manu-
it is flush with the end of the hub. The lip of the al) and check front suspension (see Front Suspension
seal must be toward the bearing. in the Adjustments section of this chapter).
C. Lubricate the inside of the new lip seal and press 13.Lubricate tie rod ball joints.
it into the wheel hub.
4. Install the wheel hub/drum onto the spindle shaft tak-

ing care to not damage seal in the wheel hub. CAUTION
5. Install greased outer bearing cone, washer and After servicing the brakes, always check the
slotted hex nut onto spindle shaft. brakes in a wide open, level area that is free of
other persons and obstructions.
6. Rotate the wheel hub/drum by hand and tighten the
slotted hex nut from 75 to 100 in-lb (8.5 to 11.3 N--m)
to set the bearings. Then, loosen the nut until the wheel 14.Check brake operation.
hub has end play.
Burnish Brake Shoes
7. Rotate the wheel hub/drum by hand and re-tighten
Sintered metal linings may not provide maximum brake
the slotted hex nut from 15 to 20 in-lb (1.7 to 2.3 N--m).
stopping distance after brake shoes are replaced. It may
If necessary, nut can be tightened slightly to align cotter
be necessary to burnish new brake shoe linings.
pin position in spindle and nut.
IMPORTANT:Do not drive machine with the brakes
8. Install cotter pin through spindle shaft hole. Install
applied. The brake shoe linings will overheat.
dust cap to hub.
IMPORTANT:Do not allow the brakes to lock up. Al-
9. Install wheel assembly with valve stem facing out
low brakes to cool between applications.
and secure with lug nuts. Torque lug nuts evenly in a
crossing pattern from 55 to 65 ft--lb (75 to 88 N--m). Drive machine while making 6 to 7 normal stops at about
200 ft (60 m) intervals while traveling at moderate
10.Lower machine to ground.
speed.
11. Bleed brakes (see Bleed Brake System in this sec-
tion).

Chassis

Front Brake Service
1
110 to 120 in--lb
(12.4 to 13.6 N--m)
3 5
2 10
4
8
7
110 to 120 in--lb
(12.4 to 13.6 N--m) 6
8
13
6
11
12
10
13
Figure 5
1. Flange head screw 6. Belleville washer 10. Brake shoe
2. Cap screw (2 used per wheel) 7. Dust cover 11. Upper spring
3. Flat washer (2 used per wheel) 8. Adjuster lever 12. Lower spring
4. Lock washer 9. Wheel cylinder 13. Shoe hold down cup and spring
5. Brake backing plate
Disassembly (Fig. 5) 4. Remove brake shoes from backing plate.
1. Remove front wheel and brake hub/drum and, if nec- 5. If brake assembly is still on machine and wheel cylin-
essary, remove brake assembly from machine (see der removal is necessary:
Front Wheels and Brakes in this section).
A. Clean hydraulic brake line area of wheel cylinder
to prevent contamination.
CAUTION B. Loosen and remove banjo bolt from wheel cylin-
der and brake line. Locate and retrieve two (2) wash-
Be careful when removing springs from brake ers from brake line fitting. Cap brake line and position
shoes. The springs are under heavy tension and it away from brake assembly.
may cause personal injury.
C. Remove two (2) flange head screws that secure
2. Remove upper and lower springs from brake shoes. wheel cylinder to backing plate. Remove wheel cylin-
der from backing plate.
3. Remove shoe hold down cups and springs that se-
cure the brake shoes to the backing plate.

6. If necessary, remove cap screws and washers to al- 2. If removed, position lubricated belleville washer be-
low adjuster levers to be separated from backing plate. tween adjuster lever and backing plate. Secure adjuster
Locate and remove belleville washers from between ad- to backing plate with washer and cap screw. Torque bolt
juster levers and backing plate. from 110 to 120 in--lb (12.4 to 13.6 N--m).
Inspection 3. If removed, install wheel cylinder:
1. Inspect brake shoes. A. Secure wheel cylinder to backing plate with two
flange head screws. Torque screws from 110 to 120
IMPORTANT:Replace front brake shoes as a set in--lb (12.4 to 13.6 N--m).
(all four shoes on both wheels) to maintain equal
braking forces. B. If brake assembly is still on machine, position two
(2) new banjo washers on sides of brake line fitting.
A. Replace brake shoes if damaged or if lining is Secure brake line to wheel cylinder with banjo bolt.
worn to 1/16” (1.6 mm). Replace shoes if lining is
contaminated by oil, grease or other fluids. 4. If removed from backing plate, install dust covers in
backing plate.
NOTE: Overheated springs lose their tension and
can cause brake linings to wear out prematurely. 5. Position brake shoes to backing plate. Make sure
that each shoe is properly positioned at anchor block,
B. Inspect brake shoe webbing, upper and lower wheel cylinder and pin on adjuster lever. Secure shoes
springs and shoe hold down springs for overheating to adjuster levers with shoe hold down cups and springs.
and stretching. Overheating is indicated by a slight
blue color. Inspect brake shoe webbing for deforma-
tion. Replace parts as necessary.
CAUTION
C. Inspect hold down pins on adjuster levers for
bends, rust or corrosion. Replace as necessary. Be careful when installing springs to brake
shoes. The springs are under heavy tension and
2. Inspect backing plate surfaces which contact with may cause personal injury.
the brake shoes for grooves that may restrict shoe
movement. Replace backing plate if grooves can not be 6. Secure brake shoes with upper and lower springs.
removed by light sanding with emery cloth or other suit-
able abrasive. Replace backing plate if cracked, warped 7. Assemble front wheel (see Front Wheels and Brakes
or excessively rusted. in this section).
3. Inspect adjuster levers. Replace levers if deforma-

tion or excessive rust is found.
Assembly (Fig. 5)
IMPORTANT:Brake shoe lining surfaces must be

free of grease, oil and other foreign matter.
1. Apply a light film of lubricant to the following:
A. Ledges on which the brake shoes rest.
B. Pin surfaces on adjuster levers.
C. Anchor block surfaces that contact shoe webs.
D. Both surfaces of belleville washers that are posi-

tioned between adjuster levers and backing plate (if
removed).
Chassis

Rear Wheels and Brakes
16 200 to 250 in--lb

(22.6 to 28.2 N--m)
15
40 to 60 ft--lb
(55 to 81 N--m)
19 220 to 225 ft--lb
Loctite #271 (299 to 305 N--m)
12
2 10
7
18
55 to 65 ft--lb
14 (75 to 88 N--m)
6 17
4
1
13
11
9 5
8
RIGHT
Loctite #271 3
FRONT
Figure 6
1. Lug nut (5 used per wheel) 8. Cap screw (4 used per wheel) 14. End yoke
2. Flange head screw 9. Lock washer (4 used per wheel) 15. Yoke strap (2 used per yoke)
3. Wheel assembly 10. Brake assembly 16. Bolt (4 used per yoke)
4. Brake drum 11. Brake cable clip 17. Flange lock nut
5. Stub axle 12. Axle housing assembly 18. Flat washer
6. Lock washer (5 used per wheel) 13. Parking brake cable 19. Flange head screw (3 per housing)
7. Drive stud (5 used per wheel)
Removal (Fig. 6)
1. Park machine on a level surface, stop engine and re-

2. Chock front wheels. Raise rear wheel using a jack or 2

hoist (see Jacking Instructions in Chapter 1 -- Safety).
Support raised machine with jack stands.
1
3. Loosen and remove lug nuts that secure rear wheel.
Remove rear wheel.
4. Loosen set screw on parking brake control lever

knob (Fig. 7). Turn knob on parking brake lever counter-
clockwise all the way to loosen brake cables.
Figure 7
5. To remove brake drum, it may be necessary to back 1. Parking brake lever 2. Set screw
off parking brake adjuster. To back off adjuster, rotate
brake drum until access hole lines up with star wheel.
Use a hooked piece of wire to pull pawl away from star
wheel, then turn star wheel. Pull brake drum from ma-
chine.
6. Inspection and service of rear brakes can be com- C. Position two (2) new banjo washers on sides of
pleted with brake assembly on machine (see Rear brake line fitting. Secure brake line to wheel cylinder
Brake Service in this section). If required, brake assem- with banjo bolt.
bly can be removed from machine as follows:
D. Install parking brake cable to brake assembly
A. Remove parking brake cable from brake assem- (see Parking Brake Cable Installation in this section).
bly (see Parking Brake Cable Removal in this sec-
tion). 3. Position brake drum so access hole in drum aligns
with hole in stub axle flange. Slide brake drum onto ma-
A. Clean hydraulic brake line area of wheel cylinder chine.
to prevent contamination.
4. Adjust brake shoes:
der and brake line. Locate and retrieve two (2) wash- A. Align access hole in brake drum with star wheel
ers from brake line fitting. Cap brake line and position on brake adjuster assembly.
it away from brake assembly.
B. Rotate star wheel to increase adjuster length until
C. Remove stub axle from machine (see Stub Axle brake shoes contact brake drum.
and Driveshaft in the Service and Repairs section of
Chapter 7 -- Drive Train). C. Back off star wheel until drum rotates freely.
D. Remove four (4) cap screws and lock washers 5. Install wheel and secure with lug nuts. Torque lug
that secure the brake assembly to the axle housing. nuts evenly in a crossing pattern from 55 to 65 ft--lb (75
to 88 N--m).
E. Remove brake assembly from machine.
Inspection
7. Bleed brakes (see Bleed Brake System in this sec-
1. Inspect brake drums. tion).
IMPORTANT:Brake drum machining is not re-

commended. Replace rear brake drums as a set
to maintain equal braking forces.
CAUTION
A. Clean drums with denatured alcohol. Check After servicing the brakes, always check the
braking surface diameter in at least three places. If brakes in a wide open, level area that is free of
the diameter exceeds 8.071” (205.0 mm), replace other persons and obstructions.
both brake drums.
8. Check brake operation. To adjust the brakes, stop
B. Replace drums that are cracked, deeply grooved,
several times while vehicle is moving in reverse.
tapered, significantly out--of--round, scored, heat
spotted or excessively rusted. 9. Adjust parking brake (see Operator’s Manual).
C. Minor scoring in brake drum can be removed with Burnish Brake Shoes
sandpaper.
Brake linings may not provide maximum brake stopping
Installation (Fig. 6) distance after brake shoes are replaced. It is necessary
to burnish new brake shoe linings.
1. Clean all parts thoroughly before assembly.
IMPORTANT:Do not drive machine with the brakes
2. If removed, position brake assembly to the machine.
applied. The brake shoe linings will overheat.
A. Apply Loctite #271 (or equivalent) to four (4) cap
IMPORTANT:Do not allow the brakes to lock up. Al-
screws (item 8). Secure backing plate of the brake
low brakes to cool between applications.
assembly to the axle housing with cap screws and
Chassis
lock washers. Drive machine while making 6 to 7 normal stops at about

200 ft (60 m) intervals while traveling at moderate
B. Install stub axle (see Stub Axle and Driveshaft in
speed.
the Service and Repairs section of Chapter 7 -- Drive
Train).

Rear Brake Service
49 to 97 in lb 15
(5.5 to 11 N--m)
16 1
2
14
3
13
17
18
12
4
19 7
6 5
9
3 11 10
Figure 8
1. Pin 8. Parking brake pawl with pin 14. Plug
2. Parking brake lever 9. Adjuster spring 15. Brake back plate
3. Brake shoe 10. Hold down washer (2 used per wheel) 16. Bolt set (2 used per wheel)
4. Upper spring 11. Hold down spring (2 used per wheel) 17. Hold down pin (2 used per wheel)
5. Lower spring 12. Bleed screw 18. Inspection plug
6. Brake adjuster assembly 13. Cap 19. Cable guide
7. Brake cylinder assembly

1. If brake assembly is still on machine, remove parking IMPORTANT:Brake shoe lining surfaces must be
brake cable (see Parking Brake Cable Removal in this free of grease, oil and other foreign matter.
section).
1. Apply a light film of lubricant to the following:
A. Ledges on which the brake shoes rest.

CAUTION
B. Hold down pins.
Be careful when removing springs from brake
shoes. The springs are under heavy tension and C. Anchor block surfaces that contact shoe webs.
may cause personal injury.
2. If removed, install wheel cylinder:
2. Remove upper and lower springs from brake shoes. A. Secure wheel cylinder to backing plate with two
(2) bolts and washers. Torque bolts from 49 to 97 in--
3. Remove shoe hold down washers and springs that lb (5.5 to 11 N--m).
secure the brake shoes to the backing plate.
B. If brake assembly is still on machine, position two
4. Remove brake shoes from backing plate. (2) new banjo washers on sides of brake line fitting.
Secure brake line to wheel cylinder with banjo bolt.
5. If brake assembly is still on machine and wheel cylin-
der removal is necessary: 3. If removed from backing plate, install dust covers in
backing plate.
A. Clean hydraulic brake line area of wheel cylinder
to prevent contamination. 4. Position brake shoes to backing plate. Make sure
that each shoe is properly positioned at anchor block,
wheel cylinder and hold down pin. Secure shoes to pins
der and brake line. Locate and retrieve two (2) wash-
with hold down springs and washers.
ers from brake line fitting. Cap brake line and position
it away from brake assembly.
C. Remove two (2) bolts and washers that secure CAUTION

wheel cylinder to backing plate. Remove wheel cylin-
der from backing plate. Be careful when installing springs to brake
shoes. The springs are under heavy tension and
Inspection may cause personal injury.
1. Inspect brake shoe linings.
5. Install lower spring to brake shoes.
IMPORTANT:Replace rear brake shoes as a set
(all four shoes) to maintain equal braking forces. 6. Install brake adjuster assembly to slots on brake
shoes, then the parking brake pawl with pin. Install ad-
A. Replace brake shoes if damaged or if lining is juster spring.
worn to 1/16” (1.6 mm). Replace if lining is contami-
nated by oil, grease or other fluids. 7. Install upper spring.
NOTE: Overheated springs lose their tension and 8. If brake assembly is still on machine, install parking
can cause brake linings to wear out prematurely. brake cable (see Parking Brake Cable Installation in this
section).
B. Inspect brake shoe webbing, upper and lower
springs and shoe hold down springs for overheating. 9. Assemble rear wheel (see Rear Wheels and Brakes
Overheating is indicated by a slight blue color. In- Installation in this section).
spect brake shoe webbing for deformation. Replace
parts as necessary.
Chassis
C. Inspect hold down pins for damage. Replace as

necessary.
2. Inspect brake adjuster, parking brake lever and park-

ing brake pawl for damage or wear. Replace compo-
nents as necessary.
Brake Lines
4 3 4 2
5
3
1
7
5
10
4
4
9
4
3
4
2
10
3
8 2
6
2
3 RIGHT
3
FRONT
Figure 9
1. Rear brake line 5. R--clamp (2 used) 8. Grommet (2 used)
2. R--clamp (5 used) 6. Front brake banjo bolt (2 used) 9. Front brake line
3. Flange nut (8 used) 7. Rear brake banjo bolt (2 used) 10. Banjo washer (2 per banjo bolt)
When performing service work on the Multi Pro brake

lines, make sure to clean brake components before dis-
assembly. Use Figure 9 as a guide for removal and
installation of hydraulic brake lines.

Parking Brake Cables
Removal
1. Loosen set screw on parking brake lever knob (Fig.

10). Turn knob on parking brake lever counterclockwise
fully to loosen cable adjustment.
2
2. Raise seat to allow access to cable connection at
parking brake lever.
3. Remove cotter pin, flat washer and clevis pin that se- 1
cure brake equalizer to parking brake lever (Fig. 11).
4. Remove retaining rings that secure brake cables to

frame. Remove cable ends from equalizer plate (Fig.
11).
Figure 10
5. Jack up and support rear of machine (see Jacking In- 1. Parking brake lever 2. Set screw
structions in Chapter 1 -- Safety). Remove both rear
wheels and brake drums (see Rear Wheels and Brakes
in this section). 1
5
6. Remove cable clip that holds each brake cable into 4
brake backing plate. Remove cable end from parking
brake lever (Fig. 12). Pull cable from rear brake assem-
3
bly.
7. Note routing of cables and location of cable ties and 2

r--clamps before removing cables from machine.
8
6
Installation
1. Install new cables to brake equalizer. Attach equaliz- 7

er to parking brake lever with clevis pin, flat washer and
cotter pin.
Figure 11
2. Position cables to frame and secure with retaining 1. Parking brake lever 5. Clevis pin
rings. 2. Cotter pin 6. LH brake cable
3. Flat washer 7. Retaining ring
4. Equalizer plate 8. RH brake cable
3. Route cables to rear brakes and secure with cable
ties and r--clamps.
4. Insert cables through cable guide on appropriate 1 4

rear brake. Connect cable end to parking brake lever. 2
Install cable clip to secure cable to brake backing plate.
5. After installing cable to each rear brake, check to

make sure that the bottoms of the brake shoes are
seated in grooves at bottom of backing plate.
6. Install brake drums and rear wheels (see Rear

Wheels and Brakes in this section). Lower machine to 3
Chassis
ground.
7. Lower seat.
Figure 12
8. Adjust parking brake (see Operator’s Manual).
Check operation of brakes before returning machine to 1. Cable clip 3. Cable guide
2. Parking brake lever 4. Brake backing plate
regular service.

Brake Master Cylinder Service
Testing
1
1. Insure that brake system is properly adjusted and
bled. 2 12
2. Apply light pressure to brake pedal. 3
3. If brake pedal fades or falls away while applying light

pressure to pedal, the master cylinder should be ser-
viced.
Disassembly (Fig. 13) 4

11
1. Remove reservoir and flange seal. Push in on the 6
push rod so the stop pin can be removed. 5
2. Disconnect lower end of the dust cover from the

housing.
10 9
8
3. Push in on the push rod and remove circlip, then re- 7
move push rod with dust cover and clevis. Remove re-
tainer washer. Figure 13
1. Reservoir 7. Dust cover
4. Remove primary piston assembly and secondary 2. Flange seal 8. Push rod
piston assembly from cylinder housing. 3. Stop pin 9. Circlip
4. Secondary piston assy 10. Retainer washer
5. Clevis 11. Primary piston assy
Inspection 6. Jam nut 12. Cylinder housing
1. Clean all metal parts with isopropyl alcohol, then

clean out and dry grooves and passageways with com-
pressed air. Make sure cylinder bore and component
pieces are thoroughly clean.
2. Check cylinder bore, pistons and springs for damage

or excessive wear. Replace brake cylinder assembly if
signs of pitting, scoring or cracks are evident in cylinder
bore. Note: Do not hone bore of brake cylinder.
Assembly (Fig. 13)
1. Apply a film of clean brake fluid to cylinder bore and

piston assemblies.
2. Install secondary piston assembly and primary pis-

ton assembly into cylinder.
3. Install retainer washer.
4. Install push rod and secure in place with circlip.

Install lower end of dust cover to housing.
5. Push in on push rod so stop pin can be installed to

retain secondary piston assembly, then install flange
seal and reservoir.

Bleed Brake System
After loosening or removing any hydraulic brake compo- 4. Repeat procedure until a continuous flow of brake
nent, the brake system should be bled to insure proper fluid, with no air bubbles, is released from bleeder valve.
brake operation. Make sure fluid level is maintained in brake fluid res-
ervoir at all times.
NOTE: A power/vacuum brake bleeding tool will pro-
vide faster and more effective brake bleeding than 5. Repeat steps 1 to 4 for other wheel cylinders.
manual bleeding.
1. Connect a suitable transparent hose to bleeder valve

on wheel cylinder and submerge other end of hose in a CAUTION
glass container partially filled with clean brake fluid.
After servicing the brakes, always check brake
2. Have a second person pump brake pedal several operation in a wide open, level area that is free of
times, then hold pedal down firmly. other persons and obstructions.
3. With pedal firmly depressed, open bleeder valve of

wheel cylinder until pedal fades to floor. Close bleeder 6. After bleeding of brakes is completed, test vehicle to
valve before releasing pedal. make sure brakes are operating correctly and that brake
pedal is solid.
Chassis

Front Suspension
200 to 250 ft--lb

(271 to 339 N--m)
1
130 to 150 ft--lb

(176 to 203 N--m)
1
2
30
24
23
22
21 3
12
29 4
17
28
6
27 15
19 5
13
26
18 11 14
80 to 90 ft--lb
25 20
9 10 (109 to 122 N--m)
12 15
13 7 FRONT
16 12
17 RIGHT
19
11 8
18
10
80 to 90 ft--lb
9
(109 to 122 N--m)
Figure 14
1. Cap screw 11. Flat washer 21. Axle assembly (RH shown)
2. Cap screw 12. Grease fitting 22. Axle bumper
3. Flange head screw (4 used) 13. Flange nut 23. Lock washer
4. Skid plate 14. Flange nut 24. Hex nut
5. Flange head screw 15. R--clamp 25. Ball joint (LH thread)
6. Pivot pin 16. Spindle 26. Flat washer
7. Flange bushing 17. Retaining ring 27. Cotter pin
8. A--arm 18. Ball joint seal 28. Slotted hex nut
9. Cotter pin 19. Ball joint 29. Jam nut (LH thread)
10. Slotted hex nut 20. Cap screw 30. Tie rod

Disassembly (Fig. 14) 3. Lubricate suspension grease fittings.
1. Park machine on a level surface, stop engine, en- 4. Install wheel and secure with lug nuts. Torque lug
gage parking brake and remove key. nuts evenly in a crossing pattern from 55 to 65 ft--lb (75
to 88 N--m).
2. Lift front of machine using a jack or hoist to allow front
suspension to hang freely from machine. Chock rear 5. Lower machine to ground.
wheels to prevent vehicle from shifting.
NOTE: Right and left tie rods should be identical length.
3. Remove front wheel assembly (see Front Wheels
and Brakes in this section). 6. Check and adjust front wheel toe--in (see Operator’s
Manual). Check front suspension (see Front Suspen-
4. Support brake and spindle assembly to prevent them sion in the Adjustments section of this chapter).
from falling during disassembly. If necessary, remove
front brake assembly from spindle (see Front Wheels IMPORTANT: If axle assembly has been replaced,
and Brakes in this section). front wheel toe--in should be rechecked after ma-
chine has been used for several hours.
5. Disassemble suspension as needed using Figure 14
as a guide. 2
A. During disassembly, note position of cap screw in
torque arm of axle assembly for assembly purposes
(Fig. 15). 3
1
Assembly (Fig. 14)
1. Assemble suspension using Figure 14 as a guide.
A. Loosely install cap screws (item 1) that secure

axle assembly to machine frame.
5 4
B. Install cap screw (item 2) in noted location of axle NOTE LOCATION
2
assembly torque arm (Fig. 15). Torque cap screw
from 130 to 150 ft--lb (176 to 203 N--m). Figure 15
1. Axle assembly (RH) 4. Cap screw
C. Torque cap screws (item 1) that secure axle as- 2. Cap screw 5. Lock nut
sembly to machine frame from 200 to 250 ft--lb (271 3. Frame
to 339 N--m).
D. If ball joints were loosened or removed from

spindle, tighten slotted hex nut to a minimum of 80 to
90 ft--lb (109 to 122 N--m). If necessary for cotter pin
installation, tighten slotted hex nut further until cotter
pin can be installed.
2. After assembly is complete, make sure that compo-

nents do not contact hoses and/or wires.
Chassis

Steering Assembly
3 FRONT
2
4 RIGHT
1
3
5 11
6 10
9
7 1
8 8
9 7
1
10 12
13
14
4 3
5
3 26
16 15 19
1 20
21 22
10
17 24
80 to 90 ft--lb
3 (109 to 122 N--m)
23
18
3
19
20
21 25
24
22 80 to 90 ft--lb
23 (109 to 122 N--m)
Figure 16
1. Cotter pin 10. Flat washer 19. Retaining ring
2. Slotted hex nut 11. Steering cylinder 20. Ball joint
3. Grease fitting 12. Grease fitting 21. Ball joint seal
4. Jam nut 13. Steering pivot 22. Flat washer
5. Tie rod end 14. Tie rod 23. Cotter pin
6. Retaining ring 15. Jam nut (LH thread) 24. Slotted hex nut
7. Thrust washer 16. Slotted hex nut 25. A--arm (RH shown)
8. Bearing 17. Tie rod end (LH thread) 26. Axle (RH shown)
9. Slotted hex nut 18. Spindle

1. Park machine on a level surface, stop engine, en- 1. Assemble steering components using Figure 16 as
gage parking brake and remove key from the ignition a guide.
switch.
2. If engine mounting plate was lowered from machine,
2. Jack front of machine off ground (see Jacking In- raise mounting plate assembly to machine (see Engine
structions in Chapter 1 -- Safety). Front of machine Mounting Plate Installation in the Service and Repairs
should be lifted enough to allow front suspension to section of Chapter 3 -- Kohler Gasoline Engine).
hang freely from machine. Support raised machine with
jack stands. 3. After assembly is complete, make sure that steering
components do not contact hoses and/or wires.
3. Remove front wheel assembly (see Front Wheels
and Brakes in this section). 4. Lubricate suspension grease fittings.
4. Support brake and spindle assembly to prevent them 5. Install wheel and secure with lug nuts. Torque lug
from falling during disassembly. If necessary, remove nuts evenly in a crossing pattern from 55 to 65 ft--lb (75
front brake assembly from spindle (see Front Wheels to 88 N--m).
and Brakes in this section).
5. If steering pivot requires removal, lower engine
mounting plate from machine (see Engine Mounting NOTE: Right and left tie rods should have identical
Plate Assembly Removal in the Service and Repairs length.
section of Chapter 3 -- Kohler Gasoline Engine).
7. Check and adjust front wheel toe--in (see Operator’s
6. Disassemble steering components as needed using Manual). Check front suspension (see Front Suspen-
Figure 16 as a guide. sion in the Adjustments section of this chapter).
Chassis

Tie Rod End Replacement
Removal (Fig. 17)
4
1. Loosen jam nut on tie rod end. Note: outside tie rod
5
end that is attached to spindle has left hand threads.
6
2. Remove cotter pin and slotted hex nut from tie rod 8
end to be removed. 7
3. Use a suitable puller to separate tie rod end from 6

spindle (outside tie rod end) or steering pivot (inside tie
rod end).
3
2
4. When removing tie rod end from tie rod, count the
1
number of revolutions it takes to remove so new tie rod
end can be installed without changing the front wheel 11
9
toe--in. 10
Installation (Fig. 17) Figure 17

1. Tie rod 7. Flat washer
1. Install new tie rod end to tie rod. Thread in new rod 2. Jam nut 8. Slotted hex nut
end the same number of revolutions as the old one took 3. Tie rod end 9. Spindle
4. Steering pivot 10. Tie rod end (LH thread)
to remove. 5. Slotted hex nut 11. Jam nut (LH thread)
6. Cotter pin
2. Install grease fitting into tie rod end.
3. Insert tie rod end shaft into spindle (outside tie rod
end) or steering pivot (inside tie rod end) and secure with
flat washer and slotted hex nut. Install cotter pin.
4. Grease tie rod end.
NOTE: Right and left tie rods should be identical length.

Manual) and front suspension (see Front Suspension in
the Adjustments section of this chapter).

Ball Joint Replacement
Removal (Fig. 18) 5. Secure ball joint with flat washer and slotted hex nut.
Torque slotted hex nut from 80 to 90 ft--lb (109 to 122
1. Park machine on a level surface, stop engine and re- N--m) and until cotter pin can be installed. Secure with
move key from the ignition switch. cotter pin.
2. Lift front wheel off the ground using a jack (see Jack- 6. Grease ball joint.
ing Instructions in Chapter 1 -- Safety). Block front and
rear of other wheels. 7. Install wheel and secure with lug nuts. Torque lug
nuts evenly in a crossing pattern from 55 to 65 ft--lb (75
3. Remove lug nuts and wheel assembly. to 88 N--m).
4. Support axle, spindle and a--arm to prevent them 8. Lower machine to ground.
from falling during disassembly.
5. Remove cotter pin from ball joint to be removed, then Manual) and front suspension (see Front Suspension in
remove slotted hex nut and flat washer. the Adjustments section of this chapter).
6. Using fork or suitable press, separate upper ball joint

from spindle or lower ball joint from A--arm. 2
1
7. Remove ball joint seal. 3
8. Remove retaining ring that secures ball joint. Press 4

upper ball joint from axle or lower ball joint from spindle. 80 to 90 ft--lb
Note: Ball joint removal may be easier if affected A--arm (109 to 122 N--m)
or spindle is removed from machine. 5 9

7 8
1. Press new upper ball joint into axle or lower ball joint
into spindle. Install retaining ring to secure ball joint. Use 2
6
punch and hammer to seat retaining ring if needed.
Make sure that retaining ring is fully seated in groove af-
ter installation. 3
9 10
2. If removed, install A--arm or spindle to machine. 4 8 80 to 90 ft--lb
5 7 (109 to 122 N--m)
3. Install grease fitting into ball joint. Install ball joint seal
over shaft on ball joint. Edge of seal must be inserted Figure 18
into ball joint slot.
1. Axle (RH shown) 6. Spindle
2. Grease fitting 7. Cotter pin
4. Position upper ball joint to spindle or lower ball joint 3. Retaining ring 8. Slotted hex nut
to A--arm. 4. Ball joint 9. Flat washer
5. Ball joint seal 10. A--arm (RH shown)
Chassis

Seat Base (Multi Pro 1200)
8
11
13
8 14
9 2
10
10
2
3
12
4
5
7 12 4 3
3
4
2
4
2
3
4 3 2
16 FRONT
RIGHT
15
6
Figure 19
1. Seat base 7. L bracket (3 used) 12. Seal (2 used)
2. Flange head screw (8 used) 8. Phillips head screw 13. Seat belt bracket
3. Spacer (6 used) 9. Console 14. Control panel
4. Rubber washer (6 used) 10. Well nut 15. Flange nut (2 used)
5. Spacer (2 used) 11. Spray control panel 16. RH inner fender
6. Flange head screw (3 used)

Removal (Fig. 19)

2. Disconnect negative (--) cable and then positive (+) 1

cable from battery.
3. Remove seat assembly by tilting seat forward and

removing hitch pin and clevis pin (Fig. 20).
2
4. Remove screws that secure control panels to seat
base. Carefully place control panels into seat base
openings. 3
5. Remove knob from shift lever.
6. Remove flange head screw (item 6) that secures

right hand inner panel (item 16) to L bracket (item 7).
7. Remove eight (8) flange head screws that fasten

seat base to machine. During screw removal, locate and
remove washers and spacers. The two (2) screws di-
rectly behind the front wheels are secured with flange
nuts (item 15). Figure 20
8. Carefully lift seat base from machine. 1. Seat assembly 3. Clevis pin
2. Hitch pin
1. Position seat base on machine.
2. Carefully pull control panels through openings in

seat base.
3. Install flange head screw (item 6) to secure right

hand inner panel (item 16) to L bracket (item 7).
4. Secure seat base to machine using washers,

spacers, flange nuts and eight (8) flange head screws.
Install all fasteners before tightening.
5. Install knob on shift lever.
6. Secure control panels to seat base.
7. Secure seat assembly to machine with clevis pin and

hitch pin.
8. Connect positive (+) cable and then negative (--)

cable to battery.
Chassis

Seat Base (Multi Pro 1250)
11 10
12
9
2
8
9 3
13 4
1 8
5
2
3
4 12
4
3
6
4
2
3
7
3 2
4 2 FRONT
RIGHT
Figure 21
1. Seat Base 6. Support bracket (2 used) 10. Control panel
2. Flange head screw (8 used) 7. Flange nut (2 used) 11. Seat belt bracket
3. Spacer (6 used) 8. Well nut 12. Seal (2 used)
4. Rubber washer (6 used) 9. Phillips head screw 13. Spray control panel
5. Spacer (2 used)

Removal (Fig. 21)

2. Disconnect negative (--) cable and then positive (+) 1

cable from battery.
3. Remove seat assembly by tilting seat forward and

removing hitch pin and clevis pin (Fig. 22).
2
4. Remove screws that secure control panels to seat
base. Carefully place control panels into seat base
openings. 3
5. Remove knob from shift lever.
6. Remove eight (8) flange head screws that fasten

seat base to machine. During screw removal, locate and
remove washers and spacers. The two (2) screws di-
rectly behind the front wheels are secured with flange
nuts (item 7).
7. Carefully lift seat base from machine.

Figure 22
1. Seat assembly 3. Clevis pin
2. Hitch pin
1. Position seat base on machine.
2. Carefully pull control panels through openings in

seat base.
3. Secure seat base to machine using washers,

spacers, flange nuts and eight (8) flange head screws.
Install all fasteners before tightening.
4. Install knob on shift lever.
5. Secure control panels to seat base.
6. Secure seat assembly to machine with clevis pin and

hitch pin.
7. Connect positive (+) cable and then negative (--)

cable to battery.
Chassis


Chapter 9
Sonic Boom
Sonic Boom System (Optional Kit)
System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . 2 Sonic Boom Light . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Precautions Concerning Chemicals Used in Sonic Boom Calibration . . . . . . . . . . . . . . . . . . . . . 16
Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . 17
Precautions for Removing or Adjusting Spray Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . 20
System Components . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 22
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sonic Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . 22
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 4 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SONIC BOOM SYSTEM OPERATION . . . . . . . . . . . 6 Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . 24
Sprayer Operation on Level Turf . . . . . . . . . . . . . . . 6 Sonic Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Downward Slope in Turf Encountered . . . . . . . . . . 8
Rise in Turf Encountered . . . . . . . . . . . . . . . . . . . . 10
Boom Level Changed by Operator During
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . 12
Manual Boom Operation . . . . . . . . . . . . . . . . . . . . 14
Multi Pro 1200/1250 Page 9 -- 1 Sonic Boom System (Optional Kit)

General Information
Installation Instructions
The Sonic Boom Kit Installation Instructions provides in-
formation regarding the installation, operation and gen-
eral maintenance for your Sonic Boom System. Refer to
that publication for additional information when servic-
ing the machine.

Chemicals can injure persons, animals, plants, soil and 4. Always wear protective clothing, chemical resistant
other property. To eliminate environmental damage and gloves, eye protection and other personal protective
personal injury: equipment as recommended by the chemical manufac-
turer.
1. Select the proper chemical for the job.
2. Carefully read the directions printed on the chemical chemicals and chemical solution.
manufacturer’s labels before handling chemicals. In-
structions on chemical manufacturer’s container labels
regarding mixing proportions should be read and strictly
followed.
3. Keep spray material away from skin. If spray material

comes in contact with a person, wash it off immediately
in accordance with manufacturer’s recommendations
Sheets).

1. Park vehicle on a level surface and apply the parking 4. Remove chemicals from pump, hoses and other
brake. spray components. Thoroughly neutralize and rinse
spray system before loosening or removing any spray
2. Shut off the vehicle’s engine and remove the key system component(s).
5. Make sure spray system pressure is relieved before
3. Disengage all power and wait until all moving parts loosening any system component.
have stopped.
Sonic Boom System (Optional Kit) Page 9 -- 2 Multi Pro 1200/1250

Special Tools
Sonic Boom
Diagnostic Display
System
The Diagnostic Display (Fig. 1) can be connected to the
Sonic Boom wire harness communication connector to
verify correct electrical functions of the Sonic Boom Sys-
tem. Electronic control unit (ECU) inputs and outputs for
the Sonic Boom System can be checked using the Diag-
nostic Display.
Toro Part Number for Diagnostic Display: 85--4750
Toro Part Number for Overlay (English): 94--8604
IMPORTANT: The Diagnostic Display must not be

left connected to the machine. It is not designed to Figure 1
withstand the environment of the machine’s every
day use. When use of Diagnostic Display is com-
pleted, disconnect it from the machine and recon-
nect loopback connector to wire harness
communication connector. Machine will not oper-
ate without loopback connector installed on wire
harness. Store Diagnostic Display in a dry, secure,
indoor location and not on machine.
Figure 2

LEFT BOOM
ACTUATOR

Electrical Schematic
RIGHT BOOM
ACTUATOR
Page 9 -- 4
RIGHT BOOM
ACTUATOR SWITCH
LEFT BOOM
ACTUATOR SWITCH
Sonic Boom System
Multi Pro 1200/1250

Sonic Boom
System

LEFT BOOM
ACTUATOR
(STATIONARY)
(IN AUTO POSITION)
(NOT ENERGIZED)
(NOT ENERGIZED)

RIGHT BOOM
ACTUATOR
(STATIONARY)
(NOT ENERGIZED)
Sonic Boom System Operation
Page 9 -- 6
(NOT ENERGIZED)
RIGHT BOOM
ACTUATOR SWITCH
LEFT BOOM
ACTUATOR SWITCH
Sonic Boom System

Sprayer Operation on Level Turf
Sonic Mode Switch in Automatic
Power Current
Control Current
Indicator Light Current
Multi Pro 1200/1250

During sprayer operation with the sonic boom switch in
Sonic Boom
the automatic position (sonic boom light is illuminated),
System
the boom mounted sonic boom sensors continually
send impulse signals and then receive echos as the sig-
nals bounce off the turf. The electronic control unit
(ECU) determines the sensor distance from the ground
based on the elapsed time between the sensor signal
generation and the received echo. As long as the sensor
height remains the same as the calibrated height, the
spray boom will remain at a fixed height from the ground
for spraying accuracy.
On level turf, the boom sensors continually send signals

and receive echoes that determine that the booms sec-
tions are at the calibrated height. Thus, there is no need
to change boom height. The boom actuators will not be
energized and the boom sections remain at the correct,
level position.
CONSISTENT BOOM HEIGHT

SO ACTUATOR MOVEMENT
IS NOT NECESSARY
LEVEL GROUND
Figure 3

LEFT BOOM
ACTUATOR
(EXTENDING)
(IN AUTO POSITION)
(NOT ENERGIZED)
(ENERGIZED)

RIGHT BOOM
ACTUATOR
(STATIONARY)
(NOT ENERGIZED)
Page 9 -- 8
(NOT ENERGIZED)
RIGHT BOOM
ACTUATOR SWITCH
LEFT BOOM
ACTUATOR SWITCH
Sonic Boom System

Downward Slope in Turf Encountered (Left Boom Shown)
Power Current
Control Current
Multi Pro 1200/1250

Downward Slope in Turf Encountered
During sprayer operation with the sonic boom switch in The boom sensor target distance is initiated during initial
Sonic Boom
the automatic position (sonic boom light is illuminated), sonic boom calibration and is typically set at twenty (20)
System
the boom mounted sonic boom sensors continually inches. When in automatic mode, the booms will not
send impulse signals and then receive echos as the sig- move if the target distance change is three (3) inches or
nals bounce off the turf. The electronic control unit less (inner dead band). Once the target distance ex-
(ECU) determines the sensor distance from the ground ceeds five (5) inches (outer dead band), the ECU will en-
based on the elapsed time between the sensor signal ergize the appropriate power switch relay. The
generation and the received echo. As long as the sensor energized relay will lead to a change in boom actuator
height remains the same as the calibrated height, the length and ultimately a change in boom height.
spray boom section will remain at a fixed distance from
the ground for spraying accuracy.
When a spray boom section encounters a downward

slope in the turf, the time necessary for the sensor to re-
ceive the signal echo is longer than the calibrated time-
frame. This change in time causes the ECU to energize
the appropriate power switch relay. The energized relay
provides a current path to the boom actuator causing the
actuator to extend and the boom section to lower. This
maintains the boom height at the calibrated distance
from the ground. Once the boom section is lowered to
the calibrated distance, the elapsed time between the
sensor signal generation and the received echo returns
to the correct timeframe and the boom stops lowering.
A HIGHER BOOM HEIGHT IS DETECTED

SO ACTUATOR EXTENDS TO LOWER BOOM SECTION
SLOPE
Figure 4

LEFT BOOM
ACTUATOR
(STATIONARY)
(IN AUTO POSITION)
(NOT ENERGIZED)
(NOT ENERGIZED)

RIGHT BOOM
ACTUATOR
(RETRACTING)
(ENERGIZED)
Page 9 -- 10
(ENERGIZED)
RIGHT BOOM
ACTUATOR SWITCH
LEFT BOOM
ACTUATOR SWITCH
Sonic Boom System

Rise in Turf Encountered (Right Boom Shown)
Power Current
Control Current
Multi Pro 1200/1250

Rise in Turf Encountered
Sonic Boom
System
the boom mounted sonic boom sensors continually inches. When in automatic mode, the booms will not
send impulse signals and then receive echos as the sig- move if the target distance change is three (3) inches or
nals bounce off the turf. The electronic control unit less (inner dead band). Once the target distance ex-
(ECU) determines the sensor distance from the ground ceeds five (5) inches (outer dead band), the ECU will en-
based on the time between the sensor signal generation ergize the appropriate power switch relay. The
and the received echo. As long as the sensor height re- energized relay will lead to a change in boom actuator
mains the same as the calibrated height, the spray length and ultimately a change in boom height.
boom section will remain at a fixed distance from the
ground for spraying accuracy.
When a spray boom section encounters a rise in the turf,

the time necessary for the sensor to receive the signal
echo is shorter than the calibrated timeframe. This
change in time causes the ECU to energize the ap-
propriate power switch relay and H--bridge relays.
These energized relays provide a current path to the
boom actuator causing the actuator to retract and the
boom section to raise. This maintains the boom height
at the calibrated distance from the ground. Once the
boom section is raised to the calibrated distance, the
elapsed time between the sensor signal generation and
the received echo returns to the correct timeframe and
the boom stops raising.
A LOWER BOOM HEIGHT IS DETECTED

SO ACTUATOR RETRACTS TO RAISE BOOM SECTION
RISE
Figure 5

LEFT BOOM
ACTUATOR
(RETRACTING)
(IN AUTO POSITION)
(ENERGIZED)
(ENERGIZED)

RIGHT BOOM
ACTUATOR
(STATIONARY)
(NOT ENERGIZED)
Page 9 -- 12
(NOT ENERGIZED)
RIGHT BOOM
ACTUATOR SWITCH
LEFT BOOM
ACTUATOR SWITCH
(PRESSED TO RAISE)
Sonic Boom System

Boom Level Changed by Operator (Raise Left Boom Shown)
Power Current
Control Current
Multi Pro 1200/1250

Boom Level Changed by Operator During Automatic Operation
During sprayer operation with the sonic boom switch in If a boom is raised by the operator while the Sonic Boom
Sonic Boom
the automatic position (sonic boom light is illuminated), System is in automatic operation, the boom will remain
System
the boom mounted sonic boom sensors continually in the raised position until it is lowered halfway with the
send impulse signals and then receive echos as the sig- boom actuator switch to re--engage automatic sonic
nals bounce off the turf. The electronic control unit boom operation. If one boom is moved by the operator,
(ECU) determines the sensor distance from the ground the other boom continues to function automatically.
based on the time between the sensor signal generation
and the received echo. As long as the sensor height re-
mains the same as the calibrated height, the spray
boom will remain at a fixed distance from the ground for
spraying accuracy.
If the sprayer operator should press a boom actuator

switch while in automatic operation, the ECU energizes
the necessary power switch relay and H--bridge relays
to raise or lower the appropriate boom. The energized
relay(s) provides a current path to the requested boom
actuator to raise or lower the boom. The boom actuator
will stay energized as long as the operator keeps the
boom actuator switch pressed. The sonic boom light will
flash as long as the boom actuator switch is pressed.

LEFT BOOM
ACTUATOR
(STATIONARY)
(IN MANUAL POSITION)
(NOT ENERGIZED)
(NOT ENERGIZED)

RIGHT BOOM
ACTUATOR
(EXTENDING)
(NOT ENERGIZED)
Page 9 -- 14
(ENERGIZED)
RIGHT BOOM
ACTUATOR SWITCH
(PRESSED TO LOWER)
LEFT BOOM
ACTUATOR SWITCH
Sonic Boom System

Manual Boom Operation (Lower Right Boom Shown)
Sonic Mode Switch in Manual
Power Current
Control Current
Multi Pro 1200/1250

Manual Boom Operation
During sprayer operation with the sonic boom switch in Lower Boom
Sonic Boom
the manual position, the spray booms will remain in posi-
System
tion unless the operator presses a boom actuator When a boom actuator switch is pressed to lower a
switch. When the sonic boom switch is in the manual boom section, the electronic control unit (ECU) ener-
position, the sonic boom light should be illuminated. The gizes the power switch relay for the requested boom
operator will control the boom position with the boom ac- section. The energized relay provides a current path to
tuator switches. the boom actuator causing the actuator to extend which
will lower the boom section. The boom will continue to
Raise Boom lower until the operator releases the boom actuator
switch.
When a boom actuator switch is pressed to raise a boom
section, the electronic control unit (ECU) energizes the
power switch relay and both H--bridge relays for the re-
quested boom section. The energized relays provide a
current path to the boom actuator causing the actuator
to retract which will raise the boom section. The boom
will continue to rise until the operator releases the boom
actuator switch.

Troubleshooting
For effective troubleshooting and repairs, there must be NOTE: When troubleshooting an electrical problem on
a good understanding of the electrical circuits and com- your Sonic Boom System, refer to information regarding
ponents used on the Sonic Boom System (see Sonic the sonic boom light in this section. Also, use the Diag-
Boom System Operation in this chapter). nostic Display (see Special Tools in this chapter) to test
electronic control unit (ECU) inputs and outputs.
Sonic Boom Light

The Sonic Boom System is designed to automatically
adjust the sprayer boom height if changes in the turf sur-
face are detected. The sonic boom light should be illumi-
nated whenever the vehicle ignition switch is ON and the 2
sonic boom switch is in either the automatic or manual
position.
The sonic boom light flashing quickly indicates that the

Sonic Boom System is in the calibration mode. This
mode allows the spray booms to be adjusted for the de- 1
sired boom height. The calibration mode lasts for twenty
(20) seconds after which the boom light should quit
flashing.
NOTE: A sequence of switch movements is necessary

to engage the calibration mode. Refer to the Sonic
Boom Kit Installation Instructions for this sequence.
The sonic boom light flashing slowly indicates that a sys-

tem error has been encountered. If the boom light is
flashing slowly, lower the affected boom(s) with the
boom actuator switch(es) to clear the error. If the error Figure 6
continues, there may be an issue with the Sonic Boom 1. Dash panel 2. Boom light location
System electronic control unit (ECU). If this occurs, see
Diagnostic Display and Troubleshooting Chart in this
section.
Sonic Boom Calibration

The Sonic Boom sensor calibration process is critical to While calibrating the Sonic Boom sensors, it is best to
the correct operation of the Sonic Boom system. The perform the calibration process on turf. A shiny surface
calibration process establishes the sensor target dis- (e.g. cement shop floor) can skew sensor signals. Also,
tance between the boom and the turf surface. Typically, ensure the calibration area is free of buildings, trees, un-
this distance is approximately twenty (20) inches. Steps derground plumbing and other machines that could in-
needed for proper calibration are identified in the Sonic terfere with sensor signals.
Boom Kit Installation Instructions.

Diagnostic Display
The Sonic Boom System is equipped with an electronic
Sonic Boom
control unit (ECU) which controls machine sonic boom
CAUTION
System
electrical functions. The ECU monitors various input
switches (e.g. boom actuator switches, sonic boom sen-
sors) and energizes outputs to actuate relays for ap- When testing ECU inputs with the Diagnostic
propriate machine functions. Display, boom actuators may be energized caus-
ing the spray booms to move. Be cautious of po-
For the ECU to control the machine as desired, each of tential sprayer component movement while veri-
the inputs (switches and sensors) and outputs (relays) fying inputs with the Diagnostic Display.
must be connected and functioning properly.
6. The Diagnostic Display will illuminate the LED
The Diagnostic Display (see Special Tools in this chap-
associated with each of the inputs when that input switch
ter) is a tool to help the technician verify correct electrical
is closed. Individually, change each of the switches from
functions of the machine.
open to closed (e.g. toggle sonic mode switch), and note
that the appropriate LED on the Diagnostic Display will
IMPORTANT: The Diagnostic Display must not be illuminate when the corresponding switch is closed. Re-
left connected to the machine. It is not designed to peat on each switch that is possible to be changed by
withstand the environment of the machine’s every hand (see Inputs and LED Operation chart on following
day use. When use of the Diagnostic Display is com- page).
nect loopback connector to harness connector. The 7. If appropriate LED does not toggle on and off when
machine will not operate without the loopback con- switch state is changed, check all wiring and connec-
nector installed on the harness. Store the Diagnos- tions to that switch and/or test switch. Replace any de-
tic Display in a dry, secure, indoor location and not fective switches and repair any damaged wiring.
on machine.
8. After input functions testing is complete, disconnect
Verify Diagnostic Display Input Functions the Diagnostic Display connector from the harness con-
nector and plug loopback connector into wire harness.
1. Park vehicle on a level surface, stop the engine and
apply the parking brake.
2. Locate Sonic Boom wire harness communication

port and loopback connector under the vehicle dash
panel. Carefully unplug loopback connector from har-
ness connector.
3. Connect the Diagnostic Display connector to the

wire harness connector. Make sure correct overlay de-
cal is positioned on the Diagnostic Display (Fig. 7).
4. Turn the vehicle ignition switch to the ON position,

but do not start vehicle.
NOTE: The red text on the Diagnostic Display overlay

decal refers to input switches and the green text refers
to ECU outputs.
5. Make sure that the “INPUTS DISPLAYED” LED, on

lower right column of the Diagnostic Display, is illumi-
nated. If “OUTPUTS DISPLAYED” LED is illuminated,
press the toggle button on the Diagnostic Display to
change to “INPUTS DISPLAYED” LED.
Figure 7
Diagnostic Display Diagnostic Display
Inputs LED Operation
AUTO MODE Sonic mode switch in auto position: LED ON
Sonic mode switch not in auto position: LED OFF
L RAISE Left boom actuator switch in raise position: LED ON
Left boom actuator switch not in raise position: LED OFF
L LOWER Left boom actuator switch in lower position: LED ON
Left boom actuator switch not in lower position: LED OFF
R RAISE Right boom actuator switch in raise position: LED ON
Right boom actuator switch not in raise position: LED OFF
R LOWER Right boom actuator switch in lower position: LED ON
Right boom actuator switch not in lower position: LED OFF
L NO SNSR DATA ECU has detected an invalid reading from left sensor: LED ON
Left sensor operating normally: LED OFF
L NOT TRACKING Left boom not tracking to target within 5 seconds: LED ON
R NO SNSR DATA ECU has detected an invalid reading from right sensor: LED ON
Right sensor operating normally: LED OFF
R NOT TRACKING Right boom not tracking to target within 5 seconds: LED ON
L -- SNSR FEEDBACK ECU receiving signal from left sensor: LED ON
ECU not receiving signal from left sensor: LED OFF
R -- SNSR FEEDBACK ECU receiving signal from right sensor: LED ON
ECU not receiving signal from right sensor: LED OFF
NOTE: When the vehicle ignition switch is in the OFF NOTE: Right and left side Sonic Boom sensors are
position, all Diagnostic Display LED’s should be OFF. identical so they can be exchanged to assist in trouble-
shooting. If a problem follows the exchanged sensor, an
NOTE: Initial calibration of the Sonic Boom sensors is electrical problem likely exists with the sensor. If the
required for proper operation of ECU inputs. Refer to problem remains unchanged, something other than the
your Sonic Boom Kit Installation Instructions for infor- sensor is the problem source (e.g. switch, circuit wiring).
mation on initial sensor calibration.

Verify Diagnostic Display Output Functions NOTE: It may be necessary to toggle between “IN-
PUTS DISPLAYED” and “OUTPUTS DISPLAYED” sev-
The Diagnostic Display also has the ability to detect eral times to perform the following step. To change from
which output solenoids or relays are energized by the inputs to outputs, press toggle button once. This may be
electronic control unit (ECU). This is a quick way to de-
Sonic Boom
done as often as required. Do not press and hold
termine which electrical component is malfunctioning.
System
toggle button.
NOTE: An open output (e.g. an unplugged connector or 6. Attempt to operate the desired function of the ma-
a broken wire) cannot be detected with the Diagnostic chine. The appropriate output LED’s should illuminate
Display. on the Diagnostic Display to indicate that the ECU is
turning on that function. The outputs can be checked
1. Park vehicle on a level surface, stop the engine and with the vehicle ignition switch in the ON position and the
engage the parking brake. engine not running.
2. Locate Sonic Boom System wire harness and loop- A. If the correct output LED’s do not illuminate, verify
back connector under the vehicle dash panel. Carefully that the required input switches are in the necessary
unplug loopback connector from harness connector. positions to allow that function to occur.
3. Connect the Diagnostic Display connector to the har- B. If the output LED’s are on as specified, but the
ness connector. Make sure correct overlay decal is posi- booms do not function properly, suspect a failed
tioned on the Diagnostic Display (see Special Tools in electrical component, an open in the tested circuit or
this chapter). a non-electrical problem (e.g. binding of the boom
hinge). Repair as necessary.
4. Turn the ignition switch to the ON position.
C. If each input switch is in the correct position and
functioning correctly, but the output LED’s are not
correctly illuminated, this indicates an ECU problem.
to ECU outputs.
If this occurs, contact your Toro Distributor for assis-
5. Make sure that the “OUTPUTS DISPLAYED” LED, tance.
on lower right column of the Diagnostic Display, is illumi-
7. After output functions testing is complete, discon-
nated. If “INPUTS DISPLAYED” LED is illuminated,
nect the Diagnostic Display connector from the harness
connector and plug loopback connector into wire har-
change the LED to “OUTPUTS DISPLAYED”.
ness.

Outputs LED Operation
L BOOM -- RAISE Left boom is rising: LED ON
Left boom is stationary: LED OFF
R BOOM -- RAISE Right boom is rising: LED ON
Right boom is stationary: LED OFF
POWER ON/ERROR Power to ECU: LED ON
No power to ECU: LED OFF
System error: LED flashing slowly
L BOOM MOTOR ECU output exists to energize left power switch relay: LED ON
No ECU output to left power switch relay: LED OFF
R BOOM MOTOR ECU output exists to energize right power switch relay: LED ON
No ECU output to right power switch relay: LED OFF

Troubleshooting Chart
The chart that follows contains suggestions that can be NOTE: When troubleshooting an electrical problem on
used to assist in diagnosing Sonic Boom System perfor- your Sonic Boom System, refer to information regarding
mance issues. These suggestions are not all--inclusive. the sonic boom light in this section. Also, use the Diag-
Also, consider that there may be more than one cause nostic Display (see Special Tools in this chapter) to test
for a machine problem. electronic control unit (ECU) inputs and outputs.

Sonic boom light is not illuminated. Sonic mode switch is in the OFF position.
5 amp or 10 amp fuse in sonic boom fuse block is faulty.
Electrical power from vehicle is not available (all sonic boom func-
tions are affected).
Sonic boom light or circuit wiring is faulty.
Sonic mode switch or circuit wiring is faulty.
LED on one of the sonic boom sen- Sonic boom sensor or circuit wiring is faulty.
sors is not illuminated.
LED on both of the sonic boom sen- Sonic mode switch is in the OFF position.
sors is not illuminated.
5 amp fuse in sonic boom fuse block is faulty.
Sonic mode switch or circuit wiring is faulty.

One of the boom actuators will not 30 amp auto resetting fuse for affected boom actuator is faulty.
retract.
Power switch relay or circuit wiring for affected boom actuator is
faulty.
One or both of the H--bridge relays or circuit wiring for the affected
boom actuator is faulty.
Boom actuator switch or circuit wiring for affected boom actuator is

faulty.
Affected boom actuator or circuit wiring is faulty.
Neither of the boom actuators will Loop back connector is unplugged from wire harness connector.
retract.
Both of the boom actuator 30 amp auto resetting fuses are faulty.
ECU or circuit wiring is faulty.

One of the boom actuators will not 30 amp auto resetting fuse for affected boom actuator is faulty.
extend.
Sonic Boom
Power switch relay or circuit wiring for affected boom actuator is
System
faulty.
Boom actuator switch or circuit wiring for affected boom actuator is

faulty.
Affected boom actuator or circuit wiring is faulty.

Neither of the boom actuators will Loop back connector is unplugged from wire harness connector.
extend.
30 amp auto resetting fuse is faulty in both boom actuators.
One of the booms does not automat- On affected boom, the sonic boom sensor cover is on sensor or is
ically follow ground irregularities. hanging in sensor path.
Boom can be controlled with boom
actuator switch. On affected boom, the sensor filter is dirty or damaged.
Calibration of the Sonic Boom sensors is incorrect.
On affected boom, the sonic sensor angle needs adjustment.
Sonic sensor or circuit wiring for affected boom is faulty.
Neither boom automatically follows Sonic mode switch is not in the AUTO position.
ground irregularities. Booms can be
controlled with boom actuator Sonic boom sensor covers are on both sensors or are hanging in
switches. sensor path.
The filters on both sensors are dirty or damaged.
Calibration of the Sonic Boom sensors is incorrect.
The sonic sensor angle on both booms need adjustment.
Both sonic sensors or circuit wiring are faulty.

Service and Repairs
Sonic Mode Switch

The sonic mode switch is used as an input for the ECU 6. If the sonic mode switch tests correctly and circuit
to activate the Sonic Boom System. This switch has problem still exists, check wire harness (see Electrical
three (3) positions: automatic, manual and off. The sonic Schematic and Wire Harness Drawings in this chapter).
mode switch is located on the console.
7. After testing is completed, connect wire harness
If the sonic mode switch is in the automatic position, the connector to the sonic mode switch.
sonic sensors will be activated to allow automatic move-
ment of the boom. The tips of the booms will remain at
MULTI PRO 1200 MULTI PRO 1250
a constant distance from the ground. The boom
switches can be used to raise/lower the booms when the
sonic mode switch is in the automatic position.
If the sonic mode switch is in the manual position, the

sonic sensors are disabled. The boom switches are
used to raise/lower the booms when the sonic mode
switch is in the manual position.
If the sonic mode switch is in the OFF position, the

booms will remain in position. The boom actuators will
not be energized regardless of sonic boom sensor activ-
ity or change in boom switch position. 1 2
Testing
1. Before disconnecting the sonic mode switch for test-

ing, the switch and its circuit wiring should be tested as
a ECU input with the Diagnostic Display (see Diagnostic Figure 8
Display in the Troubleshooting section of this chapter).
1. Mode switch (MP 1200) 2. Mode switch (MP 1250)
If the Diagnostic Display verifies that the sonic mode
switch and circuit wiring are functioning correctly, no fur-
ther switch testing is necessary. If, however, the Display
determines that the sonic mode switch and circuit wiring
are not functioning correctly, proceed with test.
2. Park vehicle on a level surface, stop engine, engage

3. Disassemble console to gain access to sonic mode

switch. BACK OF SWITCH
Figure 9
4. Disconnect harness electrical connector from the
sonic mode switch.
SWITCH CLOSED OPEN
5. The switch terminals are marked as shown in Figure POSITION CIRCUITS CIRCUITS
9. The circuit logic of the sonic mode switch is shown in AUTOMATIC 2+3 2+1
the chart to the right. With the use of a multimeter (ohms 5+6 5+4
setting), the switch functions may be tested to determine
whether continuity exists between the various terminals OFF NONE ALL
for each switch position. Verify continuity between MANUAL 2+1 2+3
switch terminals. Replace switch if testing identifies a 5+4 5+6
faulty switch.

Relays
The Sonic Boom System uses six (6) identical relays to 7. Disconnect voltage and multimeter test leads from
Sonic Boom
control the boom actuators and ultimately the boom the relay terminals. Replace relay if necessary.
System
height. Three (3) of the relays control the right actuator
and the other three (3) relays control the left actuator. 8. Secure relay to mount plate and connect wire har-
The electronic control unit (ECU) controls the operation ness connector to relay.
of the relays. The relays are located on a mounting plate
under the vehicle dash panel (Fig. 10) and can be identi-
fied by a label on the wire harness connector.
3
For each actuator, a power switch relay and two (2) H-- 7
bridge relays are used. The power switch relay is ener- 6
gized by the ECU whenever the actuator is to be
energized to change boom height (either lowered or
raised). Both H--bridge relays are energized by the ECU
when a boom is to be raised. The energized bridge re- 1
lays provide current flow to the actuator so the actuator
retracts. The H--bridge relays are not energized when a
boom is to be lowered. The non--energized bridge relays
provide current flow to the actuator so the actuator ex- 4
tends. 2
5
Testing

parking brake and remove key from ignition switch. Figure 10
1. Mount plate 5. Cap screw (4 used)
2. Locate relay to be tested and disconnect wire har- 2. Electronic control unit 6. Lock washer (4 used)
ness connector from relay. Remove relay from mount 3. Sonic boom fuse block 7. Nut (4 used)
4. Relay (6 used)
plate for testing.

digital multimeter, short the meter test leads together. 3 4
1
resistance of the meter and test leads. Subtract this val- 86 87A 87
ue from from the measured value of the component you
are testing.
3. Using a multimeter, verify that coil resistance be-

tween terminals 85 and 86 is from 71 to 88 ohms. 85 30
4. Connect multimeter (ohms setting) leads to relay ter- 2

1
VDC to terminal 85. The relay terminals 30 and 87
should have continuity as +12 VDC is applied to terminal Figure 11
85. The relay terminals 30 and 87 should not have conti- 1. Coil terminal 3. Normally closed term.
nuity as +12 VDC is removed from terminal 85. 2. Common terminal 4. Normally open term.
5. Disconnect voltage from terminal 85 and multimeter


minals 30 and 87A. With terminal 86 grounded, apply
+12 VDC to terminal 85. The relay terminals 30 and 87A
should not have continuity as +12 VDC is applied to ter-
minal 85. The relay terminals 30 and 87A should have
continuity as +12 VDC is removed from terminal 85.

Electronic Control Unit (ECU)
The Sonic Boom System uses an electronic control unit
(ECU) to control electrical system operation. The ECU
is attached to a mounting plate under the vehicle dash
panel (Fig. 12). 3
Power is provided to the ECU when the vehicle ignition

switch is ON. A 5 amp fuse provides circuit protection for
this logic power to the ECU. The fuse is located in the
Sonic Boom System fuse block. 1
The ECU monitors the states of the following compo-

nents as inputs: the sonic mode switch, the two (2) boom
actuator switches and the two (2) boom sonic sensors.
4
The ECU controls electrical output to the sonic boom 2
light and the six (6) relays that are part of the Sonic
Boom System. Circuit protection for the ECU outputs is
provided by a 10 amp fuse located in the Sonic Boom
System fuse block. Figure 12
Because of the solid state circuitry built into the ECU, 1. Mount plate 3. Sonic boom fuse block
2. Electronic control unit 4. Relay (6 used)
there is no method to test it directly. The ECU may be
damaged if an attempt is made to test it with an electrical
test device (e.g. digital multimeter or test light).
IMPORTANT: Before performing welding on the ma-

chine, disconnect both cables from the battery and
disconnect wire harness connector from the ECU.
These steps will prevent damage to the machine
electrical system.

Sonic Sensor
Two (2) identical sonic sensors are used in the Sonic
4
Sonic Boom
Boom System. The sensors are mounted to the spray 5
System
booms (Fig. 13). During sprayer operation with the sonic 3
mode switch in the automatic position, the sonic sensors
will provide inputs for the electronic control unit (ECU)
to keep the booms at a constant distance from the 2
ground. 6
7
During sprayer operation, the sonic boom sensor con- 1
tinually sends an impulse signal and then receives an
echo as the signal bounces off the turf. The ECU estab- 13
lishes the sensor distance from the ground based on the
12
time between the sensor signal generation and the re- 8
ceived echo. The ECU then determines if the boom 11
9 10
height is different than the calibrated height and, if nec-
essary, energizes the appropriate boom actuator to
Figure 13
change the boom height.
1. Sonic sensor 8. Spray boom (RH shown)
2. Sensor bracket 9. Lock washer (2 used)
Sensors and protection tubes should be rotated above 3. Screw (2 used) 10. Nut (2 used)
parallel with the ground for proper sonic sensor opera- 4. Protection tube 11. Foam sensor filter
tion. Refer to the Sonic Boom Kit Installation Instructions 5. U--bolt (2 used) 12. Sensor shield
6. Lock nut (4 used) 13. Patch
for sonic sensor setup information. 7. Sensor cover
The sonic sensor includes a LED that should be illumi-

nated during sprayer operation regardless of whether
the sonic mode switch is in manual or automatic mode.
The intensity of the LED can be used to assure that the
sensor is properly adjusted on the spray boom.
The sonic sensors and their circuit wiring can be tested

as ECU inputs with the Diagnostic Display (see Diag-
nostic Display in the Troubleshooting section of this
chapter). Because of the solid state circuitry built into the
sensors, there is no method to test them directly. The
sensors may be damaged if an attempt is made to test
them with an electrical test device (e.g. digital multime-
ter or test light)
IMPORTANT: Do not spray water at or on the sen-

sors. Water sprayed under even household pres-
sure can damage the sensor. Always install sensor
cover (item 7) on sensor before washing the spray-
er. Also, install cover when sprayer is not in use.
As required, use a damp cloth to clean the sensors.

Make sure that the sensor covers (item 7) are clean and
dry before installing them on sensors.
The patch (item 13) that is adhered to the sensor is de-

signed to allow moisture to escape from inside the sen-
sor housing. The patch should be replaced if it is
deteriorated or has loosened from the sensor.
Inspect the foam sensor filter (item 11) for damage or ex-
cessive debris buildup. Replace filter if necessary.


Chapter 9.1
Ultra Sonic Boom System

(Optional Kit)
Table of Contents
Boom System
Ultra Sonic
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 2 Sonic Boom Light . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Precautions Concerning Chemicals Used in Ultra Sonic Boom Calibration . . . . . . . . . . . . . . . . 17
Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Diagnostic Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Precautions for Removing or Adjusting Spray Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Components . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . 24
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 26
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 4 Sonic Boom Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 26
ULTRA SONIC BOOM SYSTEM OPERATION . . . . 6 Sonic Boom Switch . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sprayer Operation on Level Turf . . . . . . . . . . . . . . 6 Sonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Downward Slope in Turf Encountered . . . . . . . . . . 8 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rise in Turf Encountered . . . . . . . . . . . . . . . . . . . . 10 Toro Electronic Controller (TEC) . . . . . . . . . . . . . 31
Boom Level Changed by Operator During
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . 12
Manual Boom Operation . . . . . . . . . . . . . . . . . . . . 14
Multi Pro 1200/1250 Page 9.1 - 1 Ultra Sonic Boom System (Rev. A)
General Information
Installation Instructions
The Ultra Sonic Boom Kit Installation Instructions pro-
vides information regarding the installation, operation
and general maintenance for your Ultra Sonic Boom
System. Refer to that publication for additional informa-
tion when servicing the machine.

Chemicals can injure persons, animals, plants, soil and 4. Always wear protective clothing, chemical resistant
other property. To eliminate environmental damage and gloves, eye protection and other personal protective
personal injury: equipment as recommended by the chemical manufac-
turer.
1. Select the proper chemical for the job.
2. Carefully read the directions printed on the chemical chemicals and chemical solution.
manufacturer’s labels before handling chemicals. In-
structions on chemical manufacturer’s container labels
regarding mixing proportions should be read and strictly
followed.
3. Keep spray material away from skin. If spray material

comes in contact with a person, wash it off immediately
in accordance with manufacturer’s recommendations
Sheets).

1. Park vehicle on a level surface and apply the parking 4. Remove chemicals from pump, hoses and other
brake. spray components. Thoroughly neutralize and rinse
spray system before loosening or removing any spray
2. Shut off the vehicle’s engine and remove the key system component(s).
5. Make sure spray system pressure is relieved before
3. Disengage all power and wait until all moving parts loosening any system component.
have stopped.
Ultra Sonic Boom System (Rev. A) Page 9.1 - 2 Multi Pro 1200/1250
Special Tools
Diagnostic Display
The Diagnostic Display (Fig. 1) can be connected to the
Ultra Sonic Boom wire harness communication connec-
tor to verify correct electrical functions of the Ultra Sonic
Boom System. Toro electronic controller (TEC) inputs
and outputs for the Ultra Sonic Boom System can be
Boom System
checked using the Diagnostic Display.
Ultra Sonic
Toro Part Number for Diagnostic Display: 85--4750
Toro Part Number for Overlay (English): 119--9431
IMPORTANT: The Diagnostic Display must not be

left connected to the machine. It is not designed to Figure 1
day use. When use of Diagnostic Display is com-
nect loopback connector to wire harness
communication connector. Machine will not oper-
ate without loopback connector installed on wire
harness. Store Diagnostic Display in a dry, secure,
indoor location and not on machine.
119--9431
Figure 2
7.5A
7.5A
7.5A
2A
SONIC BOOM
SWITCH
Ultra Sonic Boom System (Rev. A)

B A
INTERFACE TO
VEHICLE POWER
RIGHT BOOM
LIFT SWITCH A B
Page 9.1 - 4
LEFT BOOM
LIFT SWITCH
Sonic Boom System

Multi Pro 1200/1250

Boom System
Ultra Sonic
7.5A
7.5A
7.5A
2A
SONIC BOOM
SWITCH

B A
INTERFACE TO
VEHICLE POWER
RIGHT BOOM
LIFT SWITCH A B
Page 9.1 - 6
Ultra Sonic Boom System Operation
LEFT BOOM
LIFT SWITCH

Sonic Boom Switch in Automatic Position
Power Current
Control Current
Multi Pro 1200/1250

During sprayer operation with the sonic boom switch in NOTE: During normal Ultra Sonic Boom system opera-
the automatic position (sonic boom light is illuminated), tion, there may be some slight movement of the booms.
the boom mounted sonic boom sensors continually
send impulse signals and then receive echoes as the On level turf, the boom sensors continually send signals
signals bounce off the turf. The Toro electronic controller and receive echoes that determine that the boom sec-
(TEC) determines the sensor distance from the ground tions are at the calibrated height. Thus, there is no need
based on the elapsed time between the sensor signal to change boom height and the boom sections will re-
generation and the received echo. As long as the sensor main at the correct, level position.
Boom System
Ultra Sonic
spray boom will remain at a fixed height from the ground
for spraying accuracy.
CONSISTENT BOOM HEIGHT

SO BOOM ACTUATOR MOVEMENT
IS NOT NECESSARY
LEVEL GROUND
Figure 3
7.5A
7.5A
7.5A
2A
SONIC BOOM
SWITCH

B A
INTERFACE TO
VEHICLE POWER
RIGHT BOOM
LIFT SWITCH A B
Page 9.1 - 8
LEFT ACTUATOR
EXTENDING
LEFT BOOM
LIFT SWITCH

Downward Slope in Turf Encountered (Left Boom Shown)
Power Current
Control Current
Multi Pro 1200/1250

Downward Slope in Turf Encountered
the boom mounted sonic boom sensors continually inches. If the boom target distance changes when in au-
send impulse signals and then receive echoes as the tomatic mode, the TEC will energize the appropriate
signals bounce off the turf. The Toro electronic controller electrical relays. The energized relays will lead to a
(TEC) determines the sensor distance from the ground change in boom actuator length and ultimately a change
based on the elapsed time between the sensor signal in boom height.
generation and the received echo. As long as the sensor
Boom System
Ultra Sonic
spray boom section will remain at a fixed distance from
the ground for spraying accuracy.
When a spray boom section encounters a downward

slope in the turf, the time necessary for the sensor to re-
ceive the signal echo is longer than the calibrated time-
frame. This change in time causes the TEC to energize
the appropriate electrical relays causing the controlled
boom actuator to extend and the boom section to lower.
Once the boom section is lowered to the calibrated dis-
tance, the elapsed time between the sensor signal gen-
eration and the received echo returns to the correct
timeframe, relays are de--energized and the boom stops
lowering. This maintains the boom height at the cali-
brated distance from the ground.
A HIGHER BOOM HEIGHT IS DETECTED SO THE

BOOM ACTUATOR EXTENDS TO LOWER BOOM SECTION
SLOPE
Figure 4
7.5A
7.5A
7.5A
2A
SONIC BOOM
SWITCH RIGHT ACTUATOR
RETRACTING

B A
INTERFACE TO
VEHICLE POWER
RIGHT BOOM
LIFT SWITCH A B
Page 9.1 - 10
LEFT BOOM
LIFT SWITCH

Rise in Turf Encountered (Right Boom Shown)
Power Current
Control Current
Multi Pro 1200/1250

Rise in Turf Encountered
the boom mounted sonic boom sensors continually inches. If the boom target distance changes when in au-
send impulse signals and then receive echoes as the tomatic mode, the TEC will energize the appropriate
signals bounce off the turf. The Toro electronic controller electrical relays. The energized relays will lead to a
(TEC) determines the sensor distance from the ground change in boom actuator length and ultimately a change
based on the time between the sensor signal generation in boom height.
and the received echo. As long as the sensor height re-
Boom System
Ultra Sonic
mains the same as the calibrated height, the spray
boom section will remain at a fixed distance from the
ground for spraying accuracy.
When a spray boom section encounters a rise in the turf,

the time necessary for the sensor to receive the signal
echo is shorter than the calibrated timeframe. This
change in time causes the TEC to energize the appropri-
ate electrical relays causing the controlled boom actuat-
or to retract and the boom section to raise. Once the
boom section is raised to the calibrated distance, the
elapsed time between the sensor signal generation and
the received echo returns to the correct timeframe, re-
lays are de--energized and the boom stops raising. This
maintains the boom height at the calibrated distance
from the ground.
A LOWER BOOM HEIGHT IS DETECTED SO THE

BOOM ACTUATOR RETRACTS TO RAISE BOOM SECTION
RISE
Figure 5
7.5A
7.5A
7.5A
2A
SONIC BOOM
SWITCH

B A
INTERFACE TO
VEHICLE POWER
RIGHT BOOM
LIFT SWITCH A B
Page 9.1 - 12
LEFT ACTUATOR
RETRACTING
LEFT BOOM
LIFT SWITCH
(PRESSED TO RAISE)

Boom Level Changed by Operator (Raise Left Boom Shown)
Power Current
Control Current
Multi Pro 1200/1250

Boom Level Changed by Operator During Automatic Operation
During sprayer operation with the sonic boom switch in If a boom is raised by the operator while the Ultra Sonic
the automatic position (sonic boom switch light is illumi- Boom System is in automatic operation, that boom will
nated), the boom mounted sonic boom sensors continu- remain in the raised position until the boom lift switch is
ally send impulse signals and then receive echoes as pressed to lower and released which will re--engage au-
the signals bounce off the turf. The Toro electronic con- tomatic sonic boom operation on that boom section.
troller (TEC) determines the sensor distance from the
ground based on the time between the sensor signal If a boom is lowered by the operator while the Ultra Sonic
generation and the received echo. As long as the sensor Boom System is in automatic operation, that boom will
Boom System
lower until the boom lift switch is released. The automat-
Ultra Sonic
spray boom will remain at a fixed distance from the ic sonic boom operation will be re--engaged as soon as
ground for spraying accuracy. the lift switch is released from lower.
If the sprayer operator should press a boom lift switch NOTE: To re--engage automatic sonic boom operation,
while in automatic operation, the TEC energizes the ap- the boom lift switch must be pressed to lower and re-
propriate boom lift control electrical relays. The ener- leased. Pressing the boom lift switch to raise will not re--
gized relays cause the boom actuator to raise or lower engage automatic operation.
the boom section. The relays will stay energized as long
as the operator keeps the boom lift switch pressed. The
sonic boom light will flash while the boom lift switch is be-
ing depressed. If one boom is moved by the operator,
the other boom continues to function automatically.
OPERATOR PRESSES LEFT BOOM LIFT SWITCH SO THE LEFT

BOOM ACTUATOR RETRACTS TO RAISE BOOM SECTION
Figure 6
7.5A
7.5A
7.5A
2A
SONIC BOOM
SWITCH RIGHT ACTUATOR
EXTENDING

B A
INTERFACE TO
VEHICLE POWER
RIGHT BOOM
LIFT SWITCH A B
(PRESSED TO LOWER)
Page 9.1 - 14
LEFT BOOM
LIFT SWITCH

Manual Boom Operation (Lower Right Boom Shown)
Sonic Boom Switch in Manual Position
Power Current
Control Current
Multi Pro 1200/1250

Manual Boom Operation
During sprayer operation with the sonic boom switch in Raise Boom
the manual position, the spray booms will remain in posi-
tion unless the operator presses a boom lift switch. The When a boom lift switch is pressed to raise a boom sec-
sonic boom light should not be illuminated when in the tion, the Toro electronic controller (TEC) energizes the
manual position. The operator will control the boom appropriate electrical relays causing the controlled
position with the boom lift switches. boom actuator to retract and the boom section to raise.
The boom will continue to rise until the operator releases
Lower Boom the boom lift switch.
Boom System
Ultra Sonic
When a boom lift switch is pressed to lower a boom sec-
tion, the Toro electronic controller (TEC) energizes the
appropriate electrical relays causing the controlled
boom actuator to extend and the boom section to lower.
The boom will continue to lower until the operator re-
leases the boom actuator switch.
Troubleshooting
For effective troubleshooting and repairs, there must be NOTE: When troubleshooting an electrical problem on
a good understanding of the electrical circuits and com- your Ultra Sonic Boom System, refer to information re-
ponents used on the Ultra Sonic Boom System (see Ul- garding the sonic boom light and diagnostic lamp in this
tra Sonic Boom System Operation in this chapter). section. Also, use the Diagnostic Display (see Special
Tools in this chapter) to test Toro electronic controller
(TEC) inputs and outputs.
Boom System
Sonic Boom Light
Ultra Sonic
The sonic boom light is included in the sonic boom
switch on the spray control console (Fig. 7 or 8). This MULTI PRO 1200
light should be illuminated whenever the vehicle ignition
2 1
switch is ON and the sonic boom switch is in the auto-
matic position.
The sonic boom light flashing quickly indicates that the

Ultra Sonic Boom System is in the calibration mode.
This mode allows the spray booms to be adjusted for the
desired boom height and continues for approximately
twenty (20) seconds. The sonic boom light will then flash
slowly for approximately two (2) minutes to finalize the
calibration settings.
NOTE: A sequence of switch movements is necessary Figure 7

to engage the calibration mode. Refer to the Sonic 1. Spray control console 2. Sonic boom switch
Boom Kit Installation Instructions for this sequence.
The sonic boom light flashes slowly when the sonic MULTI PRO 1250
boom switch is in the automatic position and a boom lift
switch is pressed to manually change the boom height. 2 1
The flashing light will return to being constantly ON and
automatic operation will be re--engaged once the boom
switch is manually pressed to the lower position.
A slowly flashing sonic boom light may also indicate that

a system fault has been encountered. In the event that
there is a fault in the Ultra Sonic Boom System (e.g.
there is no signal coming from a boom sensor), the af-
fected boom will raise briefly and then stop. The sonic Figure 8
boom light will begin to flash slowly and the diagnostic 1. Spray control console 2. Sonic boom switch
lamp on the console will also flash. If this occurs, refer
to Diagnostic Lamp, Diagnostic Display and Trouble-
shooting Chart in this section.
Ultra Sonic Boom Calibration

The sensor calibration process is critical to the correct While calibrating the Ultra Sonic Boom sensors, it is best
operation of the Ultra Sonic Boom System. The calibra- to perform the calibration process on turf. A shiny sur-
tion process establishes the sensor target distance be- face (e.g. cement shop floor) can skew sensor signals.
tween the boom and the turf surface. Typically, this Also, ensure the calibration area is free of buildings,
distance is approximately twenty (20) inches. Steps trees, underground plumbing and other machines that
needed for proper calibration are identified in the Ultra could interfere with sensor signals.
Sonic Boom Kit Installation Instructions.
Diagnostic Lamp
The Ultra Sonic Boom System includes a diagnostic
lamp that displays the status of the sonic boom system.
1 2
The diagnostic lamp is located on the dash panel (Fig.
9).
When the ignition switch is moved to the ON position

and the Ultra Sonic Boom System electrical system is
functioning properly, the diagnostic lamp will be illumi-
nated for approximately three (3) seconds and then will
turn off. The diagnostic lamp should remain off during
normal sonic boom operation.
If the sonic boom system TEC controller detects an elec-

trical system malfunction (fault) during operation (e.g.
there is no signal coming from a boom sensor), the af-
fected boom will raise briefly and then stop. The sonic Figure 9
boom light (in sonic boom switch) will begin to flash 1. Dash panel 2. Diagnostic lamp
slowly and the diagnostic lamp will flash rapidly. The
diagnostic lamp will stop flashing and will automatically
reset when the ignition switch is turned to the OFF posi-
tion. The fault, however, will be retained in controller
memory and can be retrieved at a future time (see Re-
trieving Fault Codes below).
If the diagnostic lamp does not illuminate when the igni-

tion switch is turned to the ON position, possible causes
are:
D The loopback connector (6 pin connector) is not

connected to the machine wire harness (Fig. 10). 1
The loopback connector is near the TEC controller
on the mounting plate under the dash panel. 3
4 2
D The diagnostic lamp (or circuit wiring) is faulty.
Figure 10
D TEC controller fuse(s) are faulty. 1. TEC controller location 3. Diagnostic tether cap
2. Loopback connector 4. Diagnostic shunt wires
D The TEC controller is faulty.
Check electrical connections, controller fuses and the

diagnostic lamp to determine malfunction. Make sure
that the loopback connector is secured to the wire har-
ness connector during machine operation.
Retrieving Fault Codes Fault codes displayed by the diagnostic lamp are two (2)
digit numbers with no digit larger than five (5). Fault
All Ultra Sonic Boom System fault codes are retained in codes are listed in the chart below. There will be a one
the TEC controller memory. The three (3) most recent (1) second pause between the first and second digit of
fault codes that have occurred within the last forty (40) a code. Up to three (3) fault codes retained in controller
hours of operation can be retrieved using the diagnostic memory will be displayed by the diagnostic lamp in order
lamp. To retrieve these fault codes from the controller from the most recent fault to the oldest fault. If there are
memory, perform the following steps: multiple faults in controller memory, there will be a three
(3) second pause between codes. The fault codes will
1. Make sure that ignition switch is OFF. continually repeat after a five (5) second pause until the
ignition key is turned OFF.
2. Locate diagnostic tether cap that connects the two
Boom System
Ultra Sonic
(2) diagnostic shunt wires located near the TEC control- If there are no faults that have occurred within the last
ler on the mounting plate under the dash panel (Fig. 10). forty (40) hours of operation, the diagnostic lamp will
flash continuously after performing the above steps.
3. Remove diagnostic tether cap from diagnostic shunt
wires and connect the two (2) shunt wires together. If a fault code is not retrieved from the controller memory
within forty (40) hours of machine operating time, the
4. Turn ignition switch to the ON position.
fault cannot be retrieved from controller memory using
5. Monitor the diagnostic lamp for fault code(s). this procedure. If necessary, contact your Toro distribu-
tor to retrieve older fault codes.
After necessary service has been performed, discon-

nect diagnostic shunt wires and insert shunt leads into
diagnostic tether cap. Lower operator seat.
Fault Code (Lamp Flashes) Fault Description

1 -- 2 Left sonic boom sensor fault occurred
1 -- 3 Right sonic boom sensor fault occurred
1 -- 6 TEC inputs are out of range (sonic boom operation will stop)
2 -- 1 The extreme right 7.5 Amp fuse in boom supply fuse block is faulty
2 -- 2 The middle right 7.5 Amp fuse in boom supply fuse block is faulty
2 -- 3 The middle left 7.5 Amp fuse in boom supply fuse block is faulty
2 -- 4 Main electrical power to sonic boom system was interrupted
3 -- 4 Left boom raise function (output) is grounded or faulty
4 -- 1 Right boom raise function (output) is grounded or faulty
4 -- 2 Right boom lower function (output) is grounded or faulty
4 -- 5 Left boom lower function (output) is grounded or faulty
Clearing Fault Codes 2. At the same time, press the left boom switch to lower
and the right boom switch to raise.
After fault codes have been retrieved, clearing of those
faults can be completed using the following switch se- 3. Monitor the diagnostic lamp for continuous flashing
quence: indicating that all faults have been cleared from the con-
troller memory.
1. Place sprayer in fault retrieval mode (see above).
The diagnostic lamp should be displaying the fault
codes.
Diagnostic Display
The Ultra Sonic Boom System is equipped with the Toro
electronic controller (TEC) which controls machine son-
ic boom electrical functions. The TEC monitors various
input switches (e.g. sonic boom switch, boom lift
switches, sonic boom sensors) and energizes outputs
(e.g. boom actuators, diagnostic lamp) for appropriate
machine functions.
For the TEC to control the machine as desired, each of

the inputs (switches and sensors) and outputs (e.g.
boom actuators) must be connected and functioning
properly. 1
The Diagnostic Display (see Special Tools in this chap- 3 2

ter) is a tool to help the technician verify correct electrical
functions of the machine.
Figure 11
IMPORTANT: The Diagnostic Display must not be 1. TEC controller location 3. Diagnostic tether cap
2. Loopback connector
left connected to the machine. It is not designed to
day use. When use of the Diagnostic Display is com-
nect loopback connector to harness connector. The
machine will not operate without the loopback con-
nector installed on the harness. Store the Diagnos-
tic Display in a dry, secure, indoor location and not
on machine.
Verify Diagnostic Display Input Functions
1. Park machine on a level surface, stop the engine and

apply the parking brake.
2. Locate Ultra Sonic Boom wire harness communica-

tion port and loopback connector (6 pin connector) loc-
ated near the TEC controller on the mounting plate
under the dash panel (Fig. 11). Carefully unplug loop-
back connector from harness connector.
3. Connect the Diagnostic Display connector to the

wire harness communication port connector. Make sure
correct overlay decal is positioned on the Diagnostic
Display (Fig. 12).
4. Turn the machine ignition switch to the ON position,

but do not start engine.
119--9431
to TEC outputs.
5. Make sure that the “INPUTS DISPLAYED” LED, on Figure 12

lower right column of the Diagnostic Display, is illumi-
nated. If “OUTPUTS DISPLAYED” LED is illuminated,
change to “INPUTS DISPLAYED” LED.
7. If appropriate LED does not toggle on and off when
CAUTION switch state is changed, perform test of switch and/or
check all wiring and connections to that switch. Replace
any defective switches and repair any damaged wiring.
When testing TEC inputs with the Diagnostic Dis-
play, boom actuators may be energized causing 8. After input functions testing is complete, disconnect
the spray booms to move. Be cautious of poten- the Diagnostic Display connector from the harness con-
tial sprayer component movement while verify- nector. Plug loopback connector into wire harness.
ing inputs with the Diagnostic Display.
6. The Diagnostic Display will illuminate the LED
Boom System
associated with each of the inputs when that input switch
Ultra Sonic
is closed. Individually, change each of the switches from
open to closed (e.g. toggle sonic boom switch), and note
that the appropriate LED on the Diagnostic Display will
illuminate when the corresponding switch is closed. Re-
peat on each switch that is possible to be changed by
hand (see Inputs and LED Operation chart below).

Inputs LED Operation
AUTO MODE Sonic boom switch in auto position: LED ON
Sonic boom switch not in auto position: LED OFF
RIGHT RAISE Right boom lift switch in raise position: LED ON
Right boom lift switch not in raise position: LED OFF
RIGHT LOWER Right boom lift switch in lower position: LED ON
Right boom lift switch not in lower position: LED OFF
LEFT RAISE Left boom lift switch in raise position: LED ON
Left boom lift switch not in raise position: LED OFF
LEFT LOWER Left boom lift switch in lower position: LED ON
Left boom lift switch not in lower position: LED OFF
RETRIEVE FAULTS Diagnostic shunt wires are connected for fault retrieval: LED ON
Diagnostic shunt wires are not connected: LED OFF
LEFT SENSOR FAULT The TEC has detected an invalid reading from left sensor: LED ON
RIGHT SENSOR FAULT The TEC has detected an invalid reading from right sensor: LED ON
KEY RUN Ignition key is in ON position: LED ON
Ignition key is in OFF position: LED OFF
NOTE: When the vehicle ignition switch is in the OFF NOTE: Right and left side Ultra Sonic Boom sensors
position, all Diagnostic Display LED’s should be OFF. are identical so they can be exchanged to assist in trou-
bleshooting. If a problem follows the exchanged sensor,
NOTE: Initial calibration of the Ultra Sonic Boom sen- an electrical problem likely exists with the sensor. If the
sors is required for proper operation of TEC inputs. Re- problem remains unchanged, something other than the
fer to your Sonic Boom Kit Installation Instructions for sensor is the problem source (e.g. switch, circuit wiring).
information on initial sensor calibration.
Verify Diagnostic Display Output Functions 6. Attempt to operate the desired function of the ma-
chine. The appropriate output LED’s should illuminate
The Diagnostic Display also has the ability to detect on the Diagnostic Display to indicate that the TEC is
which output boom actuators or lights (sonic boom or turning on that function (see Outputs and LED Opera-
diagnostic) are energized by the Toro electronic control- tion chart on next page). The outputs can be checked
ler (TEC). This is a quick way to determine which electri- with the ignition switch in the ON position and the engine
cal component is malfunctioning. not running.
NOTE: An open output (e.g. an unplugged connector or A. If the correct output LED’s do not illuminate, verify
a broken wire) cannot be detected with the Diagnostic that the required input switches are in the necessary
Display. positions to allow that function to occur.
1. Park machine on a level surface, stop the engine and B. If the output LED’s are on as specified, but the
engage the parking brake. booms do not function properly, suspect a failed
electrical component, an open in the tested circuit or
2. Locate Ultra Sonic Boom wire harness communica- a non-electrical problem (e.g. binding of the boom
tion port and loopback connector (6 pin connector) loc- hinge). Repair as necessary.
ated near the TEC controller on the mounting plate
under the dash panel (Fig. 13). Carefully unplug loop- C. If each input switch is in the correct position and
back connector from harness connector. functioning correctly, but the output LED’s are not
correctly illuminated, this may indicate a TEC prob-
3. Connect the Diagnostic Display connector to the har- lem. If this occurs, contact your Toro Distributor for
ness communication port connector. Make sure correct assistance.
overlay decal is positioned on the Diagnostic Display
(see Special Tools in this chapter). 7. After output functions testing is complete, discon-
nect the Diagnostic Display connector from the harness
4. Turn the ignition switch to the ON position. connector and plug loopback connector into wire har-
ness.
to TEC outputs.
5. Make sure that the “OUTPUTS DISPLAYED” LED,

on lower right column of the Diagnostic Display, is illumi-
nated. If “INPUTS DISPLAYED” LED is illuminated,
change the LED to “OUTPUTS DISPLAYED”.
NOTE: It may be necessary to toggle between “IN-

PUTS DISPLAYED” and “OUTPUTS DISPLAYED” sev-
eral times to perform the following step. To change from 1
inputs to outputs, press toggle button once. This may be
done as often as required. Do not press and hold
3 2
toggle button.
Figure 13
CAUTION 1. TEC controller location
2. Loopback connector
3. Diagnostic tether cap
When testing TEC inputs with the Diagnostic Dis-

play, boom actuators may be energized causing
the spray booms to move. Be cautious of poten-
tial sprayer component movement while verify-
ing inputs with the Diagnostic Display.
Outputs LED Operation
DIAG LAMP Diagnostic lamp is ON or FLASHING: LED ON or FLASHING
Diagnostic lamp is not ON or FLASHING: LED OFF
SONIC SENSOR TEC output exists to sonic sensors: LED ON
No TEC output to sonic sensors: LED OFF
RIGHT RAISE TEC output exists to energize relays to raise right boom: LED ON
No TEC output to energize relays to raise right boom: LED OFF
RIGHT LOWER TEC output exists to energize relays to lower right boom: LED ON
Boom System
Ultra Sonic
No TEC output to energize relays to lower right boom: LED OFF
INDICATOR LAMP Sonic boom switch is in automatic position: LED ON
Sonic boom switch is in manual position: LED OFF
LEFT RAISE TEC output exists to energize relays to raise left boom: LED ON
No TEC output to energize relays to raise left boom: LED OFF
LEFT LOWER TEC output exists to energize relays to lower left boom: LED ON
No TEC output to energize relays to lower left boom: LED OFF
Troubleshooting Chart
The chart that follows contains suggestions that can be NOTE: When troubleshooting an electrical problem on
used to assist in diagnosing Ultra Sonic Boom System your Ultra Sonic Boom System, refer to information re-
performance issues. These suggestions are not all--in- garding the sonic boom light in this section. Also, use the
clusive. Also, consider that there may be more than one Diagnostic Display (see Special Tools in this chapter) to
cause for a machine problem. test Toro electronic controller (TEC) inputs and outputs.

Light in sonic boom switch is not illu- Sonic boom switch is in the MANUAL position.
minated.
2 Amp fuse in sonic boom fuse block is faulty (all sonic boom func-
Upper, middle right fuse (7.5 Amp) in sonic boom fuse block is
faulty.
Loopback connector is unplugged from wire harness connector (all

sonic boom functions are affected).
Sonic boom switch or circuit wiring is faulty.
One of the boom actuators will not Boom lift switch or circuit wiring for affected boom actuator is faulty.
extend or retract.
A problem exists with the affected boom actuator.
Neither of the boom actuators will Loopback connector is unplugged from wire harness connector (all
extend or retract. sonic boom functions are affected).
Fuse(s) in sonic boom fuse block is faulty.
A problem exists with both boom actuators.
The Toro electronic controller (TEC) or circuit wiring is faulty.
The LED’s on one of the sonic boom Sonic boom sensor or circuit wiring is faulty.
sensors are not illuminated.
The LED’s on both of the sonic Sonic boom switch is in the MANUAL position.
boom sensors are not illuminated.
Upper, middle left fuse (7.5 Amp) in sonic boom fuse block is faulty
(diagnostic lamp also affected).
Sonic boom switch or circuit wiring is faulty.
One of the booms does not automat- On affected boom, the sonic boom sensor cover is on sensor.
ically follow ground irregularities.
Boom can be controlled with boom On affected boom, calibration of the sonic boom sensors is incor-
lift switch. rect.
The sonic boom sensor is incorrectly installed.
Sonic boom sensor or circuit wiring for affected boom is faulty.
Boom System
Ultra Sonic
Neither boom automatically follows Sonic boom switch is not in the AUTOMATIC position.
ground irregularities. Booms can be
controlled with boom lift switches. Sonic boom sensor covers are on both sensors.
Calibration of the sonic boom sensors is incorrect.
Both sonic boom sensors or circuit wiring are faulty.
Service and Repairs
Sonic Boom Fuses

Fuses for the Ultra Sonic Boom system are included in
the fuse blocks attached to the mounting plate under the
1
dash panel (Fig. 14).
Fuse Identification and Function
The upper row of fuses protect circuits as follows:
1. The upper, extreme left 2 Amp fuse protects power

supply for TEC logic.
2. The upper, middle left 7.5 Amp fuse is not used.
3. The upper, middle right 7.5 Amp fuse protects TEC

output circuits (sonic boom switch light and boom actu-
ator power supply).
2
4. The upper, extreme right 7.5 Amp fuse protects TEC
output circuits (diagnostic light and sonic sensor power Figure 14
supply). 1. Dash panel 2. Fuse blocks
The lower row of fuses protect circuits as follows:
1. The lower, extreme left fuse position is not used. 1 2 3 4

2. The lower, middle left fuse position is not used.
3. The lower, middle right 30 Amp fuse (auto resetting)

protects the left boom actuator circuit.
4. The extreme right 30 Amp fuse (auto resetting) pro-

tects the right boom actuator circuit.
Fuse Testing
Remove fuses from the fuse block for testing. Fuse 7

should have continuity between fuse terminals.
6
NOTE: The auto resetting fuses should only be re- 5
moved if they are faulty.
Figure 15
1. Upper, extreme left fuse 4. Upper right fuse
2. Upper middle left fuse 5. Auto resetting fuse
3. Upper, middle right fuse 6. Auto resetting fuse
Sonic Boom Switch
The sonic boom switch is used as an input for the Toro
electronic controller (TEC) to activate the Ultra Sonic MULTI PRO 1200
Boom System. This switch has two (2) positions: auto-
2 1
matic and manual. The sonic boom switch is located on
the spray control console (Figs. 16 and 17).
If the sonic boom switch is in the automatic position, the

sonic sensors will be activated to allow automatic move-
Boom System
ment of the booms. The tips of the booms will remain at
Ultra Sonic
a constant distance from the ground. The boom lift
switches can be used to raise/lower the booms when the
sonic boom switch is in the automatic position. The light
in the switch should be illuminated when the switch is in
the automatic position.
Figure 16
If the sonic boom switch is in the manual position, the 1. Spray control console 2. Sonic boom switch
sonic sensors are disabled. The boom lift switches are
used to raise/lower the booms when the sonic boom
switch is in the manual position. MULTI PRO 1250
Testing 2 1
NOTE: Before disconnecting sonic boom switch for

testing, the switch and its circuit wiring should be tested
as a TEC input with the Diagnostic Display (see Diag-
nostic Display in the Troubleshooting section of this
chapter). If the Diagnostic Display verifies that the sonic
boom switch and circuit wiring are functioning correctly,
no further switch testing is necessary. If, however, the
Display determines that the sonic boom switch and cir- Figure 17
cuit wiring are not functioning correctly, proceed with 1. Spray control console 2. Sonic boom switch
switch test.
1. Park vehicle on a level surface, stop engine, engage 7 4 5 6

2. Locate sonic boom switch, remove console panel

and unplug wire harness connector from switch.
3. The switch terminals are shown in Figure 18. The cir-

cuit logic of the sonic boom switch is shown in the chart
to the right. With the use of a multimeter (ohms setting), 8 1 2 3
the switch functions may be tested to determine whether BACK OF SWITCH
continuity exists between the various terminals for each
switch position. Verify continuity between switch termi- Figure 18
nals. Replace switch if testing identifies a faulty switch.
SWITCH CLOSED OPEN
4. To test switch light, apply 12 VDC to terminal 8 (+) POSITION CIRCUITS CIRCUITS
and ground terminal 7 (--). The light should illuminate.
MANUAL 2+3 2+1
5. If the sonic boom switch tests correctly and circuit 5+6 5+4
problem still exists, check sonic boom system wire har- AUTOMATIC 2+1 2+3
ness. 5+4 5+6
6. After testing is completed, connect wire harness

connector to the sonic boom switch. Install console pan-
el to machine.
Sonic Sensors
Two (2) identical sonic sensors are used in the Ultra
Sonic Boom System. The sensors are mounted to the
spray booms (Figs. 19, 20 and 21). During sprayer op-
eration with the sonic boom switch in the automatic posi- 4
tion, the sonic sensors will provide inputs for the Toro
electronic controller (TEC) to keep the booms at a 14 to 16 ft--lb
constant distance from the ground. (19 to 21 N--m)
During sprayer operation, the sonic boom sensor con-

tinually sends an impulse signal and then receives an 2
echo as the signal bounces off the turf. The TEC estab- 3
lishes the sensor distance from the ground based on the
time between the sensor signal generation and the re- 5
ceived echo. The TEC then determines if the boom
height is different than the calibrated height and, if nec-
essary, energizes the appropriate boom actuator(s) to 6
change the boom height.
1
Sensors should be secured to the spray booms correctly
for proper sonic sensor operation. Refer to the Ultra
Sonic Boom Kit Installation Instructions for sonic sensor Figure 19
installation and setup information.
1. Sonic sensor 4. Cover
2. Lower housing 5. Programming plug
The sonic sensors and their circuit wiring can be tested 3. Nut (2 used) 6. Cap
as TEC inputs with the Diagnostic Display (see Diagnos-
tic Display in the Troubleshooting section of this chap-
ter). Because of the solid state circuitry built into the 1
sensors, there is no method to test them directly. The
sensors may be damaged if an attempt is made to test
them with an electrical test device (e.g. digital multime-
2
ter or test light).
IMPORTANT: Do not spray water at or on the sen-

sors. Water sprayed even under household pres-
sure can damage the sensor. Always install sensor
Figure 20
cap on sensor before washing the sprayer. Also,
install cap when sprayer is not in use. 1. Sensor with cover 2. Sensor without cover
As required, use a damp cloth to clean the sensors.

Make sure that the sensor covers and caps are clean
and dry before installing them on sensors. When the 1
sprayer is not being used, it is recommended to have the
caps installed on the sensors for sensor protection. 2
Each of the sonic sensor assemblies includes a pro-

gramming plug for sensor accuracy. If a programming
3
plug is removed from the sensor, make sure that the ar-
row below the sideways T on the plug is aligned with the
notch on the top edge of the sensor (Fig. 22).
NOTE: The two (2) sonic sensors are identical. To as-

sist in troubleshooting, sensors can be exchanged. If the
problem follows the exchanged sensor, an electrical
problem likely exists with the sensor. If the problem re- Figure 21
mains unchanged, something other than the sensor is 1. Sonic sensor 3. Nut (2 used)
the problem source. 2. Lower housing
Sonic Sensor LED Window
The sonic sensor includes a LED window that identifies

sensor status during sprayer operation during operation
of the Ultra Sonic Boom system (Fig. 23). To view the
LED window, carefully remove cover from sonic sensor.
2
The LED window includes four (4) LED’s.
3
During normal operation, the green LED and both yellow
LED’s should be illuminated. The red LED will be off.
4
If there is some interference with normal sensor opera-
Boom System
Ultra Sonic
tion, the red LED will be flashing. The green LED will be
off. The yellow LED’s may flash, be illuminated or be off. 1
5
If the sensor programming plug is removed or is faulty,
the red LED will be illuminated. The green LED will be Figure 22
off. The yellow LED’s may flash, be illuminated or be off.
1. Sonic sensor 4. Plug arrow
2. Programming plug 5. Sensor notch
The status of the LED’s on the sensors can be used to 3. Letter T
identify a faulty or unplugged programming plug. The
LED’s also can be used to identify the presence of inter-
ference that can affect Ultra Sonic Boom system opera-
tion. If the LED’s do not illuminate correctly, a problem 1 2 3 4
may exist with circuit wiring to the sensor or with the sen-
sor itself.
Figure 23
1. Yellow LED 3. Red LED
2. Green LED 4. Yellow LED
Relays
The Ultra Sonic Boom System uses four (4) identical re- 8. Disconnect voltage and multimeter test leads from
lays to control the boom actuators and ultimately the the relay terminals. Replace relay if necessary.
boom height. Two (2) of the relays control the right boom
actuator and the other two (2) relays control the left 9. Secure relay to mount plate and connect wire har-
boom actuator. The Toro electronic controller (TEC) ness connector to relay. Secure mount plate to machine
controls the operation of the relays. The appropriate frame.
relay is energized by the TEC to allow current flow to the
boom actuators in the proper direction so that the actu-
ator extends (boom raise) or retracts (boom lower). 6
5
The relays are located on a mount plate under the ve-
hicle dash panel (Fig. 24) and can be identified by a label
8
on the wire harness connector.
Testing 7

parking brake and remove key from ignition switch. 4
3
2. Remove mount plate from under dash panel to allow 2
easier relay access.
1
3. Locate relay to be tested and disconnect wire har-
ness connector from relay. Remove relay from mount
plate for testing.
Figure 24
digital multimeter, short the meter test leads together. 1. Mount plate 5. Relay (4 used)
2. Flange screw (2 used) 6. Cap screw (4 used)
The meter will display a small resistance value (usually 3. Lock washer (2 used) 7. Lock washer (4 used)
0.5 ohms or less). This resistance is due to the internal 4. Flat washer (2 used) 8. Nut (4 used)
ue from from the measured value of the component you
are testing. 3 4
1
4. Using a multimeter, verify that coil resistance be-
tween terminals 85 and 86 is from 71 to 88 ohms. 86 87A 87

VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is 85 30
applied and removed from terminal 85.
2
6. Disconnect voltage from terminal 85 and multimeter 1
Figure 25
1. Coil terminal 3. Normally closed term.
minals 30 and 87A. Apply +12 VDC to terminal 85. The 2. Common terminal 4. Normally open term.
relay should make and break continuity between termi-
nals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
Toro Electronic Controller (TEC)
The Ultra Sonic Boom System uses the Toro Electronic
Controller (TEC) to control electrical system operation.
The TEC is attached to a mounting plate under the dash 1
panel (Fig. 26). 2
Power is provided to the TEC when the vehicle ignition

switch is ON. A 2 Amp fuse provides circuit protection for
this logic power to the TEC. The fuse is located in the Ul-
Boom System
tra Sonic Boom System fuse block under the dash pan-
Ultra Sonic
el.
The TEC monitors the states of the following compo-

nents as inputs: the sonic boom switch, the two (2) boom
lift switches, the two (2) sonic boom sensors and the
diagnostic shunt wires.
The TEC controls electrical output to the sonic boom Figure 26

light, the diagnostic lamp, the four (4) relays used to con- 1. Dash panel 2. TEC controller
trol the sonic boom system and the two (2) sonic boom
sensors. Circuit protection for the TEC outputs is pro-
vided by three (3) 7.5 Amp fuses located in the Ultra
Sonic Boom System fuse block. 4
Testing of the TEC inputs and outputs can be completed

with the use of the Diagnostic Display (see the Special
Tools and Troubleshooting sections of this chapter).
Because of the solid state circuitry built into the TEC,

there is no method to test it directly. The TEC may be
damaged if an attempt is made to test it with an electrical
test device (e.g. digital multimeter or test light).
IMPORTANT: Before performing welding on the ma-

chine, disconnect both cables from the battery and 3 2 1
disconnect wire harness connector from the TEC.
These steps will prevent damage to the machine
electrical system.
Figure 27
1. Mount plate 3. Cap screw (4 used)
2. TEC controller 4. Flange nut (4 used)
Chapter 10
Electrical Drawings
Table of Contents
ELECTRICAL SCHEMATICS
Vehicle Electrical Schematic: Multi Pro 1200/1250 3
Spray System Electrical Schematic: Multi Pro
1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Spray System Electrical Schematic: Multi Pro
1250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CIRCUIT DIAGRAMS
Start Circuit: Multi Pro 1200/1250 . . . . . . . . . . . . . 6
Drawings
Electrical
Run Circuit: Multi Pro 1200/1250 . . . . . . . . . . . . . . 7
Neutral Engine Speed Control Circuit: Multi
Pro 1200/1250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Spray Circuit: Multi Pro 1200 . . . . . . . . . . . . . . . . . 9
Spray Circuit: Multi Pro 1250
(Master Boom Switch ON) . . . . . . . . . . . . . . . . . 10
(Master Boom Switch ON, LH Boom OFF) . . . . 11
(Master Boom Switch OFF) . . . . . . . . . . . . . . . . 12
Spray Circuit Application Rate Change:
Multi Pro 1250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WIRE HARNESS DRAWINGS
Main Wire Harness: Multi Pro 1200/1250 . . . . . . 14
Spray System Wire Harness: Multi Pro 1200 . . . 16
Spray System Wire Harness: Multi Pro 1250 . . . 18
Multi Pro 1200/1250 Page 10 -- 1 Electrical Drawings

Electrical Drawings Page 10 -- 2 Multi Pro 1200/1250

Multi Pro 1200/1250
J25
BK
Vehicle Electrical Schematic
All relays and solenoids
are shown as de-- energized.
GROUND BLOCK All ground wires are black.
(+) (--)
R BK Wire harness connector numbers
are identified on schematic.
BATTERY
(GRP 26, 540 CCA)
J04
BK
PK PK
CHASSIS GRD ENGINE GRD
P17&J18
OFF G,M,A
RUN B,L,A
START B,L,S
LEFT ACTUATOR POWER (30A RESETTABLE)
1 2 J07 B A
OR R
RIGHT ACTUATOR POWER (30A RESETTABLE) S
3 4 J12 BU/BK
R (+) (+)
L M P04
FOAM MARKER POWER (15A) S
5 6 J03 L P29 P28
Y G B R/BK
BK NEUTRAL HR VOLT
R/W SPARE HOUR VOLT
7 8 J08 A SWITCH
PK (--) METER (--) METER
G
AUXILIARY GN/R
FUSE BLOCK--4 WAY PK
M
P07
BU
BK BK
1 2 30A
PK R R BU 2
IGNITION SWITCH
3 4 10A
Y W 3
BK
5 6 5A
BU/R BU 5
J01 W
R J02
7 8 J05 P15
R/W PK 6
BN
SPRAY SYSTEM POWER (20A)
2 8 7
MAIN R
J09 J15 FUSE BLOCK--4 WAY BK
ACCESSORY Y
3 BU/BK
R SOLENOID BK P05 NEUTRAL ENGINE SPEED
87a LOCK SWITCH
30
87
85 86 V
HEADLIGHT
FUSIBLE LINK SWITCH PK
START RELAY
Y
P06 GN/R
W 87a BN
FUSIBLE LINK 30
J13 J11 87 V
W P01
85 86 P36
KOHLER TWIN ENGINE R BK 4 BK
SPEED LOCK
HEADLIGHTS RELAY SPEED LOCK
J14 J10 COIL
B+
BU Y/BU
START C1 D1 6
P19 2
K1 K2 1
STARTER R 2 BU/W
SHIFT
SOLENOID C2
CARB
OIL SOLENOID
SWITCH
3
4 R/BK
5
GN 3
SPEED LOCK MODULE
AC
BK BK
V 5
AC
W 1 W
IGNITION
MODULES
SPARK PLUG SPARK PLUG
Page 10 -- 3
Multi Pro 1200
Spray System RIGHT BOOM
Electrical Schematic ACTUATOR

All ground wires are black.
(LOWER)
Wire harness connector numbers
(RAISE)
LEFT BOOM
ACTUATOR
(LOWER)
(RAISE)
(OPTIONAL KIT)
Page 10 -- 4
RIGHT BOOM
ACTUATOR
Multi Pro 1250
Spray System
RELAY (LOWER) Electrical Schematic
All ground wires are black.
Wire harness connector numbers
RELAY (RAISE)
LEFT BOOM
ACTUATOR
RELAY (LOWER)
RELAY (RAISE)
MASTER BOOM
SWITCH
(OPTIONAL KIT)
BLACK
CLEAR
SHIELD
D A
RATE LOCKOUT
SWITCH
APPLICATION
RATE SWITCH
BLACK
CLEAR
SHIELD
REGULATING
VALVE
Page 10 -- 5
J25
Multi Pro 1200/1250 BK
Start Circuit
Power Current GROUND BLOCK
(+) (--)
Control Current R BK
Indicator/Gauge Current BATTERY
(GRP 26, 540 CCA)
J04
BK
PK PK
P17&J18
OFF G,M,A
RUN B,L,A
START B,L,S
1 2 J07 B A
OR R
3 4 J12 BU/BK
R (+) (+)
L M P04
5 6 J03 L P29 P28
Y G B R/BK
BK NEUTRAL HR VOLT
SPARE HOUR VOLT
7 8 J08 A SWITCH
(IN NEUTRAL)
G
AUXILIARY GN/R
M
P07
BU
BK BK
1 2 30A
PK R R BU 2
IGNITION SWITCH
3 4 10A
Y W 3
BK
5 6 5A
BU/R BU 5
J01 W
R J02
7 8 J05 P15
R/W PK 6
BN
2
MAIN R 8 7
ACCESSORY Y
3 BU/BK
R SOLENOID BK
P05 NEUTRAL ENGINE SPEED
87a LOCK SWITCH
30
87
85 86 V
HEADLIGHT
START RELAY
(ENERGIZED)
Y
GN/R BN
P06
W
FUSIBLE LINK 87a
J11 30
J13 87 V
W P01
85 86 P36
KOHLER TWIN ENGINE R BK 4
SPEED LOCK BK
J14 HEADLIGHTS J10 RELAY SPEED LOCK
B+ COIL
BU Y/BU
START C1 D1 6
P19 2
K1 K2 1
STARTER R 2 BU/W
SHIFT
C2
SOLENOID CARB
OIL SOLENOID
SWITCH
3
4 R/BK
5
GN 3 SPEED LOCK MODULE
AC
BK BK
V 5
AC
W 1 W
IGNITION
MODULES
Page 10 -- 6
J25 Multi Pro 1200/1250
BK
Run Circuit
Power Current
GROUND BLOCK Control Current
(+) (--)
R BK Indicator/Gauge Current
BATTERY
(GRP 26, 540 CCA)
J04
BK
PK PK
P17&J18
OFF G,M,A
RUN B,L,A
START B,L,S
1 2 J07 B A
OR R
3 4 J12 BU/BK
R (+) (+)
L M P04
5 6 J03 L P29 P28
Y G B R/BK
BK NEUTRAL HR VOLT
SPARE HOUR VOLT
7 8 J08 A SWITCH
G
AUXILIARY GN/R
M
P07
BU
BK BK
1 2 30A
PK R R BU 2
IGNITION SWITCH
3 4 10A
Y W 3
BK
5 6 5A
BU/R BU 5
J01 W
R J02
7 8 J05 P15
R/W PK 6
BN
2
MAIN R 8 7
ACCESSORY Y
3 BU/BK
R SOLENOID BK
(ENERGIZED) P05 NEUTRAL ENGINE SPEED
87a LOCK SWITCH
30
87
85 86 V
HEADLIGHT
START RELAY
Y
GN/R BN
P06
W
FUSIBLE LINK 87a
30
J13 J11 87 V
W P01
85 86 P36
KOHLER TWIN ENGINE R BK 4
SPEED LOCK BK
HEADLIGHTS J10 RELAY SPEED LOCK
J14 COIL
B+
BU Y/BU
START C1 D1 6
P19 2
K1 K2 1
STARTER R 2 BU/W
SHIFT
C2
SOLENOID CARB
OIL SOLENOID
SWITCH
3
4 R/BK
5
GN 3 SPEED LOCK MODULE
AC
BK BK
V 5
AC
W 1 W
IGNITION
MODULES
Page 10 -- 7
Multi Pro 1200/1250 J25
BK
Neutral Engine Speed
Control Circuit
GROUND BLOCK
Power Current (+) (--)
Control Current R BK
BATTERY
Indicator/Gauge Current (GRP 26, 540 CCA)
J04
BK
PK PK
P17&J18
OFF G,M,A
RUN B,L,A
START B,L,S
1 2 J07 B A
OR R
3 4 J12 BU/BK
R (+) (+)
L M P04
5 6 J03 L P29 P28
Y G B R/BK
BK NEUTRAL HR VOLT
SPARE HOUR VOLT
7 8 J08 A SWITCH
(IN NEUTRAL)
G
AUXILIARY GN/R
M
P07
BU
BK BK
1 2 30A
PK R R BU 2
IGNITION SWITCH
3 4 10A
Y W 3
BK
5 6 5A
BU/R BU 5
J01 W
R J02
7 8 J05 P15
R/W PK 6
BN
2
MAIN R 8 7
ACCESSORY Y
3 BU/BK
R SOLENOID BK
(ENERGIZED) P05 NEUTRAL ENGINE SPEED
87a LOCK SWITCH
30
87
85 86 V
HEADLIGHT
START RELAY
Y
GN/R BN
P06
W
FUSIBLE LINK 87a
30
J13 J11 87
V
W P01
85 86 P36
KOHLER TWIN ENGINE R BK 4 BK
SPEED LOCK
J14 HEADLIGHTS J10 SPEED LOCK
RELAY COIL
B+ (ENERGIZED)
BU Y/BU
START C1 D1 6
P19 2
K1 K2 1
STARTER R 2 BU/W
SHIFT
SOLENOID C2
CARB
OIL SOLENOID
SWITCH
4 R/BK 3
5
GN 3
SPEED LOCK MODULE
AC
BK BK
V 5
AC
W 1 W
NOTE: WHEN THE CRUISE CONTROL SWITCH
IGNITION IS PRESSED TO THE MOMENTARY SET POSITION,
MODULES
SWITCH TERMINALS 5 AND 6 ARE USED TO
INITIALLY ENERGIZE THE CRUISE MODULE AND
ALSO CREATE A LATCH CIRCUIT THROUGH SWITCH
TERMINALS 2 AND 3. THIS LATCH CIRCUIT KEEPS
THE CRUISE MODULE ENERGIZED AS SHOWN.
Page 10 -- 8
RIGHT BOOM
ACTUATOR
Multi Pro 1200
Spray Circuit
(LOWER) Pump Switch ON
Power Current
Control Current
Indicator/Gauge Current
(RAISE)
LEFT BOOM
ACTUATOR
(LOWER)
(RAISE)
(OPTIONAL KIT)
(ENERGIZED)
(ENERGIZED)
NOTE: WHEN THE PUMP SWITCH IS PRESSED

TO THE MOMENTARY ON POSITION, SWITCH
TERMINALS 5 AND 6 ARE USED TO INITIALLY
ENERGIZE THE PUMP RELAY AND ALSO TO CREATE
A LATCH CIRCUIT THROUGH SWITCH TERMINALS
2 AND 3. THIS LATCH CIRCUIT KEEPS THE PUMP
RELAY ENERGIZED AS SHOWN.
Page 10 -- 9
RIGHT BOOM
Multi Pro 1250 ACTUATOR
Spray Circuit
Master Boom Switch ON RELAY (LOWER)
Pump Switch and All Spray Switches ON

Power Current
Control Current
RELAY (RAISE)
LEFT BOOM
ACTUATOR
RELAY (LOWER)
RELAY (RAISE)
MASTER BOOM
SWITCH
(OPTIONAL KIT)
BLACK
CLEAR
SHIELD
D A
RATE LOCKOUT
SWITCH (ENERGIZED)
(ENERGIZED)
APPLICATION
RATE SWITCH
BLACK
CLEAR
SHIELD
NOTE: BOOM VALVES SHOWN AS OPENING AND NOTE: WHEN THE PUMP SWITCH IS PRESSED
USING CURRENT. ONCE BOOM VALVES ARE TO THE MOMENTARY ON POSITION, SWITCH
OPENED, A SWITCH IN THE BOOM VALVE WILL TERMINALS 5 AND 6 ARE USED TO INITIALLY
SHUT OFF THE BOOM VALVE MOTOR. THE LIGHT ENERGIZE THE PUMP RELAY AND ALSO TO CREATE
IN THE SPRAY SWITCH WILL STAY ILLUMINATED A LATCH CIRCUIT THROUGH SWITCH TERMINALS
REGULATING AS LONG AS THE SWITCH IS IN THE ON POSITION. 2 AND 3. THIS LATCH CIRCUIT KEEPS THE PUMP
VALVE RELAY ENERGIZED AS SHOWN.
Page 10 -- 10
RIGHT BOOM Multi Pro 1250
ACTUATOR
Spray Circuit
Master Boom Switch ON
RELAY (LOWER)
Pump, Center Spray and Right Spray Switches ON
Left Spray Switch Turned To OFF
Power Current
Control Current
RELAY (RAISE) Indicator/Gauge Current
LEFT BOOM
ACTUATOR
RELAY (LOWER)
RELAY (RAISE)
MASTER BOOM
SWITCH
(OPTIONAL KIT)
BLACK
CLEAR
SHIELD
D A
RATE LOCKOUT
SWITCH (ENERGIZED)
(ENERGIZED)
APPLICATION
RATE SWITCH
BLACK
CLEAR
SHIELD
NOTE: LEFT BOOM VALVE CLOSING AND USING NOTE: WHEN THE PUMP SWITCH IS PRESSED
CURRENT. ONCE LEFT BOOM VALVE IS CLOSED, A TO THE MOMENTARY ON POSITION, SWITCH
SWITCH IN THE BOOM VALVE WILL SHUT OFF THE TERMINALS 5 AND 6 ARE USED TO INITIALLY
BOOM VALVE MOTOR. THE LIGHT IN THE LEFT ENERGIZE THE PUMP RELAY AND ALSO TO CREATE
SPRAY SWITCH WILL NOT BE ILLUMINATED. A LATCH CIRCUIT THROUGH SWITCH TERMINALS
2 AND 3. THIS LATCH CIRCUIT KEEPS THE PUMP
REGULATING
VALVE
RELAY ENERGIZED AS SHOWN.
Page 10 -- 11
Multi Pro 1250 RIGHT BOOM
ACTUATOR
Spray Circuit
(Master Boom Switch OFF)
RELAY (LOWER)
(Spray Pump and All Boom Switches ON)
Power Current
Control Current
RELAY (RAISE)
LEFT BOOM
ACTUATOR
RELAY (LOWER)
RELAY (RAISE)
MASTER BOOM
SWITCH
(OPTIONAL KIT)
BLACK
CLEAR
SHIELD
D A
RATE LOCKOUT
SWITCH (ENERGIZED)
(ENERGIZED)
APPLICATION
RATE SWITCH
BLACK
CLEAR
SHIELD
NOTE: WHEN MASTER BOOM SWITCH IS TURNED NOTE: WHEN THE PUMP SWITCH IS PRESSED
OFF, ALL BOOM VALVES WILL CLOSE AND USE TO THE MOMENTARY ON POSITION, SWITCH
CURRENT AS SHOWN. ONCE BOOM VALVES ARE TERMINALS 5 AND 6 ARE USED TO INITIALLY
CLOSED, BOOM VALVE MOTORS WILL EACH BE ENERGIZE THE PUMP RELAY AND ALSO TO CREATE
SHUT OFF BY A SWITCH IN THE BOOM VALVE. THE A LATCH CIRCUIT THROUGH SWITCH TERMINALS
LIGHT IN ALL SPRAY SWITCHES WILL NOT BE 2 AND 3. THIS LATCH CIRCUIT KEEPS THE PUMP
REGULATING
ILLUMINATED. RELAY ENERGIZED AS SHOWN.
VALVE
Page 10 -- 12
RIGHT BOOM
ACTUATOR
Multi Pro 1250
Spray Circuit
RELAY (LOWER)
Application Rate (Increase Shown)
Power Current
Control Current
RELAY (RAISE)
LEFT BOOM
ACTUATOR
RELAY (LOWER)
RELAY (RAISE)
MASTER BOOM
SWITCH
(OPTIONAL KIT)
BLACK
CLEAR
SHIELD
D A
RATE LOCKOUT
SWITCH
(ON)
APPLICATION
RATE SWITCH
(PRESSED TO INCREASE)
BLACK
CLEAR
SHIELD
REGULATING
VALVE
Page 10 -- 13
J10
RIGHT HEADLIGHT
J11
4 3 J13
LEFT
HEADLIGHT
2 P19 J14
5 ENGINE LEFT
1
CONNECTION HEADLIGHT
B
P31
POWER
INPUT
J04
A ENGINE
B GROUND
P04
NEUTRAL
SWITCH
87A
85 (3)
87
(2) (4)
P06
SPEED 86
LOCK 30
(1) (5)
RELAY
P29 1 23 P07 J05
HOUR SPEED
METER SPRAY
LOCK POWER
SWITCH P05
J06 START
”G” RELAY
P02
MAIN 8 7
VOLT FUSE 6 5
METER BLOCK 4 3
2 1
J16 J03
”I” FOAM MARKER POWER
P17 3 4 J07
IGNITION P15 J08 LEFT ACTUATOR POWER
SWITCH 6547 HEADLIGHT SPARE
2 SWITCH J25
5 J15 GROUND J12
1 3218 GND BLOCK RIGHT ACTUATOR POWER
2 1
J18 3
J01
IGNITION INPUT 4 P37
SWITCH 5 2 4 6 8 AUXILIARY
J02 6 FUSE
1 3 5 7
OUTPUT P36 BLOCK
ACCESSORY SPEED
SOLENOID LOCK
J09 MODULE
ENERGIZE
P01
SPEED LOCK
COIL
Multi Pro 1200/1250

Main Wire Harness
Page 10 -- 14
AUXILARY SOLENOID
SPRAY AUXILARY FUSE BLOCK FOAM RIGHT LEFT
INPUT OUTPUT ENERGIZE GND SYSTEM MARKER ACTUATOR ACTUATOR SPEED LOCK RELAY SPEED LOCK
MAIN FUSE BLOCK POWER P37 SPARE POWER POWER POWER SWITCH
P06
J01 J02 J09 J15 P02 J05 J08 J03 J12 J07 P07
30 85 87A 87 86
1 1 1 1 1 2 3 4 5 6 7 8 1 1 2 3 4 5 6 7 8 1 1 1 1 1 2 3 4 5 1 2 3 4 5 6 7 8
GREEN/RED
BLUE/RED
BROWN
VIOLET
BLUE
PINK
BLACK
BLACK
PINK
BLACK
RED/WHITE
RED/WHITE
A RED
RED
POWER
PINK
RED/WHITE
P31
INPUT B RED
PINK
YELLOW
ENGINE J04 1 BLACK RED
GROUND
ORANGE
SP04
GROUND
J25 1 BLACK
BLOCK
VIOLET 1
BROWN 2
S 1 BLUE/BLACK PINK 3 SPEED LOCK
P36 MODULE
M 2 WHITE BLACK 4
P17 L 3 RED/BLACK BLACK 5
IGNITION G 4 BLACK BLACK 6
SWITCH B 5 RED
YELLOW/BLUE
J18 A 1 PINK
SP01
1 SPEED LOCK
P01
2 COIL
A PINK 1 +
NEUTRAL RED/BLACK
P04 2 P29 HOUR METER
SWITCH B GREEN/RED
SP02
3
--
SP03
BLACK 1 J06 ”G”
VOLT
30 1 METER
85 2 BLACK PINK 1 J16 ”I”
START P05 87A 3
RELAY
87 4 BLUE/WHITE
86 5 GREEN/RED
BLACK
WHITE
YELLOW
BLACK
RED
1
2 WHITE
ENGINE P19 3
CONNECTION 1 2 3 4 5 6 7 8 1 1 1 1
4
5 P15 J13 J14 J11 J10
HEADLIGHT LEFT HEADLIGHT RIGHT HEADLIGHT

SWITCH
Multi Pro 1200/1250

Main Wire Harness
Page 10 -- 15
Multi Pro 1200
Spray System Wire Harness
Page 10 -- 16
BLUE
YELLOW
ORANGE
PINK
BLUE
GRAY
BLACK
BLACK
GREEN
VIOLET
YELLOW
ORANGE
PINK
BLACK
BLACK
PINK
BLUE
BLUE
ORANGE
TAN
PINK
YELLOW
GREEN/WHITE
YELLOW
BLACK
BLACK
PINK
BLACK
GREEN
BLACK
BLACK
ORANGE
BLACK BLACK
GREEN/WHITE
YELLOW
GREEN
GREEN/WHITE
BLACK
BLACK
GREEN
YELLOW
BLACK
RED
RED
YELLOW
YELLOW
RED
YELLOW
WHITE BROWN
BLACK
BLACK
RED
ORANGE
YELLOW
BLUE
BLUE YELLOW
BLACK RED
BLACK
RED
YELLOW
RED
WHITE BLACK
BLUE
Multi Pro 1200
BLUE
WHITE
Page 10 -- 17
REGULATING
VALVE
MASTER
BOOM SWITCH
RATE LOCKOUT
KEY SWITCH
APPLICATION
RATE
SWITCH
Multi Pro 1250

Page 10 -- 18
VALVE
REGULATING
RATE LOCKOUT
BOOM SWITCH
MASTER
RATE SWITCH
APPLICATION
KEY SWITCH
BLACK
BLACK
BLACK
PINK
PINK
PINK
PINK
ORANGE
BLACK
BLACK
GREEN
BLACK
CLEAR
SHIELD
BLACK
ORANGE
YELLOW
GREEN/WHITE
RED/WHITE
ORANGE/BLUE
ORANGE/BLACK
RED/YELLOW
RED/WHITE
WHITE
GREEN/
WHITE/BLUE
BLACK
TAN
BLACK
RED/YELLOW
GREEN/WHITE
BLUE
BLACK
YELLOW
BLACK
BLACK
BROWN
RED/BLACK
BLACK
RED/YELLOW
PINK
PINK
YELLOW
BLACK PINK
BLUE BLACK
RED/BLACK
BROWN
RED/YELLOW
BLACK
BLACK
ORANGE
RED/BLACK
BLUE
BROWN
BLUE BLUE/RED
ORANGE
TAN
YELLOW/BLACK
BLACK
GREEN
GREEN/WHITE
YELLOW
BLACK
BLACK BLUE/BLACK
ORANGE
GREEN YELLOW
BLACK YELLOW/WHITE
BLACK
ORANGE
GREEN/BLACK
YELLOW
GREEN PINK
PINK
GREEN RED/BLACK
YELLOW BLACK
BLUE
BLACK BROWN
BLACK
RED
YELLOW PINK
RED
ORANGE RED/BLACK
BLACK
GREEN
BROWN
BLACK
WHITE
BLACK
BLACK
RED
BLACK
YELLOW
BLUE
BLACK
BLACK
RED
YELLOW
YELLOW
YELLOW
RED
RED
RED
YELLOW
YELLOW
BLUE
BROWN
BLACK
BLUE
WHITE GREEN
BLUE YELLOW
BLUE
WHITE
Multi Pro 1250
Page 10 -- 19
Page 10 -- 20

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PART NO.

Multi ProR 1200/1250

E The Toro Company - 2011, 2014

Multi Pro 1200/1250

Chapter 1 - Safety Chapter 6 - Spray System

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2

Chapter 4 - Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2

Multi Pro 1200/1250

Multi Pro 1200/1250

Chapter 9.1 -- Ultra Sonic Boom System (Optional

General Information . . . . . . . . . . . . . . . . . . . . . . 9.1 -- 2

Chapter 10 -- Electrical Drawings

Multi Pro 1200/1250 Rev. A

Multi Pro 1200/1250

Multi Pro 1200/1250 Page 1 -- 1 Safety

Safety Page 1 -- 2 Multi Pro 1200/1250

10.If engine must be running to perform maintenance or

Multi Pro 1200/1250 Page 1 -- 3 Rev. A Safety

IMPORTANT: Before raising the sprayer, it is rec-

Jacking the Front End

2. Position jack securely under the A--arms, just to the Figure 2

3. Jack front of machine off the ground.

4. Position jack stands under the A--arms as close to

Jacking the Rear End

1. Set parking brake and chock both front tires to pre-

2. Place jack securely under the rear most frame sup-

3. Jack rear of machine off the ground.

4. Position jack stands under the frame to support the

Safety and Instruction Decals

Product Records and Maintenance

Multi Pro 1200/1250 Page 2 -- 1 Product Records and Maintenance

Product Records and Maintenance Page 2 -- 2 Multi Pro 1200/1250

Grade 1 Grade 5 Grade 8 Class 8.8 Class 10.9

Inch Series Bolts and Screws Metric Bolts and Screws

Using a Torque Wrench with an Offset Wrench

Example: The measured effective length of the torque

The calculated torque conversion factor for this torque Figure 3

Multi Pro 1200/1250 Page 2 -- 3 Product Records and Maintenance

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

# 6 -- 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

# 8 -- 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

# 10 -- 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14

1/2 -- 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81

Product Records and Maintenance Page 2 -- 4 Multi Pro 1200/1250

M5 X 0.8 57 + 5 in--lb 640 + 60 N--cm 78 + 7 in--lb 885 + 80 N--cm

M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 27 + 2 ft--lb 36 + 3 N--m

M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 53 + 5 ft--lb 72 + 7 N--m

M12 X 1.75 66 + 7 ft--lb 90 + 10 N--m 92 + 9 ft--lb 125 + 12 N--m

Multi Pro 1200/1250 Page 2 -- 5 Product Records and Maintenance