Toro Multi Pro 1200 Service Manual
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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Multi Pro 1200 and Multi Pro 1250 sprayers with a serial
number below 290999999.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE,
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator's Manual and Parts Catalog
for your machine. Replacement Operator's Manuals
and Parts Catalogs are available on the internet at
www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
AND
ADJUSTMENT
E The Toro Company - - 2003, 2005, 2007, 2011
Service Manual
(Serial Number Below 290999999)
R
Multi Pro
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
PART NO. 03112SL (Rev. C)
1200/1250

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Summary of Contents for Toro Multi Pro 1200

  • Page 1 The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Multi Pro 1200 and Multi Pro 1250 sprayers with a serial number below 290999999. This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUC- REFER TO THE OPERATOR’S MANUAL FOR OPER-...
  • Page 2 This page is intentionally blank. Multi Pro 1200/1250...
  • Page 3: Table Of Contents

    ......5 -- 7 Service and Repairs ..... . . 5 -- 21 Multi Pro 1200/1250 Rev. C...
  • Page 4 This page is intentionally blank. Multi Pro 1200/1250...
  • Page 5 ......9 -- 9 Wire Harness Drawings ....9 -- 16 Multi Pro 1200/1250 Rev. C...
  • Page 6 This page is intentionally blank. Multi Pro 1200/1250 Rev. C...
  • Page 7 While Operating ......2 Maintenance and Service ....3 Multi Pro 1200/1250 Page 1 – 1...
  • Page 8: Safety Instructions

    Safety Instructions The Multi Pro 1200 and Multi Pro 1250 Turf Sprayers are result in injury or death. To reduce the potential for injury designed and tested to offer safe service when operated or death, comply with the following safety instructions.
  • Page 9: Maintenance And Service

    Use 16.To assure optimum performance and continued cardboard or paper to find hydraulic leaks. Hydraulic safety of the machine, use genuine Toro replacement fluid escaping under pressure can penetrate skin and parts and accessories. Replacement parts and acces- cause injury.
  • Page 10: Jacking Instructions

    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.
  • Page 11: Product Records

    MAINTENANCE ......7 Product Records Insert Operator’s Manual and Parts Catalog for your Multi Pro 1200/1250 at the end of this Chapter. Refer to Operator’s Manual for recommended maintenance in- tervals. Additionally, insert Installation Instructions, Op- erator’s Manuals, and Parts Catalogs for any...
  • Page 12: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Multi Pro 1200/1250 Rev. C Page 2 - - 2...
  • Page 13: Torque Specifications

    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.
  • Page 14: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series Fasteners)

    + 10% of the nominal torque value. Thin The specific torque value should be determined based height nuts include jam nuts. Product Records and Maintenance Multi Pro 1200/1250 Page 2 – 4...
  • Page 15: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)

    Torque values may have to be reduced when SAE J1199. The tolerance is approximately + 10% of the installing fasteners into threaded aluminum or brass. nominal torque value. The specific torque value should be determined based Multi Pro 1200/1250 Product Records and Maintenance Page 2 – 5...
  • Page 16: Other Torque Specifications

    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 Product Records and Maintenance Multi Pro 1200/1250 Page 2 – 6...
  • Page 17: Maintenance

    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.
  • Page 18 This page is intentionally blank. Product Records and Maintenance Multi Pro 1200/1250 Page 2 – 8...
  • Page 19: Introduction

    Introduction This Chapter gives information about specifications and Most repairs and adjustments require tools which are repair of the Kohler engine used in the Multi Pro 1200 commonly available in many service shops. Special and 1250. tools are described in the Kohler Engine Service Manu- al.
  • Page 20: Specifications

    API SF or SG (see Operator’s Manual for viscosity) Oil Pump Gear driven trochoid type Crankcase Oil Capacity 1.9 liters (2 U.S. qt.) with filter Starter 12 VDC Alternator/Regulator 12 VDC 30 AMP Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 2...
  • Page 21: Adjust Engine Speed

    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...
  • Page 22: Adjust Choke Cable

    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. Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 4...
  • Page 23: Service And Repairs

    Overheating and engine 1. Grass screen 2. Blower housing damage will result. 4. Make sure grass screen and blower housing are re- installed to the engine if removed. Multi Pro 1200/1250 Page 3 – 5 Kohler Gasoline Engine...
  • Page 24: Fuel System

    2. Foam strip 6. Hose clamp 10. Cap screw (4 used) 3. Nut (4 used) 7. Fuel hose 11. Fuel tank strap 4. Flat washer 8. Fuel filter 12. Fuel cap Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 6...
  • Page 25 To clean fuel tank, flush tank out with clean solvent. Make sure tank is free of contaminates and debris. Multi Pro 1200/1250 Page 3 – 7 Kohler Gasoline Engine...
  • Page 26: Exhaust System

    18. Cap screw 5. Header support 12. Cap screw 19. Muffler heat shield 6. Flange head screw 13. Flat washer 20. Spark arrester (optional) 7. Exhaust stud 14. Flange head screw Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 8...
  • Page 27 B. Position muffler/tailpipe to muffler hanger with muffler clamp and two (2) flange nuts. 6. Remove exhaust gaskets from engine. Replace gas- kets if damaged or torn. C. Tighten muffler clamps to secure muffler/tailpipe. Multi Pro 1200/1250 Page 3 – 9 Kohler Gasoline Engine...
  • Page 28: Engine Mounting Plate Assembly

    The hydrau- lic hoses to the steering pump and the fuel hose do not need to be disconnected unless the mounting plate is to be completely removed from the machine. Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 10...
  • Page 29: Removal

    2. RH frame rail fuel leakage. Disconnect fuel hose from fuel pump on engine and pull fuel line from R–clamps on mount plate. Position disconnected fuel line away from engine. Multi Pro 1200/1250 Page 3 – 11 Kohler Gasoline Engine...
  • Page 30: Installation

    Drive Gearbox in the Service and Repairs Section of Chapter 7 – Drive Train). D. From below, install flange head screw and nut un- der starter motor that secures engine and negative (–) cable (Fig. 11). Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 12...
  • Page 31 14.Check engine speed (see Adjust Engine Speed in 8. If fuel line was removed, route fuel line through R– the Adjustments Section of this Chapter). clamps on mounting plate. Connect fuel line to the fuel pump. Multi Pro 1200/1250 Page 3 – 13 Kohler Gasoline Engine...
  • Page 32: Engine

    16. Hydraulic steering pump 25. Oil drain elbow 8. CVT belt guide 17. Engine mounting plate 26. Oil drain nipple 9. Lock washer 18. Engine support strap 27. Flange head screw Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 14...
  • Page 33: Engine Removal

    Adjust belt guides (see Drive Belt Service in Ser- vice and Repairs Section of Chapter 7 – Drive Train). 7. Install engine mounting plate to machine (see En- gine Mounting Plate Installation in this section). Multi Pro 1200/1250 Page 3 – 15 Kohler Gasoline Engine...
  • Page 34 This page is intentionally blank. Kohler Gasoline Engine Multi Pro 1200/1250 Page 3 – 16...
  • Page 35 Test No. 2: Steering Control Valve and Steering Cylinder ......14 Multi Pro 1200/1250 Page 4 – 1...
  • Page 36: Specifications

    Specifications Item Description Gear Pump Positive displacement, gear type pump Steering Relief Pressure 1000 PSI (69.0 bar) Hydraulic Filter 10 Micron spin–on cartridge type Hydraulic Reservoir In transaxle Hydraulic System Page 4 – 2 Multi Pro 1200/1250...
  • Page 37 This page is intentionally blank. Multi Pro 1200/1250 Page 4 – 3 Hydraulic System...
  • Page 38: General Information

    8 (1/2 in.) 0.75 + 0.25 Finger Tight After Proper Tightening 10 (5/8 in.) 1.00 + 0.25 12 (3/4 in.) 0.75 + 0.25 16 (1 in.) 0.75 + 0.25 Figure 2 Hydraulic System Page 4 – 4 Multi Pro 1200/1250...
  • Page 39 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 Figure 5 Multi Pro 1200/1250 Page 4 – 5 Hydraulic System...
  • Page 40: Hydraulic Schematic

    CONTROL UNIT R: WORKING PRESSURE (RIGHT TURN) L: WORKING PRESSURE (LEFT TURN) STEERING CYLINDER GEAR RETURN PUMP RELIEF FILTER VALVE TRANSAXLE HOUSING SUCTION STRAINER IN TRANSAXLE Multi Pro 1200/1250 Hydraulic Schematic Hydraulic System Page 4 – 6 Multi Pro 1200/1250...
  • Page 41: Hydraulic Flow Diagrams

    The rotary meter ensures that the oil flow to the cyl- STEERING CYLINDER STEERING CYLINDER STEERING CYLINDER PISTON MOVEMENT PISTON MOVEMENT NO PISTON MOVEMENT STEERING STEERING STEERING CONTROL CONTROL CONTROL RIGHT TURN NEUTRAL POSITION LEFT TURN Figure 6 Multi Pro 1200/1250 Page 4 – 7 Hydraulic System...
  • Page 42: Special Tools

    Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
  • Page 43: Hydraulic Test Fitting Kit

    Hydraulic Test Fitting Kit Toro Part Number: TOR4079 TORO TEST FITTING KIT (NO. TOR4079) This kit includes a variety of O–ring Face Seal fittings to enable connection of test gauges to the hydraulic sys- tem. The kit includes: tee’s, unions, reducers, plugs, caps, and test fittings.
  • Page 44: Troubleshooting

    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. Hydraulic System Page 4 - - 10 Multi Pro 1200/1250...
  • Page 45: Testing

    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. Multi Pro 1200/1250 Page 4 – 11 Hydraulic System...
  • Page 46: Test No. 1: Steering Pump Flow And Relief Pressure

    L: WORKING PRESSURE (LEFT TURN) 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 10 Hydraulic System Page 4 – 12 Multi Pro 1200/1250...
  • Page 47 B. Worn, stuck, or out of adjustment relief valve. 1. Steering pump 3. Suction hose 2. Pressure hose C. Pump suction line restriction. D. Steering pump needs to be repaired or replaced. Multi Pro 1200/1250 Page 4 – 13 Hydraulic System...
  • Page 48: Test No. 2: Steering Control Valve And Steering Cylinder

    CONTROL UNIT R: WORKING PRESSURE (RIGHT TURN) L: WORKING PRESSURE (LEFT TURN) OPEN FITTING PLUG STEERING CYLINDER GEAR PUMP RETURN RELIEF FILTER VALVE TRANSAXLE HOUSING SUCTION STRAINER IN TRANSAXLE Figure 12 Hydraulic System Page 4 – 14 Multi Pro 1200/1250...
  • Page 49 A. Park machine on a level surface with the spray system turned off. B. Turn the steering wheel all the way to the right (clockwise) so the steering cylinder rod is fully ex- tended. Multi Pro 1200/1250 Page 4 – 15 Hydraulic System...
  • Page 50: Service And Repairs

    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. Hydraulic System Page 4 – 16 Multi Pro 1200/1250...
  • Page 51: Flush Hydraulic System

    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 12 again. 17.Resume normal operation and follow recommended maintenance intervals. Multi Pro 1200/1250 Page 4 – 17 Hydraulic System...
  • Page 52: Steering Pump Drive Belt

    (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 Page 4 – 18 Multi Pro 1200/1250...
  • Page 53 This page is intentionally blank. Multi Pro 1200/1250 Page 4 – 19 Hydraulic System...
  • Page 54: Steering Pump

    7. Loosen and remove two (2) set screws in pulley and poses. Clean hydraulic hose ends prior to disconnecting remove pulley from the pump shaft. Locate and remove the hoses. key from pump shaft. Hydraulic System Page 4 – 20 Multi Pro 1200/1250...
  • Page 55 7. Adjust belt tension (see Operator’s Manual). 8. Remove any plugs or caps that were placed during disassembly. Connect hydraulic hoses to pump. 9. Check fluid level in transaxle and adjust as required (see Operator’s Manual). Multi Pro 1200/1250 Page 4 – 21 Hydraulic System...
  • Page 56: Steering Pump Service

    7. Check pump relief pressure (see TEST NO.1 – damaged parts. Steering Pump Flow and Relief Pressure). If adjustment is needed, tighten adjusting screw to increase relief pressure or loosen adjusting screw to reduce pressure. Hydraulic System Page 4 – 22 Multi Pro 1200/1250...
  • Page 57 11. Place a small amount of Dexron III ATF in pump inlet Inspection and rotate pump one revolution. If binding is noted, dis- assemble pump and check for assembly problems. 1. Wash all parts in cleaning solvent. Multi Pro 1200/1250 Page 4 – 23 Hydraulic System...
  • Page 58 This page is intentionally blank. Hydraulic System Page 4 – 24 Multi Pro 1200/1250...
  • Page 59: Steering Control Valve

    3. Connect hydraulic hoses to steering control valve (Fig. 19). Tighten hose connections. Figure 20 1. Steering wheel 2. Dash panel 4. Position dash panel to front hood and secure with fasteners (Fig. 20). Multi Pro 1200/1250 Page 4 – 25 Hydraulic System...
  • Page 60: Steering Control Valve Service

    9. Carefully slide the spool out of the sleeve. The cen- tering springs and spring retaining ring will stay with the 3. Remove the plug, o–ring, and check ball from the spool as it is removed. housing. Hydraulic System Page 4 – 26 Multi Pro 1200/1250...
  • Page 61 Quad Seal 6. Install the pin. Figure 22 7. Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. Multi Pro 1200/1250 Page 4 – 27 Hydraulic System...
  • Page 62: Steering Cylinder

    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 Hydraulic System Page 4 – 28 Multi Pro 1200/1250...
  • Page 63 2. Hyd hose (Left turn) 5. Steering control valve 3. Hyd hose (Right turn) 6. Hyd hose (to filter) move rod end. Secure rod end with jam nut. Multi Pro 1200/1250 Page 4 – 29 Hydraulic System...
  • Page 64: Steering Cylinder Service

    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 Hydraulic System Page 4 – 30 Multi Pro 1200/1250...
  • Page 65 5. Coat all internal parts with a light coat of clean Dex- ron III ATF. Slide piston, shaft, and head assembly into the barrel being careful not to damage the seals. 6. Secure head into the barrel with retaining ring. Multi Pro 1200/1250 Page 4 – 31 Hydraulic System...
  • Page 66 This page is intentionally blank. Hydraulic System Page 4 – 32 Multi Pro 1200/1250...
  • Page 67 Control Switches ......11 Battery Service ......23 Multi Pro 1200/1250 Electrical System Rev.
  • Page 68: Electrical Schematics And Electrical Har- Ness And Connector Drawings

    Electrical Schematics and Electrical Harness and Connector Drawings The electrical schematics and other electrical drawings for the Multi Pro 1200 and Multi Pro 1250 are located in Chapter 9 – Electrical Diagrams. Electrical System Multi Pro 1200/1250 Page 5 – 2...
  • Page 69: Special Tools

    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.
  • Page 70: Troubleshooting

    Wiring to start circuit components is loose, corroded, or damaged (see Chapter 9 – Electrical Diagrams). Neutral interlock switch is out of adjustment or faulty. Ignition switch is faulty. Fuse block is faulty. Starter solenoid is faulty. Electrical System Multi Pro 1200/1250 Page 5 – 4...
  • Page 71: General Run Problems

    Chapter 9 – Electrical Diagrams). Circuit wiring to carburetor solenoid is loose, corroded, or damaged (see Chapter 9 – Electrical Diagrams). Engine or fuel system is malfunctioning (see Chapter 3 – Kohler Gasoline Engine). Multi Pro 1200/1250 Electrical System Page 5 – 5...
  • Page 72: Electrical System Quick Checks

    Check Operation of Neutral Interlock Switch Neutral interlock switch operation is described in the CAUTION Multi Pro 1200 and 1250 Operator’s Manual. Testing of this interlock switch is included in the Component Test- ing section of this Chapter. Do not disconnect neutral interlock switch. It is for the operator’s protection.
  • Page 73: Component Testing

    POSITION CIRCUIT G + M + A B + L + A START B + L + S Figure 4 HEX NUT SWITCH LOCK WASHER Figure 5 Multi Pro 1200/1250 Electrical System Page 5 – 7...
  • Page 74: Start, Neutral Engine Speed Control, Spray Pump And Spray Valve Relays

    Start, Neutral Engine Speed Control, Spray Pump and Spray Valve Relays The start and neutral engine speed control relays are used on both the Multi Pro 1200 and Multi Pro 1250. The Multi Pro 1250 uses an additional three (3) relays for the spray valve system.
  • Page 75: Neutral Interlock Switch

    Two types of neutral interlock switches have been used on Multi Pro 1200 and 1250 sprayers: On machines with serial numbers below 250000000, the neutral interlock switch is a ball type switch (Fig.
  • Page 76: Hour Meter

    3. Reconnect the harness connectors to the switch af- ter testing. Install console panel to machine. Figure 12 1. Control console 2. Headlight switch BACK OF SWITCH Figure 13 Electrical System Multi Pro 1200/1250 Page 5 – 10...
  • Page 77 Pump Control and Neutral Engine Speed Control Switches The pump control and neutral engine speed control MULTI PRO 1200 MULTI PRO 1250 switches are identical switches. The pump control switch is located on the sprayer (right side) console (Fig. 14). The neutral engine speed control switch is posi- tioned on the control console (Fig.
  • Page 78: Traction Speed Sensor

    Reconnect speed sensor to wire har- ness. Figure 18 1. Speed sensor 4. Red striped wire 2. Sensor tip 5. Gray striped wire 3. Sensor connector 6. Black wire Electrical System Multi Pro 1200/1250 Rev. C Page 5 - - 12...
  • Page 79: Shifter Solenoid (Machines With Serial Number Below 250000000)

    5. If solenoid does not retract the pin when voltage is applied or if coil resistance is incorrect, replace shifter solenoid. 6. If removed, reinstall air cleaner cover. Multi Pro 1200/1250 Electrical System Rev. A Page 5 – 13...
  • Page 80: Pump Drive Electric Clutch

    3. If clutch does not engage when voltage is applied or coil resistance is incorrect, replace clutch. 4. See Pump Drive Electric Clutch in the Service and Repairs section of Chapter 6 – Spray System if clutch re- moval is necessary. Electrical System Multi Pro 1200/1250 Page 5 – 14...
  • Page 81: Neutral Engine Speed Control Coil

    3. If coil does not engage when voltage is applied or coil Figure 22 resistance is incorrect, replace control coil. 1. Accelerator lever 3. Brake lever 2. Control coil 4. Reconnect the coil connector to the machine har- ness after testing. Multi Pro 1200/1250 Electrical System Page 5 – 15...
  • Page 82: Accessory Solenoid

    Reconnect battery. WIRING DIAGRAM Figure 24 1. Main contact post 3. Solenoid mount 2. Solenoid coil post Electrical System Multi Pro 1200/1250 Page 5 – 16...
  • Page 83: Brake Pedal Switch (Machines With Serial Number Below 250000000)

    (open) between the switch terminals. 3. Reconnect the harness connector to the switch after testing. Figure 25 1. Brake lever 2. Brake pedal switch Figure 26 1. Switch plunger 2. Switch terminal Multi Pro 1200/1250 Electrical System Rev. A Page 5 – 17...
  • Page 84: Spray Pro Monitor

    Spray Pro Monitor The Multi Pro 1200 and 1250 are equipped with a spray monitor to provide the machine operator with spray sys- tem information. Operation, calibration, and trouble- shooting information for the Spray Pro Monitor is SPRAY PRO MP–1200 included in the Operator’s Manual.
  • Page 85: Rate Lockout Key Switch (Multi Pro 1250 Only)

    3. Reconnect the harness connectors to the switch af- ter testing. Install console panel to machine. Figure 30 1. Spray control console 2. Rate lockout key switch FRONT OF SWITCH BACK OF SWITCH Figure 31 Multi Pro 1200/1250 Electrical System Page 5 – 19...
  • Page 86: Master Boom (Foot) Switch (Multi Pro 1250 Only)

    The light should be illuminated when the switch is in the ON position. 4. Reconnect the harness connector to the switch after testing. Install console panel to machine. BACK OF SWITCH Figure 35 Electrical System Multi Pro 1200/1250 Page 5 – 20...
  • Page 87: Service And Repairs

    2. Outside notch 7. 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. Multi Pro 1200/1250 Electrical System Page 5 – 21...
  • Page 88: Battery Storage

    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 skin–over grease (Toro Part No. 505-47) or petro- leum jelly to prevent corrosion. Electrical System Multi Pro 1200/1250 Page 5 –...
  • Page 89: Battery Service

    IMPORTANT: Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly. Multi Pro 1200/1250 Electrical System Page 5 – 23...
  • Page 90 Connect a digital multimeter to the battery terminals. 1.155 12.06 1.120 11.89 F. Apply a test load of one half the Cranking Perfor - mance (see Battery Specifications) rating of the bat- tery for 15 seconds. Electrical System Multi Pro 1200/1250 Page 5 – 24...
  • Page 91 Do not smoke. Nausea may result if the gases are inhaled. Un- plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts. Multi Pro 1200/1250 Electrical System Page 5 – 25...
  • Page 92 This page is intentionally blank. Electrical System Multi Pro 1200/1250 Page 5 – 26...
  • Page 93 Tank Drain Valve ......48 Multi Pro 1200 ......4 Turret Bodies .
  • Page 94: Specifications

    It is recommended that o–rings be replaced every two (2) years or whenever a fitting is loosened. Spray System Multi Pro 1200/1250 Page 6 – 2 Rev. A...
  • Page 95: Spray System Operation

    Spray System Operation The Multi Pro 1200 and 1250 spray systems use a posi- The spray system on the Multi Pro 1250 is controlled tive displacement diaphragm pump to move spray solu- electrically and consists of a main control valve and tion from the spray tank to the boom nozzles.
  • Page 96: Spray System Flow Diagrams

    Spray System Flow Diagrams SUCTION PRESSURE AGITATION Multi Pro 1200 BOOM SUPPLY Spray System Flow Diagram FLOW DIRECTION Spray System Multi Pro 1200/1250 Page 6 – 4...
  • Page 97: Multi Pro 1250

    SUCTION PRESSURE AGITATION BOOM SUPPLY Multi Pro 1250 Spray System Flow Diagram FLOW DIRECTION Multi Pro 1200/1250 Spray System Page 6 – 5...
  • Page 98: Troubleshooting

    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 not seating (Multi Pro 1200).
  • Page 99 No spray output from one spray Hoses on boom are pinched or kinked. boom. Distribution valve for affected boom not open (Multi Pro 1200). Boom valve motor for affected boom not opening (Multi Pro 1250). Console boom switch dirty, corroded, or damaged (Multi Pro 1250).
  • Page 100: Service And Repairs

    13. Lock washer 20. Pump drive gearbox shaft 6. Rubber coupling 14. Clutch retainer 21. Cap screw (2 used) 7. Lock nut 15. Electric clutch 22. Pump hub 8. Drive coupler Spray System Multi Pro 1200/1250 Page 6 – 8...
  • Page 101: Pump Drive Electric Clutch Service

    Pump Drive Electric Clutch in the Service and Repair section of Chapter 5 – Electrical System. The pump drive electric clutch used on the Multi Pro has sealed, non–serviceable bearings. If bearing failure oc- curs, clutch replacement is necessary. Multi Pro 1200/1250 Spray System Page 6 – 9...
  • Page 102: Suction Dampener

    (Fig. 3). Figure 2 1. Spray pump 3. Suction hose 2. Suction dampener Figure 3 1. Spray pump 3. Dampener housing 2. O–ring 4. Diaphragm Spray System Multi Pro 1200/1250 Page 6 – 10...
  • Page 103: Pressure Dampener

    2. Pressure dampener Figure 5 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 Multi Pro 1200/1250 Spray System Page 6 – 11...
  • Page 104: Spray Pump

    30. Rubber coupling 9. O–ring 20. Flange head screw (4 used) 31. Set screw 10. Pressure dampener 21. Flange nut 32. Pump hub 11. Suction hose (1 1/2”) 22. Square key Spray System Multi Pro 1200/1250 Page 6 – 12 (Rev. B)
  • Page 105 Orientate tee toward rear of machine (Fig. 7). 3. Install elbow (pressure), tee (pressure), and pres- sure dampener to pump outlet. Orientate elbow toward rear of machine (Fig. 7). Multi Pro 1200/1250 Spray System Page 6 – 13 (Rev. B)
  • Page 106: Spray Pump Service

    30. Valve (outlet position) IMPORTANT: The spray pump used on the Multi Pro may have SAE, metric, and Whitworth fasteners. To prevent component damage, take special care to identify correct location of all fasteners. Spray System Multi Pro 1200/1250 Page 6 – 14...
  • Page 107 1. Hex bolt (30 mm long) 2. Hex bolt (55 mm long) Torque hex nuts to 25 ft–lb (34 N–m) to secure con- necting rod to crankshaft. Multi Pro 1200/1250 Spray System Page 6 – 15...
  • Page 108 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). Figure 12 1. Inlet (suction) 3. Outlet valve 2. Inlet valve Spray System Multi Pro 1200/1250 Page 6 – 16...
  • Page 109 This page is intentionally blank. Multi Pro 1200/1250 Spray System Page 6 – 17...
  • Page 110: Agitation Control Valve

    18. Phillips head screw 5. Hosebarb 12. Hose: tank suction (1 1/2”) 19. Connector 6. Hose: agitation supply(1”) 13. Hosebarb 20. Spray pump 7. Hosebarb 14. Suction hose (1 1/2”) 21. Spray tank Spray System Multi Pro 1200/1250 Page 6 – 18...
  • Page 111 6. Cap screw (4 used) 14. Spindle 7. End cover 15. Valve ball 8. Screw (4 used) 16. Lock nut (4 used) Figure 16 1. Valve handle arrow 2. Valve ball large hole Multi Pro 1200/1250 Spray System Page 6 – 19...
  • Page 112: Agitation Nozzles (Tank Mounted)

    14. Bulkhead gasket 23. Tee 6. Fork 15. Bulkhead 24. Nipple 7. Hosebarb 16. Tee 25. Adapter 8. Hose clamp 17. O–ring 26. Hose (3/4”) 9. Hose (3/4”) 18. Elbow 27. Spray tank Spray System Multi Pro 1200/1250 Page 6 – 20...
  • Page 113 2. Drain spray tank (see Operator’s Manual). 3. Label disconnected hoses for proper installation af- ter repairs are completed. 4. Remove agitation nozzles as required using Figure 17 as a guide. Discard all removed o–rings and gaskets. Multi Pro 1200/1250 Spray System Page 6 – 21...
  • Page 114: Pressure Relief Valve (Tank Mounted)

    21. Phillips head screw (4 used) 6. Gasket 14. Hose: control supply (1”) 22. Coupler (pressure gauge) 7. Ringnut 15. O–ring 23. Spray pump 8. O–ring 16. Hosebarb 24. Spray tank Spray System Multi Pro 1200/1250 Page 6 – 22...
  • Page 115 1. Install pressure relief valve using Figure 18 and 19 as guides. Replace all removed o–rings and gaskets. 2. Check spray system for leaks. Multi Pro 1200/1250 Spray System Page 6 – 23...
  • Page 116: Spray Control (Multi Pro 1200)

    Spray Control (Multi Pro 1200) FRONT RIGHT Figure 20 1. Boom distribution valves 6. Flange head screw 10. Master boom valve 2. Screw 7. Flowmeter 11. Valve mount 3. Hex nut 8. Hex nut 12. Pressure control valve 4. Washer 9.
  • Page 117 3. Install spray console, spray control panel, and mas- ter boom valve handle to machine (Fig. 21). Figure 22 1. Flowmeter 3. Master boom valve 2. Pressure control valve 4. Boom distribution valves Multi Pro 1200/1250 Spray System Page 6 – 25...
  • Page 118: Flowmeter (Multi Pro 1200)

    Flowmeter (Multi Pro 1200) Figure 23 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.
  • Page 119 2. Operate spray system and check for leaks. Figure 26 1. Rotor shaft 3. Rotor magnet 3. Install spray console, spray control panel, and mas- 2. Rotor ter boom valve handle to machine (Fig. 24). Multi Pro 1200/1250 Spray System Page 6 – 27...
  • Page 120: Master Boom Valve (Multi Pro 1200)

    Master Boom Valve (Multi Pro 1200) Figure 27 1. Housing 13. Hose: pressure supply (1”) 25. Valve assembly 2. Ball 14. Nut 26. Pressure valve housing 3. Seat 15. Hose barb 27. Pin 4. O–ring 16. Seal 28. O–ring 5. Hosebarb 17.
  • Page 121 Wear protective clothing, chemical resist- ant gloves, and eye protection during repair. 1. Remove master boom valve from machine (see Spray Control (Multi Pro 1200) in this section). 2. Disassemble master boom valve using Figure 27 as a guide. Discard all removed o–rings.
  • Page 122: Pressure Control Valve (Multi Pro 1200)

    Pressure Control Valve (Multi Pro 1200) Figure 29 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.
  • Page 123 Wear protective clothing, chemical resist- ant gloves, and eye protection during repair. 1. Remove pressure control valve from machine (see Spray Control (Multi Pro 1200) in this section). 2. Disassemble pressure control valve using Figure 29 as a guide. Discard all removed o–rings.
  • Page 124: Boom Distribution Valves (Multi Pro 1200)

    Boom Distribution Valves (Multi Pro 1200) FRONT RIGHT Figure 31 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.
  • Page 125 1. Cap screw and washer 3. Seat components 5. Install boom distribution valve assembly to machine 2. Seat assembly (2 used) 4. Retaining ring location (see Spray Control (Multi Pro 1200) in this section). Multi Pro 1200/1250 Spray System Page 6 – 33...
  • Page 126: Spray Control (Multi Pro 1250)

    IMPORTANT: Rate control and boom valve motors may have a fuse for circuit protection. Make sure that correct fuse is installed in the in–line fuse hold- er located in the motor harness. Spray System Multi Pro 1200/1250 Page 6 – 34 Rev. A...
  • Page 127 (Fig. 37). 5. Plug electrical connectors from rate control motor, flowmeter, and three (3) boom valve motors to machine electrical harness. 6. Operate spray system and check for leaks. Multi Pro 1200/1250 Spray System Page 6 – 35...
  • Page 128: Flowmeter (Multi Pro 1250)

    26. LH boom control motor 8. Tee piece 18. Coupler (pressure gauge) 27. Center boom control motor 9. Hose: control supply (1”) 19. Flowmeter housing 28. RH boom control motor 10. Hose clamp Spray System Multi Pro 1200/1250 Page 6 – 36...
  • Page 129 1. Reassemble flowmeter using Figures 38 and 40 as guides. Replace all removed o–rings and gaskets. 2. Operate spray system and check for leaks. Multi Pro 1200/1250 Spray System Page 6 – 37...
  • Page 130: Rate Control Motor (Multi Pro 1250)

    D. The inside of motor housing should be free of ex- chemicals from spray components before disas- cessive moisture, corrosion, and dirt. sembly. Wear protective clothing, chemical resist- ant gloves, and eye protection during repair. Spray System Multi Pro 1200/1250 Page 6 – 38...
  • Page 131 1/2” (13 mm) from the spindle sec- tion housing. Align slot in motor with post in spindle and install motor. 7. Secure motor to assembly by evenly tightening four (4) phillips head screws (item 5). Multi Pro 1200/1250 Spray System Page 6 – 39...
  • Page 132: Boom Valve Motor (Multi Pro 1250)

    Remove four phillips head screws spray control components to allow boom valve motor (item 15) and separate spindle section from motor sec- disassembly (see Spray Control (Multi Pro 1250) in this tion. section). Spray System Multi Pro 1200/1250 Page 6 – 40...
  • Page 133 A. Install o–ring, balancing valve, and knob to man- ifold. B. Secure balancing valve to knob by carefully installing roll pin. Figure 46 1. Boom valve manifold 3. Balancing valve knob 2. Balancing valve 4. Roll pin Multi Pro 1200/1250 Spray System Page 6 – 41...
  • Page 134 (see Spray Control (Multi Pro 1250) in four phillips head screws (item 15). this section). 5. Replace rear housing to boom valve motor. 8. Operate spray system and check for leaks. Spray System Multi Pro 1200/1250 Page 6 – 42...
  • Page 135 This page is intentionally blank. Multi Pro 1200/1250 Spray System Page 6 – 43...
  • Page 136: Boom Bypass

    Boom Bypass FRONT RIGHT Figure 47 1. Hose: boom bypass (1”) 4. O–ring/gasket 7. Bulkhead gasket 2. Hose clamp 5. Fork 8. Bulkhead 3. Hosebarb 6. Nut 9. Spray tank Spray System Multi Pro 1200/1250 Page 6 – 44...
  • Page 137 2. Drain spray tank (see Operator’s Manual). NOTE: The boom bypass hose on the Multi Pro 1200 (item 1) is routed between the spray tank hosebarb (item 3) and the boom distribution valves. On the Multi Pro...
  • Page 138: Tank Suction

    9. Nut 15. Hose clamp 4. Suction screen 10. Hose clamp 16. Suction hose (1 1/2”) 5. Filter housing 11. Suction hose (2”) 17. Spray tank 6. Expansion pin 12. Suction tube Spray System Multi Pro 1200/1250 Page 6 – 46...
  • Page 139 1. Assemble and install suction tube assembly using Figure 48 as a guide. Replace all removed o–rings and gaskets. 2. Check spray tank for leaks. Multi Pro 1200/1250 Spray System Page 6 – 47...
  • Page 140: Tank Drain Valve

    3. Lock nut 10. Connector 16. Bulkhead fitting 4. O–ring 11. Pin 17. Bulkhead gasket 5. Bulkhead 12. Flex tube 18. Ringnut 6. O–ring 13. Pin 19. Spray tank 7. Ringnut Spray System Multi Pro 1200/1250 Page 6 – 48...
  • Page 141 1. Assemble drain tube using Figure 50 as a guide. Re- place all removed o–rings and gaskets. 2. Check spray tank for leaks. Multi Pro 1200/1250 Spray System Page 6 – 49...
  • Page 142: Turret Bodies

    2. Loosen hose clamp(s) and remove supply hose(s) clamp(s). from turret body. 3. Remove screw that secures turret body clamp to spray boom. Separate clamp halves and remove turret body from machine. Spray System Multi Pro 1200/1250 Page 6 – 50...
  • Page 143: Turret Body Service

    16. End cap 8. Turret 17. Diaphragm C. Install e–clip (item 5) into body to secure assem- 9. O–ring 18. Hose barb bly. Figure 54 1. Body 3. Detent groove 2. Detent post Multi Pro 1200/1250 Spray System Page 6 – 51...
  • Page 144: Boom Frame Breakaway Pivot Assembly

    12. Clevis pin 19. Flat washer (4 used per side) 6. Hex nut 13. Main boom frame 20. Cap screw (4 used per side) 7. Support bracket 14. Breakaway pivot assembly Spray System Multi Pro 1200/1250 Page 6 – 52 Rev. A...
  • Page 145 1. Assemble breakaway pivot using Figures 55 and 56 as guides. 2. Lubricate grease fitting on breakaway pivot after as- sembly is complete (see Operator’s Manual). Figure 57 1. Roll pin 2. Spring Multi Pro 1200/1250 Spray System Page 6 – 53...
  • Page 146: Boom Hinge (Machines With Serial Numbers Above 260000000)

    6. Clean all removed components. If pivot bracket was tee fitting (item 6) on spray boom. removed, inspect bushings and pivot pin for damage or wear. 3. Support spray boom to prevent it from falling. Spray System Multi Pro 1200/1250 Page 6 – 54 Rev. A...
  • Page 147 (Fig. 60). 6. Connect supply hose to tee fitting on spray boom and secure with hose clamp. 7. Lubricate grease fittings on boom hinge (see Opera- tor’s Manual). Figure 60 Multi Pro 1200/1250 Spray System Page 6 – 55 Rev. A...
  • Page 148: Boom Actuator (Optional) (Machines With Serial Numbers Below 260000000)

    3. Support boom to prevent it from falling. Remove cot- ter pins and clevis pins that attach boom actuator to cen- ter and side boom. 4. Pull boom actuator from machine. Spray System Multi Pro 1200/1250 Page 6 – 56 Rev. A...
  • Page 149 Tighten end nut to secure cle- 1. Boom actuator 3. Jam nut 2. Adjustable clevis 4. End nut vis adjustment. Figure 63 1. Breakaway pivot gusset 3. Boom actuator 2. Boom frame slot Multi Pro 1200/1250 Spray System Page 6 – 57 Rev. A...
  • Page 150: Boom Actuator Service (Machines With Serial Numbers Below 260000000)

    4. Woodruff key 11. Housing gasket 18. Cover tube 5. Clutch 12. Front housing 19. O–ring 6. Thin washer 13. Cover tube gasket 20. O–ring 7. Intermediate gear 14. Motor seal Spray System Multi Pro 1200/1250 Page 6 – 58 Rev. A...
  • Page 151 B. Install four (4) washer head screws through cover rings. tube. C. Torque screw (item 1) to 20 in–lb (2.3 N–m). Torque four washer head screws to 70 in–lb (7.9 N–m). Multi Pro 1200/1250 Spray System Page 6 – 59 Rev. A...
  • Page 152: Boom Actuator (Machines With Serial Numbers Above 260000000)

    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) Spray System Multi Pro 1200/1250 Page 6 – 60 Rev. A...
  • Page 153 4. Connect boom actuator to machine wire harness. 4. Remove cotter pin (item 11) from clevis pin (item 12). Support boom actuator and slide clevis pin from boom pivot bracket. Remove actuator from machine. Multi Pro 1200/1250 Spray System Page 6 – 61 Rev. A...
  • Page 154: Boom Actuator Service (Machines With Serial Numbers Above 260000000)

    Remove actuator from vise and install on ma- seal. The freeplay should be less than 0.100” (2.5 mm). chine. If excessive freeplay is found, bleed air from actuator. Spray System Multi Pro 1200/1250 Page 6 – 62 Rev. A...
  • Page 155 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). 2. Drain oil from actuator. Multi Pro 1200/1250 Spray System Page 6 – 63 Rev. A...
  • Page 156 This page is intentionally blank. Spray System Multi Pro 1200/1250 Page 6 – 64 Rev. A...
  • Page 157: Specifications

    Transaxle Inspection ..... 38 Transaxle Assembly ..... . 42 Multi Pro 1200/1250 Page 7 – 1...
  • Page 158: Special Tools

    Reducing Worm Gear for Pump Drive (through shaft for Transaxle) Fluid Capacity .5 quarts (.47 liters) Fluid Type Mobil SHC 634 Synthetic Lubricant (Toro Part No. 104--8772) Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier.
  • Page 159: General Information

    This shifting changes the turning ratio between the drive and driven clutches and allows the engine to operate at optimum efficiency. Multi Pro 1200/1250 Page 7 – 3 Drive Train...
  • Page 160: Drive Clutch

    This inward weights. movement of the sheave engages the drive belt to drive the driven clutch. Drive Train Page 7 – 4 Multi Pro 1200/1250...
  • Page 161: Driven Clutch

    The drive belt becomes posi- tioned closer to the outer diameter of the driven clutch sheaves to respond to the load increase. Multi Pro 1200/1250 Page 7 – 5 Drive Train...
  • Page 162: Troubleshooting

    Shifter capscrew loose (at operator station). Loose shift lever on transaxle. Cable clamp securing cables near shifter is loose. Sliding gear tight on shaft or splines. Synchronizing unit damaged. Sliding gear teeth damaged. Synchro keys damaged. Drive Train Page 7 – 6 Multi Pro 1200/1250...
  • Page 163 Excessive end play in gears. Lack of spring pressure on shift fork detent ball. Badly worn bearings. Overheating of transaxle. Oil level too high. Excessive hydraulic load. See Chapter 8 – Hydraulic System. Multi Pro 1200/1250 Page 7 – 7 Drive Train...
  • Page 164: Adjustments

    Figure 6 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 Drive Train Page 7 – 8 Multi Pro 1200/1250...
  • Page 165: Service And Repairs

    Rotate driven clutch while routing the belt into position. NOTE: The current drive belt used on Multi Pro 1200 and Multi Pro 1250 sprayers is double cogged. If ma- chine has belt guides and a double cogged drive belt, belt guides should be secured away from drive belt or re- moved from machine.
  • Page 166: Drive Clutch

    12. Pump drive electric clutch 3. Lock washer 8. Engine 13. Driven clutch 4. Cap screw 9. Steering pump belt 14. Drive belt 5. Cap screw 10. Steering pump 15. Clutch cap Drive Train Page 7 – 10 Multi Pro 1200/1250...
  • Page 167 6. Use clutch removal tool (see Special Tools) to re- move drive clutch from the engine tapered shaft. Multi Pro 1200/1250 Page 7 – 11 Drive Train...
  • Page 168: Drive Clutch Service

    Unequal pressure on the cam towers may damage them. Figure 10 CAUTION 1. Clutch holding bar 2. Spanner Remove spider from fixed sheave slowly. The moveable sheave is under pressure from the spring. Drive Train Page 7 – 12 Multi Pro 1200/1250...
  • Page 169 5. Torque spider to 100 ft–lb (136 N–m). 6. Position cover to clutch. Secure cover to the mov- able sheave with cap screws. Torque cap screws from 75 to 100 in–lb (8.5 to 11.3 N–m). Multi Pro 1200/1250 Page 7 – 13 Drive Train...
  • Page 170: Driven Clutch

    Mounting Plate Assembly Installation in the Service 5. Pull driven clutch from the input shaft. and Repairs section of Chapter 3 – Kohler Gasoline En- gine). Drive Train Page 7 – 14 Multi Pro 1200/1250...
  • Page 171 2. Remove drive belt from the driven clutch (see Drive Belt Service). IMPORTANT: Use protective strips of soft metal when clamping the moveable sheave with locking pliers to prevent damage to the sheave. 3. Clamp moveable sheave with locking pliers. Multi Pro 1200/1250 Page 7 – 15 Drive Train...
  • Page 172: Pump Drive Gearbox

    21. Lock washer 6. Coupler/nipple 14. Engine 22. Clutch retainer 7. Breather 15. Drive clutch 23. Engine mounting plate 8. Flange head screw (4 used) 16. Lock nut (4 used) 24. Set screw Drive Train Page 7 – 16 Multi Pro 1200/1250...
  • Page 173 5. Check and adjust gearbox lubricant level (see Oper- remove key and spacer from gearbox pump driveshaft. ator’s Manual). 5. Remove four flange head screws and lock nuts that secure gearbox to engine mounting plate. Remove gearbox from machine. Multi Pro 1200/1250 Page 7 – 17 Drive Train...
  • Page 174: Pump Drive Gearbox Service

    3. Loosen and remove cap screws that secure output caps (item 6 and 25) to gearbox housing. Remove caps 6. Carefully pull worm (input) shaft (item 26) with bear- with bearing cups and o–rings. Remove shims. ings from housing. Drive Train Page 7 – 18 Multi Pro 1200/1250...
  • Page 175 Total shim thickness at and torque cap screws 8 ft–lb (10.8 N–m). one input cap should be within .005” (.13 mm) of the total shim thickness of the other cap. Multi Pro 1200/1250 Page 7 – 19 Drive Train...
  • Page 176 Apply light coat of grease on seal lip and place seal on the shaft with the seal lip facing in. C. Press seal evenly into cap bore until seal is flush to the cap face. Rev. C Drive Train Page 7 - - 20 Multi Pro 1200/1250...
  • Page 177 This page is intentionally blank. Multi Pro 1200/1250 Page 7 – 21 Drive Train...
  • Page 178: Stub Axle And Driveshaft

    B. Remove three (3) flange head screws that secure the end yoke. axle housing to machine frame. Remove axle hous- ing. Rev. C Drive Train Page 7 - - 22 Multi Pro 1200/1250...
  • Page 179 Torque fasteners 75 ft--lb (101 N--m). C. Install brake assembly to axle housing (see Rear Wheels and Brakes in Service and Repairs Section of Chapter 8 -- Chassis). Rev. C Multi Pro 1200/1250 Page 7 - - 23 Drive Train...
  • Page 180: Driveshaft Universal Joint Service

    2. Seal 7. Lock nut (2 per yoke) 3. Snap ring 8. Clamp yoke 9. Hardened washer 4. Cross and bearing kit 5. Yoke and hub 10. Cap screw (2 per yoke) Drive Train Page 7 – 24 Multi Pro 1200/1250...
  • Page 181 This page is intentionally blank. Multi Pro 1200/1250 Page 7 – 25 Drive Train...
  • Page 182: Transaxle

    42. Hardened washer 13. Flange nut (4 used) 28. O–ring 43. Lock nut 14. Hydraulic return hose 29. Strainer 44. Cap screw (3 used) 30. O–ring 45. Input shaft cover plate 15. O–ring Drive Train Page 7 – 26 Multi Pro 1200/1250...
  • Page 183: Removal

    16.If required, remove front transaxle mount, shift cable 1. Cap screw w/washer 3. Driveshaft (RH) mount, and transaxle strap mounts from transaxle. 2. Driveshaft (LH) 17.Remove oil strainer from transaxle. Locate, remove, and discard strainer o–ring. Multi Pro 1200/1250 Page 7 – 27 Drive Train...
  • Page 184: Installation

    11. Check and adjust shift cables as needed (see Shift Cable Adjustment in the Adjustments section of this Chapter). 12.Secure shift cable ends to shift arm levers of trans- axle with clevis pins and cotter pins. Drive Train Page 7 – 28 Multi Pro 1200/1250...
  • Page 185: Transaxle Service

    6. Loosen cap screws and separate center plate from transaxle case. Note dowel pin locations in transaxle case. Remove seal cap (Item 1), shims (Items 2 and 4), and snap ring (Item 3) from center plate. Figure 31 Multi Pro 1200/1250 Page 7 – 29 Drive Train...
  • Page 186 9. Remove, all at the same time, reduction shaft as- NOTE: This shaft not sembly (Item 1), 1st–reverse fork shaft assembly (Item used on Multi Pro 2), and countershaft assembly (Item 3) Figure 34 Drive Train Page 7 – 30 Multi Pro 1200/1250...
  • Page 187 Figure 36 13.Loosen cap screws (Item 1) and remove R.H. axle shaft assembly (Item 2) from transaxle case. Figure 37 14.Slide differential gear assembly (Item 1) from trans- axle case. Figure 38 Multi Pro 1200/1250 Page 7 – 31 Drive Train...
  • Page 188 (Item 1) and slide speed sensor (Item 2) from upper cov- er (Item 4). 20.Loosen and remove cap screws (Item 3) that secure upper cover to transaxle case. Remove upper cover (Item 4) from case. Figure 41 Drive Train Page 7 – 32 Multi Pro 1200/1250...
  • Page 189 J. Use a bearing puller to remove bearing (Item 14). K. Remove 14T gear (Item 15), retaining ring (Item 16), 20T gear (Item 17), and 16T gear (Item 18). Figure 43 Multi Pro 1200/1250 Page 7 – 33 Drive Train...
  • Page 190 (Item 16), and thrust washer (Item 17). Inspect needle bearings and replace if necessary. Measure thickness of thrust washer. Replace thrust washer if thickness is less than .0709” (1.8 mm). Figure 45 Drive Train Page 7 – 34 Multi Pro 1200/1250...
  • Page 191 (Item 13), and collar (Item 14). Measure thickness of thrust washer. Replace washer if thickness is less than .110” (2.8 mm). I. Use a bearing puller to remove two (2) bearings (Item 15) from shaft. Figure 48 Multi Pro 1200/1250 Page 7 – 35 Drive Train...
  • Page 192 H. Remove two (2) differential pinion gears (Item 9) and two (2) washers (Item 10). I. Remove L.H. side gear (Item 11), R.H. side gear (Item 12), and two (2) thrust washers (Item 13). Figure 51 Drive Train Page 7 – 36 Multi Pro 1200/1250...
  • Page 193 B. Remove retaining ring (Item 2) and washer (Item 3) from axle shaft. C. Use a bearing puller to remove bearing (Item 4) R.H. SHAFT from axle shaft. D. Remove oil seal (Item 5) from seal cover. Figure 53 Multi Pro 1200/1250 Page 7 – 37 Drive Train...
  • Page 194: Transaxle Inspection

    (Fig. 56). 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) Figure 56 Drive Train Page 7 – 38 Multi Pro 1200/1250...
  • Page 195 (Item 4) with three tabless shims (Item 2) (Fig. 59). 7. Inspect retaining ring (item 3) and shims (items 2 and 4) for damage (Fig. 59). Replace all parts if any compo- nent is cracked or broken. Figure 59 Multi Pro 1200/1250 Page 7 – 39 Drive Train...
  • Page 196 O.D. of needle bearing area is less than .864” (21.95 mm) or .982” (24.95 mm), replace the reduction shaft. STD. O.D. 0.866” (22 mm) Reject O.D. 0.864” (21.95 mm) Figure 62 Drive Train Page 7 – 40 Multi Pro 1200/1250...
  • Page 197 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. Multi Pro 1200/1250 Page 7 – 41 Drive Train...
  • Page 198: Transaxle Assembly

    C. Install washer (Item 3) and retaining ring (Item 2) onto R.H. axle shaft. R.H. SHAFT D. Insert washer (Item 6) into seal cover. E. Install R.H. axle shaft assembly into seal cover Figure 66 (Item 7). Drive Train Page 7 – 42 Multi Pro 1200/1250...
  • Page 199 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. Multi Pro 1200/1250 Page 7 – 43 Drive Train...
  • Page 200 H. Install thrust washer (Item 4) and retaining ring (Item 3). Oil groove on washer must face the gear. I. Install collar (Item 2) and new bearing (Item 1) us- ing a press. Figure 72 Drive Train Page 7 – 44 Multi Pro 1200/1250...
  • Page 201 B. Install shifter (Item 1) onto hub assembly (Item 2). Figure 74 C. Insert two (2) springs (Item 1) into hub to secure hub assembly. Pay attention to direction of spring. Figure 75 Figure 76 Multi Pro 1200/1250 Page 7 – 45 Drive Train...
  • Page 202 J. Use a press to install bearing (Item 1) onto shaft. Figure 78 9. Assemble reverse shaft: A. Install 33T gear (Item 2) onto reverse shaft (Item B. Use a press to install bearings (Item 3 and 1). Figure 79 Drive Train Page 7 – 46 Multi Pro 1200/1250...
  • Page 203 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. Multi Pro 1200/1250 Page 7 – 47 Drive Train...
  • Page 204 3. Flat washer 10. Cap screw 4. Cap screw 11. Lock washer 5. Lock nut 12. Keeper plate 6. Shift arm plate 13. Oil seal 7. Flat washer 0.080” (2 mm) Figure 83 Drive Train Page 7 – 48 Multi Pro 1200/1250...
  • Page 205 Multi Pro Figure 85 13.Install main shaft together with 2nd–3rd fork shaft. Insert head of shift arm into groove of fork (Item 1) while installing. Figure 86 Figure 87 Multi Pro 1200/1250 Page 7 – 49 Drive Train...
  • Page 206 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 89 with face of housing. Drive Train Page 7 – 50 Multi Pro 1200/1250...
  • Page 207 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. 91 and 92). Figure 92 Multi Pro 1200/1250 Page 7 – 51 Drive Train...
  • Page 208 Figure 93 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 94 Drive Train Page 7 – 52 Multi Pro 1200/1250...
  • Page 209 (Items 2 and 1) noting location of longer (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 shifters and detent. Figure 97 Multi Pro 1200/1250 Page 7 – 53 Drive Train...
  • Page 210 - er. B. Install axle shaft assembly (Item 2) and secure with cap screws. Torque cap screws (Item 1) from 18 to 22 ft–lb (24.5 to 29.5 N–m). Figure 100 Drive Train Page 7 – 54 Multi Pro 1200/1250...
  • Page 211 B. If backlash exceeds the target range, increase to- tal thickness of shim set until correct backlash is achieved. Figure 103 NOTE: The thickest shim should be installed against the bearing. Multi Pro 1200/1250 Page 7 – 55 Drive Train...
  • Page 212 (Item 4). Install cap screw (Item 1) with lock wash- er to secure sensor. Figure 105 32.Position input shaft cover plate (Item 2) to transaxle and secure it with three (3) cap screws (Item 1). Figure 106 Drive Train Page 7 – 56 Multi Pro 1200/1250...
  • Page 213 Ball Joint Replacement ..... 21 Seat Base (Multi Pro 1200) ....22 Seat Base (Multi Pro 1250) .
  • Page 214: Specifications

    55 to 65 ft–lb (75 to 88 N–m) Rear wheel lug nut torque 45 to 65 ft–lb (61 to 88 N–m) Front wheel Toe–in 0 to 1/8 inch (0 to 3.2 mm) Page 8 – 2 Chassis Multi Pro 1200/1250...
  • Page 215: Adjustments

    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. Multi Pro 1200/1250 Page 8 – 3 Chassis...
  • Page 216: Service And Repairs

    8. Inspection and service of front brakes can be com- pleted with brake assembly on machine (see Front 5. Remove cotter pin from front spindle. Brake Service). If required, brake assembly can be re- moved from machine as follows: Page 8 – 4 Chassis Multi Pro 1200/1250...
  • Page 217 200 ft (60 m) intervals while traveling at moderate seal must be toward the bearing. speed. C. Lubricate the inside of the new lip seal and press it into the wheel hub. Multi Pro 1200/1250 Page 8 – 5 Chassis...
  • Page 218: Front Brake Service

    Locate and remove belleville washers from between ad- 3. Remove brake shoes from backing plate. juster levers and backing plate. Page 8 – 6 Chassis Multi Pro 1200/1250...
  • Page 219 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). Multi Pro 1200/1250 Page 8 – 7 Chassis...
  • Page 220: Rear Wheels And Brakes

    Parking brake lever Set screw Use a hooked piece of wire to pull pawl away from star wheel, then turn star wheel. Pull brake drum from ma- chine. Page 8 – 8 Chassis Multi Pro 1200/1250...
  • Page 221 B. Install stub axle (see Stub Axle and Driveshaft in Chapter 7 – Drive Train). C. Install hydraulic brake line to wheel cylinder. D. Install parking brake cable to brake assembly (see Parking Brake Cable Installation). Multi Pro 1200/1250 Page 8 – 9 Chassis...
  • Page 222: Rear Brake Service

    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 Page 8 – 10 Chassis Multi Pro 1200/1250...
  • Page 223 C. Inspect hold down pins for damage. Replace as necessary. 2. Inspect brake adjuster, parking brake lever, and parking brake pawl for damage or wear. Replace com- ponents as necessary. Multi Pro 1200/1250 Page 8 – 11 Chassis...
  • Page 224: Brake Lines

    When performing service work on the Multi Pro brake lines, make sure to clean brake components before dis- assembly. Use Figure 8 as a guide for removal and installation of hydraulic brake lines. Page 8 – 12 Chassis Multi Pro 1200/1250...
  • Page 225: Parking Brake Cables

    Wheels and Brakes). Lower machine to ground. 7. Lower seat. 8. Adjust parking brake (see Operator’s Manual). Check operation of brakes before using the machine. Figure 11 Cable clip Cable guide Parking brake lever Brake backing plate Multi Pro 1200/1250 Page 8 – 13 Chassis...
  • Page 226: Brake Master Cylinder Service

    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. Page 8 – 14 Chassis Multi Pro 1200/1250...
  • Page 227: Bleed Brake System

    6. After bleeding of brakes is completed, test vehicle to wheel cylinder until pedal fades to floor. Close bleeder make sure brakes are operating correctly and that brake valve before releasing pedal. pedal is solid. Multi Pro 1200/1250 Page 8 – 15 Chassis...
  • Page 228: Front Suspension

    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 Page 8 – 16 Chassis Multi Pro 1200/1250...
  • Page 229 (189 N–m). If necessary for cotter pin installa- tion, 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. Multi Pro 1200/1250 Page 8 – 17 Chassis...
  • Page 230: Steering Assembly

    15. Jam nut (LH thread) 24. Slotted hex nut 7. Thrust washer 16. Slotted hex nut 25. A–arm 8. Bearing 17. Tie rod end (LH thread) 26. Axle 9. Slotted hex nut 18. Spindle Page 8 – 18 Chassis Multi Pro 1200/1250...
  • Page 231 6. Disassemble steering components as needed using 7. Check and adjust front wheel toe–in (see Operator’s Figure 15 as a guide. Manual). Check front suspension (see Front Suspen- sion in the Adjustments section of this Chapter). Multi Pro 1200/1250 Page 8 – 19 Chassis...
  • Page 232: Tie Rod End Replacement

    NOTE: Right and left tie rods should be identical length. 5. Check and adjust front wheel toe–in (see Operator’s Manual) and front suspension (see Front Suspension in the Adjustments section of this Chapter). Page 8 – 20 Chassis Multi Pro 1200/1250...
  • Page 233: Ball Joint Replacement

    55 to 65 ft–lb (75 to 88 N–m). 8. Lower machine to ground. 9. Check and adjust front wheel toe–in (see Operator’s Manual) and front suspension (see Front Suspension in the Adjustments section of this Chapter). Multi Pro 1200/1250 Page 8 – 21 Chassis...
  • Page 234: Seat Base (Multi Pro 1200)

    Seat Base (Multi Pro 1200) FRONT RIGHT Figure 18 1. Seat base 7. L bracket 12. Seal 2. Cap screw 8. Phillips head screw 13. Seat belt bracket 3. Flat washer 9. Console 14. Control panel 4. Rubber washer 10. Well nut 15.
  • Page 235 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 (see Operator’s Manual). Multi Pro 1200/1250 Page 8 – 23 Chassis...
  • Page 236: Seat Base (Multi Pro 1250)

    2. Flange head screw 7. Flange nut 11. Seat belt bracket 3. Flat washer 8. Well nut 12. Seal 4. Rubber washer 9. Phillips head screw 13. Spray control panel 5. Spacer Page 8 – 24 Chassis Multi Pro 1200/1250...
  • Page 237 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 (see Operator’s Manual). Multi Pro 1200/1250 Page 8 – 25 Chassis...
  • Page 238 This page is intentionally blank. Page 8 – 26 Chassis Multi Pro 1200/1250...
  • Page 239 ..... . Manual Boom Operation ....Rev. C Multi Pro 1200/1250 Page 8.1 - - 1 Sonic Boom System (Optional Kit)
  • Page 240: General Information

    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 8.1 - - 2 Rev. C Multi Pro 1200/1250...
  • Page 241: Special Tools

    (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.
  • Page 242: Electrical Schematic

    Electrical Schematic Sonic Boom System (Optional Kit) Page 8.1 - - 4 Rev. C Multi Pro 1200/1250...
  • Page 243 This page is intentionally blank. Rev. C Multi Pro 1200/1250 Page 8.1 - - 5 Sonic Boom System (Optional Kit)
  • Page 244: Sonic Boom System Operation

    Sonic Boom System Operation Sonic Boom System (Optional Kit) Page 8.1 - - 6 Rev. C Multi Pro 1200/1250...
  • Page 245: Sprayer Operation On Level Turf

    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 24 Rev. C Multi Pro 1200/1250 Page 8.1 - - 7 Sonic Boom System (Optional Kit)
  • Page 246 Sonic Boom System (Optional Kit) Page 8.1 - - 8 Rev. C Multi Pro 1200/1250...
  • Page 247: Downward Slope In Turf Encountered

    A HIGHER BOOM HEIGHT IS DETECTED SO ACTUATOR EXTENDS TO LOWER BOOM SECTION SLOPE Figure 25 Rev. C Multi Pro 1200/1250 Page 8.1 - - 9 Sonic Boom System (Optional Kit)
  • Page 248 Sonic Boom System (Optional Kit) Page 8.1 - - 10 Rev. C Multi Pro 1200/1250...
  • Page 249: Rise In Turf Encountered

    A LOWER BOOM HEIGHT IS DETECTED SO ACTUATOR RETRACTS TO RAISE BOOM SECTION RISE Figure 26 Rev. C Multi Pro 1200/1250 Page 8.1 - - 11 Sonic Boom System (Optional Kit)
  • Page 250 Sonic Boom System (Optional Kit) Page 8.1 - - 12 Rev. C Multi Pro 1200/1250...
  • Page 251: Boom Level Changed By Operator During Automatic Operation

    The sonic boom light will flash as long as the boom actuator switch is pressed. Rev. C Multi Pro 1200/1250 Page 8.1 - - 13 Sonic Boom System (Optional Kit)
  • Page 252 Sonic Boom System (Optional Kit) Page 8.1 - - 14 Rev. C Multi Pro 1200/1250...
  • Page 253: Manual Boom Operation

    The boom will continue to rise until the operator releases the boom actuator switch. Rev. C Multi Pro 1200/1250 Page 8.1 - - 15 Sonic Boom System (Optional Kit)
  • Page 254: Troubleshooting

    Sonic terfere with sensor signals. Boom Kit Installation Instructions. Sonic Boom System (Optional Kit) Page 8.1 - - 16 Rev. C Multi Pro 1200/1250...
  • Page 255: Diagnostic Display

    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 28 Rev. C Multi Pro 1200/1250 Page 8.1 - - 17 Sonic Boom System (Optional Kit)
  • Page 256 Sonic Boom Kit Installation Instructions for infor- sensor is the problem source (e.g. switch, circuit wiring). mation on initial sensor calibration. Sonic Boom System (Optional Kit) Page 8.1 - - 18 Rev. C Multi Pro 1200/1250...
  • Page 257 ECU problem. to ECU outputs. If this occurs, contact your Toro Distributor for assis- tance. 5. Make sure that the “OUTPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display, is illumi- 7.
  • Page 258: Troubleshooting Chart

    Electrical power from vehicle is not available (all sonic boom func- tions are affected). Both of the boom actuator 30 amp auto resetting fuses are faulty. ECU or circuit wiring is faulty. Sonic Boom System (Optional Kit) Page 8.1 - - 20 Rev. C Multi Pro 1200/1250...
  • Page 259 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. ECU or circuit wiring is faulty. Rev. C Multi Pro 1200/1250 Page 8.1 - - 21 Sonic Boom System (Optional Kit)
  • Page 260: Service And Repairs

    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.
  • Page 261: Relays

    +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. Rev. C Multi Pro 1200/1250 Page 8.1 - - 23 Sonic Boom System (Optional Kit)
  • Page 262: Electronic Control Unit (Ecu)

    ECU. These steps will prevent damage to the machine electrical system. Sonic Boom System (Optional Kit) Page 8.1 - - 24 Rev. C Multi Pro 1200/1250...
  • Page 263: Sonic Sensor

    Inspect the foam sensor filter (item 11) for damage or ex- cessive debris buildup. Replace filter if necessary. Rev. C Multi Pro 1200/1250 Page 8.1 - - 25 Sonic Boom System (Optional Kit)
  • Page 264 This page is intentionally blank. Sonic Boom System (Optional Kit) Page 8.1 - - 26 Rev. C Multi Pro 1200/1250...
  • Page 265: Electrical Schematics

    ..Serial Numbers Above 260000000 ..Multi Pro 1200 Spray System Electrical Schematic Multi Pro 1200 Spray System Wire Harness Serial Numbers Below 260000000 .
  • Page 266 This page is intentionally blank. Electrical Diagrams Page 9 - 2 Multi Pro 1200/1250...
  • Page 267: Multi Pro 1200/1250 Vehicle Electrical Schematic

    12 GA. RED NOTE: BRAKE PEDAL SWITCH, SHIFTER SOLENOID 5/16” STUD AND 2 AMP FUSE USED ONLY ON MACHINES WITH SERIAL NUMBERS BELOW 250000000. RED/BLACK Multi Pro 1200/1250 SHIFTER SOLENOID Vehicle Electrical Schematic STARTER BLUE/WHITE All relays and solenoids BLUE (START)
  • Page 268: Serial Numbers Above 260000000

    MAGNET SHIFT Y/BU BU/W SOLENOID SOLENOID CRUISE MODULE CARB SWITCH R/BK Multi Pro 1200/1250 IGNITION MODULES Vehicle Electrical Schematic All relays and solenoids SPARK PLUG SPARK PLUG are shown as de–energized. (Serial Numbers Above 260000000) Page 9 - 4 Rev. A...
  • Page 269: Serial Numbers Below 260000000

    OFF POSITION BLACK 16 GA. GREEN/WHITE ACCESSORY SOLENOID MULTI PRO 1200 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000308 AND 260000000 USE A RELAY AND TWO DIODES IN PLACE TO BATTERY + OF SCR DIODE D1 AND RESISTOR R1. 16 GA. BLACK...
  • Page 270: Serial Numbers Above 260000000

    RELAY SPRAY MONITOR OUT GND CLUTCH DP–CUSTOM (2&3,5&6)–(2&3)–OFF FLOW METER SPEED SENSOR Multi Pro 1200 Spray System Electrical Schematic All relays and solenoids are shown as de–energized. All ground wires are black. (Serial Numbers Above 260000000) Page 9 - 6...
  • Page 271: Serial Numbers Below 260000000

    MASTER BOOM (FOOT) SWITCH VEHICLE RED/YELLOW RED/YELLOW FUSE BLOCK 18 GA . RED BLACK BLACK FOAM MARKER RED/YELLOW BOOM 18 GA . BLACK LIFTS 18 GA . TAN/BLACK 14 GA . SPRAY SYSTEM 10 GA . RED RUN/HOLD RELAY K3 SPRAY VALVE SPRAY VALVE RELAY K4...
  • Page 272: Serial Numbers Above 260000000

    RIGHT ACTUATOR RELAY RIGHT ACTUATOR RIGHT ACTUATOR SWITCH ACTUATOR (20A) DIODE, TVS, 24V RIGHT ACTUATOR DPDT–(ON)OFF(ON) RELAY LEFT ACTUATOR LEFT ACTUATOR SWITCH RELAY LEFT ACTUATOR ACTUATOR (20A) LEFT ACTUATOR DIODE, TVS, 24V DPDT–(ON)OFF(ON) RELAY 30 A THERMAL BREAKER 30 A THERMAL BREAKER FUSE BLOCK–4 WAY LEFT FOAM SWITCH FROM MAIN HARNESS...
  • Page 273: Start Circuit

    NOTE: SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 260000000 SHOWN. ACCESORY SOLENOID BRAKE PEDAL SWITCH BATTERY WHITE 12 GA. RED 5/16” STUD Multi Pro 1200/1250 RED/BLACK SHIFTER Start Circuit SOLENOID STARTER Power Current BLUE/WHITE Control Current BLUE (START) (START) ENGINE PLUG Indicator/Gauge Current 12 GA.
  • Page 274: Run Circuit

    NOTE: SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 260000000 SHOWN. ACCESORY SOLENOID (ENERGIZED) BRAKE PEDAL SWITCH BATTERY WHITE 12 GA. RED 5/16” STUD Multi Pro 1200/1250 RED/BLACK Run Circuit SHIFTER SOLENOID Power Current STARTER Control Current BLUE/WHITE BLUE (START) Indicator/Gauge Current (START) ENGINE PLUG 12 GA.
  • Page 275: Neutral Engine Speed Control Circuit

    NOTE: SCHEMATIC FOR MACHINE WITH SERIAL ENGINE NUMBER BELOW 260000000 SHOWN. ACCESORY SOLENOID BRAKE PEDAL SWITCH BATTERY WHITE 12 GA. RED 5/16” STUD Multi Pro 1200/1250 RED/BLACK Neutral Engine Speed Control Circuit SHIFTER SOLENOID Power Current STARTER Control Current BLUE/WHITE BLUE (START) Indicator/Gauge Current (START) ENGINE PLUG 12 GA.
  • Page 276 18 GA. GRAY/BLACK RESISTOR 18 GA. GRAY/RED MOMENTARY SPEED SENSOR GREEN/WHITE ON POSITION 14 GA. BLACK 16 GA. GREEN/WHITE Multi Pro 1200 Spray Circuit (Spray Pump ON) Power Current Control Current 16 GA. BLACK Indicator/Gauge Current PUMP FLOWMETER Logic Direction...
  • Page 277 MASTER BOOM (FOOT) SWITCH ON POSITION VEHICLE RED/YELLOW RED/YELLOW FUSE BLOCK 18 GA . RED BLACK BLACK FOAM MARKER NOTE: SCHEMATIC FOR MACHINE WITH SERIAL RED/YELLOW NUMBER BELOW 260000000 SHOWN. 18 GA . BLACK BOOM LIFTS 14 GA. 18 GA . TAN/BLACK SPRAY SYSTEM SPRAY VALVE K3...
  • Page 278 MASTER BOOM (FOOT) SWITCH OFF POSITION VEHICLE RED/YELLOW RED/YELLOW FUSE BLOCK 18 GA . RED BLACK BLACK FOAM NOTE: SCHEMATIC FOR MACHINE WITH SERIAL MARKER NUMBER BELOW 260000000 SHOWN. RED/YELLOW 18 GA . BLACK BOOM LIFTS 18 GA . TAN/BLACK 14 GA.
  • Page 279 MASTER BOOM (FOOT) SWITCH OFF POSITION VEHICLE RED/YELLOW RED/YELLOW FUSE BLOCK 18 GA . RED BLACK BLACK NOTE: SCHEMATIC FOR MACHINE WITH SERIAL FOAM NUMBER BELOW 260000000 SHOWN. MARKER RED/YELLOW BOOM 18 GA . BLACK LIFTS 18 GA . TAN/BLACK SPRAY 14 GA .
  • Page 280: Multi Pro 1200/1250 Main Wire Harness Serial Numbers Below 260000000

    WHITE YELLOW/RED RED/BLACK YELLOW/RED BLACK BLACK BLACK ORANGE WHITE WHITE (10 AMP) BLUE/RED BROWN YELLOW/RED BLACK BLACK VIOLET VIOLET BLACK YELLOW/RED BLACK Multi Pro 1200/1250 BROWN Main Wire Harness YELLOW/BLUE (Serial Numbers Below 260000000) Page 9 - 16 Rev. A...
  • Page 281 IGNITION GROUND SWITCH SWITCH BLOCK CHASSIS GROUND SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000301 AND 260000000 COMBINE RING TERMINALS P31 AND P32 IN ONE CONNECTOR. Multi Pro 1200/1250 Main Wire Harness (Serial Numbers Below 260000000) Page 9 - 17 Rev. A...
  • Page 282: Serial Numbers Above 260000000

    – SP03 BLACK ”G” VOLT METER BLACK PINK ”I” START RELAY BLUE/WHITE GREEN/RED WHITE BLACK WHITE ENGINE CONNECTION Multi Pro 1200/1250 HEADLIGHT LEFT HEADLIGHT RIGHT HEADLIGHT SWITCH Main Wire Harness (Serial Numbers Above 260000000) Page 9 - 18 Rev. A...
  • Page 283 SWITCH GROUND 3 2 1 8 RIGHT ACTUATOR POWER BLOCK IGNITION INPUT SWITCH AUXILARY FUSE OUTPUT BLOCK AUXILARY CRUISE RELAY MODULE ENERGIZE CRUISE COIL Multi Pro 1200/1250 Main Wire Harness (Serial Numbers Above 260000000) Page 9 - 19 Rev. A...
  • Page 284: Multi Pro 1200 Spray System Wire Harness Serial Numbers Below 240000400

    PINK PINK BLACK GREEN/WHITE GRAY/RED GRAY/RED GRAY/BLACK GRAY/BLACK PUMP MULTI PRO 1200 SPRAYERS WITH SERIAL CLUTCH GRAY GRAY NUMBERS BETWEEN 230000308 AND 230999999 USE RELAY AND TWO DIODES IN PLACE OF SCR DIODE D1 AND RESISTOR R1. BLACK BLACK Multi Pro 1200...
  • Page 285 MULTI PRO 1200 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000308 AND 230999999 USE A RELAY AND TWO DIODES IN PLACE OF SCR DIODE D1 AND RESISTOR R1. PUMP RELAY VEHICLE GROUND BLOCK SCR DIODE D1 AND RESISTOR R1 USED ON MULTI PRO 1200 SPRAYERS WITH SERIAL...
  • Page 286 SP14 PUMP LATCH RELAY BLACK MASTER FOAM SOLENOID WHITE FLOW MONITOR FOAM COMPRESSOR WHITE BLACK GREEN/ WHITE Multi Pro 1200 RH FOAM LH FOAM SPEED SENSOR FLOW METER RIGHT PUMP DIODE DIODE LEFT SOLENOID SOLENOID Spray System Wire Harness ACTUATOR...
  • Page 287: Serial Numbers From 240000401 To 250999999

    MONITOR ACTUATOR SWITCH BACK ACTUATOR SWITCH FLOW METER RH FOAM SWITCH BACK LH FOAM PUMP SWITCH SWITCH BACK BACK BACK BACK Multi Pro 1200 Spray System Wire Harness (Serial Numbers From 240000401 To 250999999) Page 9 - 23 Rev. A...
  • Page 288: Serial Numbers From 260000001 To 280000110

    85 87A 87 RIGHT ACTUATOR RIGHT ACTUATOR RIGHT SWITCH RIGHT ACTUATOR RELAYS DIODE POWER ACTUATOR Multi Pro 1200 Spray System Wire Harness 85 87A 87 85 87A 87 (Serial Numbers From 260000001 to 280000110) LEFT LEFT ACTUATOR LEFT ACTUATOR RELAYS LEFT ACTUATOR...
  • Page 289 BLOCK LEFT ACTUATOR RH FOAM SWITCH MARKER SWITCH SPEED SENSOR RIGHT ACTUATOR LH FOAM SWITCH MARKER SWITCH PUMP SWITCH FLOW METER Multi Pro 1200 Spray System Wire Harness (Serial Numbers From 260000001 to 280000110) Page 9 - 25 Rev. C...
  • Page 290: Serial Numbers Above 280000111

    BLACK PINK PINK BLACK BLACK BLACK ORANGE YELLOW GREEN BLUE VIOLET GRAY BLACK PINK Multi Pro 1200 Spray System Wire Harness (Serial Numbers Above 280000111) Page 9 - 26 Rev. C...
  • Page 291 Multi Pro 1200 Spray System Wire Harness (Serial Numbers Above 280000111) Page 9 - 27 Rev. C...
  • Page 292 RED/YELLOW RED/YELLOW RED/YELLOW RED/BLACK RED/BLACK BLACK BLACK BLACK BLACK BLACK/RED BLACK/RED RED/ YELLOW LEFT SPRAY CENTER SPRAY RIGHT SPRAY BLUE/ GREEN/ VALVE SWITCH VALVE SWITCH BLACK YELLOW/ VALVE SWITCH BLACK BLACK BLACK/ RED/ BLACK TAN/BLACK BLUE BLACK BLACK BLACK BLACK BLACK BLACK BLACK...
  • Page 293: Multi Pro 1250 Spray System Wire Harness Serial Numbers Below 240000400

    MULTI PRO 1250 SPRAYERS WITH SERIAL NUMBERS BETWEEN 230000413 AND 240000400 USE A RELAY AND TWO DIODES IN PLACE OF SCR DIODE AND RESISTOR. PUMP RELAY VEHICLE GROUND BLOCK LEFT SPRAY VALVE SWITCH CENTER SPRAY VALVE SWITCH RIGHT SPRAY SCR DIODE D1 AND RESISTOR R1 USED ON VALVE MULTI PRO 1250 SPRAYERS WITH SERIAL SWITCH...
  • Page 294 RUN/HOLD RELAY 3 SPRAY VALVE RELAY 5 LEFT SPRAY SPRAY VALVE RELAY 4 CENTER SPRAY RIGHT SPRAY VALVE SWITCH VALVE SWITCH VALVE SWITCH 85 87A 30 85 BLACK BLACK BLACK RED/BLACK RED/BLACK RED/ RED/YELLOW YELLOW BLACK/RED BLACK/RED SUPERVISOR SWITCH FOOT SWITCH BLACK/RED RED/YELLOW...
  • Page 295 RIGHT ACTUATOR LH FOAM SOLENOID 2 3 4 2 3 4 2 3 4 RH FOAM SOLENOID MASTER FOAM FOAM COMPRESSOR RUN/HOLD SPRAY VALVE SPRAY VALVE SOLENOID RELAY 5 RELAY 3 RELAY 4 PUMP LATCH RELAY BACK FOAM SPRAY MARKER SYSTEM POWER POWER...
  • Page 296: Serial Numbers From 260000001 To 260999999

    LEFT CENTER SPRAY VALVE RIGHT SPRAY VALVE LEFT SPRAY VALVE CENTER SPRAY VALVE SPRAY RUN/HOLD RELAY 3 AMP SPRAY 3 AMP SPRAY 3 AMP RIGHT SPRAY VALVE RELAY SPRAY RELAY SWITCH VALVE FUSE SWITCH MONITOR FUSE VALVE FUSE SWITCH VALVE 30 85 87A 87 86 30 85 87A 87 86 30 85 87A 87 86...
  • Page 297 LH FOAM SOLENOID FOAM RH FOAM COMPRESSOR PUMP SOLENOID RELAY P42 LEFT ACTUATOR MASTER RELAYS FOAM SOLENOID P39 RIGHT FLOW ACTUATOR RIGHT METER RELAYS DIODE SPRAY CENTER VALVE SPRAY VALVE J07 LEFT ACTUATOR POWER RIGHT ACTUATOR PRESSURE LEFT J12 RIGHT ACTUATOR POWER REGULATOR SPRAY FOOT...
  • Page 298: Serial Numbers From 270000001 To 280000237

    RED/YELLOW PINK BROWN RED/BLACK PINK BLACK BLACK YELLOW BLACK YELLOW BLACK WHITE YELLOW ORANGE BLACK YELLOW GREEN BLACK BLACK BLUE VIOLET GRAY BLACK YELLOW PINK YELLOW WHITE BLACK BLUE BLACK ORANGE BLACK ORANGE WHITE ORANGE/BLUE BLACK WHITE ORANGE/BLACK BLACK BLACK RED/WHITE RED/WHITE PINK...
  • Page 299 Multi Pro 1250 Spray System Wire Harness (Serial Numbers From 270000001 to 280000237) Page 9 - 35 Rev. C...
  • Page 300: Serial Numbers Above 280000238

    RED/YELLOW PINK BROWN RED/BLACK PINK YELLOW BLACK BLACK YELLOW BLACK BLACK YELLOW BROWN ORANGE YELLOW GREEN BLACK BLACK BLUE VIOLET GRAY YELLOW BLACK YELLOW PINK BLUE BLACK ORANGE ORANGE/BLUE ORANGE/BLACK BLACK BLACK RED/WHITE RED/WHITE PINK GREEN/ GREEN/WHITE WHITE BLACK BLUE YELLOW BLACK Multi Pro 1250...
  • Page 301 Multi Pro 1250 Spray System Wire Harness (Serial Numbers Above 280000238) Page 9 - 37 Rev. C...
  • Page 302 This page is intentionally blank. Page 9 - 38...

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