Form No. 3439-983 Rev C Multi Pro® 5800-G Turf Sprayer with ExcelaRate® Spray System Model No. 41394—Serial No. 403445001 and Up Model No. 41394CA—Serial No. 400000000 and Up Register at www.Toro.com.
Introduction This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. This machine is a dedicated turf spray application vehicle and is intended to be used by professional, hired operators in commercial applications. It is designed primarily for spraying on well-maintained lawns in parks, golf courses, sports fields, and on commercial grounds.
Sprayer Functions for Application Rate Mode and Manual Mode ......................................... 35 Spraying with the ExcelaRate Sprayer System.......................................................... 35 Positioning the Spray Sections ......................... 39 Taking Proper Turf Care Precautions while Operating in Stationary Modes ...................... 40 Spraying Tips.................................................... 40 Unclogging a Nozzle.........................................
Safety Cooling System Maintenance .............................. 70 Cooling System Safety ..................................... 70 Coolant Specification........................................ 70 Checking the Coolant Level .............................. 70 Coolant Quantity............................................... 71 Changing the Coolant ....................................... 71 Brake Maintenance ............................................. 72 Adjusting the Brakes....................................
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal107-8731 decal93-6686 107-8731 93-6686 1. Hydraulic fluid 1. Warning—read the Operator's Manual. 2. Read the Operator's Manual. 2. Torque the lug nuts to 75 to 102 N∙m (55 to 75 ft-lb). decal107-8732 107-8732 1. Warning—read the Operator's Manual. decal107-8667 2.
decal133-2758 133-2758 1. TEC logic—2 A 8. TEC power—7.5 A 2. TEC power—7.5 A 9. Cruise control—10 A 3. Extra fuse slot—10 A 4. Ignition—15 A 5. TEC power—7.5 A 10. InfoCenter—1 A 11. Boom and headlight—30 A 12. USB power—15 A 6. Boom control—10 A 13. Tank spray—40 A 7. Work light—15 A decal117-4955 117-4955 1. Warning—read the Operator's Manual; wear the seat belt when seated in the operator's position; avoid tipping the machine. 2. Warning—wear hearing protection. decal120-0616 120–0616 1.
decal120-0623 120-0623 decal120-0617 120-0617 1. Tow hitch location 2. Tie down locations 3. Warning—Read the Operator's Manual. 1. Pinch point—keep hands away from the hinge. 2. Crushing hazard, boom—keep bystanders away. decal127-6976 decal120-0624 127-6976 120-0624 1. Decrease 1. Crushing/dismemberment hazard of bystanders—do not enter or exit the machine while it is moving; stop the machine before entering or exiting. 2. Increase 2.
decal127-6981 127-6981 1. Bypass-return flow 3. Section spray 2. Flow decal132-7689 132-7689 1. Auto spray mode 7. Rinse system—off 2. Spray mode 8. Sonic sensor—on 3. Manual spray mode 9. Sonic sensor—off 4. Foam marker—on 10. Application rate—increase 5. Foam marker—off 11. Application rate—decrease 6. Rinse system—on decal127-6982 127-6982 1. Pump-return flow 2. Section spray decal132-7708 132-7708 1. Headlight—on 2. Headlight—off 8 3.
decal136-2351 136-2351 1. To engage the parking brake, press down the brake and parking-brake pedal. 2. To disengage the parking brake, press and release the parking-brake pedal. decal132-7783 132-7783 1. Engine stop 3. Engine start 2. Engine run decal133-8062 133-8062 decal120-0619 120-0619 1. Warning—read the Operator's Manual. 5. Tipping hazard—do not turn sharply while traveling fast, drive slowly when turning; use caution and drive slowly when traveling across or up and down slopes. 2.
decal132-7786 132-7786 1. Spray—off 3. USB 2. Spray—on decal132-7695 132-7695 1. Pump—on 5. Speed control—on 9. Lower the right section. 2. Pump—off 6. Speed control—off 10. Raise the right section. 14. Center section spray 3. Agitation—on 7. Lower the left section. 11. Engine speed—fast 15. Right section spray 4. Agitation—off 8. Raise the left section. 12. Engine speed—slow 10 13.
decal139-3065 139-3065 1. Read the Operator's Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 Description Use Qty. Quick-disconnect fitting 1 Assemble the sprayer tank fill fitting. No parts required – Check the section-hinge springs. No parts required – Remove the shipping bumper. Media and Additional Parts Description Starter key Operator's Manual Engine owner's manual Parts Catalog Instruction Card Screen filter Use Qty. 2 1 1 1 2 Read the manuals before operating the machine.
1 Assembling the Sprayer Tank Fill Fitting g191615 Figure 4 Parts needed for this procedure: 1 1. PTFE thread sealant 3. Quick-disconnect fitting 2. Fill hose fitting (1 inch—national pipe thread) Quick-disconnect fitting Procedure 6. Note: To complete this procedure, you will need to supply a hose with 1-inch male national pipe thread (NPT) fitting and PTFE thread sealant. 1. Thread the quick-disconnect coupling onto the fill hose and tighten it by hand (Figure 4).
3 Removing the Shipping Bumper No Parts Required Procedure 1. Remove the bolts, washers, and nuts that secure the shipping bumper to the front chassis plate (Figure 6). g035648 Figure 5 1. Section-hinge spring 3. Compressed spring dimension—4 cm (1-1/2 inches) 2. Jam nut 4. Repeat the procedure for each spring on both section hinges. 5. Move the sections into the transport ‘X’ position. See Using the Boom-Section Transport Cradle (page 39) for more information. g028179 Figure 6 1. Nut 2.
Product Overview g190621 Figure 7 1. Fresh-water tank 4. Roll bar (ROPS) 7. Drain valve (sprayer tank) 2. Passenger seat 5. Tank lid 8. Spray pump 3. Operator’s seat 6. Chemical tank 9. Battery 10. Work lights g190600 Figure 8 1. Lift cylinder 3. Valve manifolds 5. Hydraulic tank 7. Center boom section 2. Boom-transport cradle 4. Fuel tank 6. Right boom section 8.
Controls g216445 Figure 9 1. Work-light switch 6. Storage compartment 2. Steering wheel 7. InfoCenter 3. Pressure gauge 8. Quick Find™ console 4. Fuel gauge 5. Passenger-hand hold 9. Arm rest 10. Ignition switch Vehicle Controls begins to decrease, release the traction pedal slightly to allow the engine speed to increase. Traction Pedal The traction pedal (Figure 10) controls the movement of the machine, both forward and reverse.
Brake Pedal Use the brake pedal to stop or slow the machine (Figure 10). CAUTION If you operate the sprayer with poorly adjusted or worn brakes, you could lose control of the sprayer, resulting in serious injury or death to you or bystanders. Always check the brakes before operating the sprayer and keep them properly adjusted and repaired. Parking Brake g032469 Figure 11 The parking brake is a pedal to the left of the brake pedal (Figure 10).
USB Power Port Sprayer Controls The 2-socket USB power port is located at the back of the armrest. g194424 Figure 12 1. USB port g195515 2. USB sockets Figure 13 1. Application-rate switch 7. Center-section switch 2. Pressure gauge 8. Left-section switch 3. Spray-mode switch 9. Master section switch 4. Tank-agitation switch 5. Right boom-section lift switch 6. Right-section switch 10. Left boom-section lift switch 11.
Spray-Pump Switch The spray-pump switch is located on the center console to the right of the seat (Figure 13). Toggle this switch forward to run the spray pump or rearward to stop the pump. When the switch is turned on, a light on the switch illuminates. Important: Engage the spray-pump switch only when the engine is at LOW IDLE to avoid damaging the pump drive.
Section Bypass Valves Anti-Siphon Fill Receptacle The section bypass valves are used to adjust the sprayer system pressure to the section valves to ensure that the sprayer pressure to the spray section remains constant no matter how many spray sections are on (Figure 16). At the front of the tank cover is a hose receptacle with a threaded fitting, a 90-degree barbed fitting, and a short hose, which you can direct toward the tank opening.
InfoCenter Controls Machine Specifications (cont'd.) The InfoCenter controls use the 5 buttons below the LED display to navigate menus, enter data, and change functions. Description Tank capacity Overall width with standard spray system sections stored in the X position Measurement 1135.
Operation • Do not store the machine or fuel container where Note: Determine the left and right sides of the machine from the normal operating position. • Before Operation there is an open flame, spark, or pilot light, such as on a water heater or other appliance. If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated.
Checking the Hydraulic System • Keep chemicals in their original packages and stored in a safe location. Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic Fluid (page 74). • Properly dispose of unused chemicals and chemical containers as instructed by the chemical manufacturer and your local codes. Checking the Tire Air Pressure • Chemicals and fumes are dangerous; never enter the tank or place your head over or in the opening of a tank.
Preparing the Sprayer Filling the Fuel Tank Fuel tank capacity: approximately 45 L (12 US gallons). Selecting a Nozzle 1. Park the machine on a level surface, engage the parking brake, shut off the spray pump, shut off the engine, remove the key, and allow the engine to cool. 2. Clean the area around the fuel-tank cap (Figure 19). Note: Refer to the nozzle-selection guide that is available through your authorized Toro distributor. The turret bodies can accept up to 3 different nozzles.
Pressure Filter Table g214212 Figure 20 Mesh size—chemical or solution viscosity 1. Higher-viscosity chemicals 3. Screen mesh size or solutions 2. Lower-viscosity chemicals or solutions When you spray at a higher application rate, consider using a coarser optional suction-filter mesh; refer to Figure 21. Spray Nozzle Color Code (flow rate) Screen Mesh Size* Filter Color Code As required for low viscosity chemicals or solutions or low application rates 100 Green Yellow (0.
When you spray at a higher application rate, consider using a coarser optional pressure-filter mesh; refer to Figure 23. g214245 Figure 24 Mesh size—chemical or solution viscosity g214240 1. Higher-viscosity chemicals 3. Screen mesh size or solutions 2. Lower-viscosity chemicals or solutions Figure 23 Mesh size—application rate 1. Higher application rate 3. Screen mesh size 2.
Filling the Tanks Filling the Fresh-Water Tank 2. Determine the amount of water needed to mix the amount of chemical you need as prescribed by the chemical manufacturer. 3. Open the tank cover on the spray tank. Important: Do not use reclaimed water (gray Note: The tank cover is located at the center water) in the fresh-water tank. of the top of the tank. To open it, turn the front half of the cover counterclockwise and swing it open.
Note: To seal the tank, close the cover and Before using the sprayer for the first time, whenever you change the nozzles, or as needed, calibrate the sprayer flow, speed, and set the section bypass. rotate the front half clockwise. Important: After filling the tank for the first time, check the tank straps for any play. Tighten as necessary. Important: Select an open flat area to perform this procedure.
Note: The numbered indicators on the bypass knob and needle are for reference only. g214029 Figure 30 1. Open 3. Intermediate position 2. Closed (0) g191413 Figure 29 1. Section-bypass adjustment knobs 2. Sections-bypass shutoff valve 3. Turn on the left-section switch and turn off the right-section switch. 4. Adjust the right section-bypass knob (Figure 29) until the rate displayed is at the previous level according to the table. 5.
During Operation During Operation Safety General Safety • The owner/operator can prevent and is responsible • g191362 Figure 31 1. Actuator (agitation valve) • 2. Agitation-bypass valve • 12. Turn the spray-pump switch to the OFF position. 13. Move the throttle lever to the IDLE/SLOW position and turn the key switch to the OFF position. • • Locating the Spray Pump The spray pump is located near the back of the tank on the left side (Figure 32). • • • • • • g194233 Figure 32 • 1.
• • • • • • • • Review the slope instructions listed below for an abnormal vibration in the machine. Make all necessary repairs before resuming operation. Slow down and use caution when making turns and crossing roads and sidewalks with the machine. Always yield the right-of-way. Use extra caution when operating the machine on wet surfaces, in adverse weather conditions, at higher speeds, or with a full load. Stopping time and distance increase in these conditions.
Operating the Machine 1. Start the spray pump by pressing the spray-pump switch to the ON position; refer to Spray-Pump Switch (page 19). Starting the Engine 2. Drive forward and attain the desired ground speed; refer to Driving the Machine (page 32). 1. Sit on the operator’s seat and keep your foot off the traction pedal. 2. Ensure that the following controls are set: Note: You must drive the machine less than 11 km/h (7 mph) to set the ground-speed lock. • The parking brake is engaged. 3.
Engine Messaging There are 2 categories of engine messages that display on the InfoCenter when the engine is running outside the safe operating limit: • Engine advisories messages • Stop engine messages Note: You must set the audio mute option in the InfoCenter to ON for engine advisory and stop engine alarms to sound; refer to Muting the Audio Indicator in the Software Guide for the Multi Pro 5800-D and 5800-G turf sprayers with ExcelaRate spray system.
g194663 g194665 Figure 38 Figure 36 4. Press button 1 through 5 to view the active fault list ; refer to Figure 35 in Engine Advisories Messages (page 33). • Press button 1 or 2 to navigate up or down the list. • Press button 3 to mute the audio alarm. 5. Press button 5 to exit the active fault list and return to the home screen; refer to Figure 36 in Engine Advisories Messages (page 33).
Spraying in the Application Rate Mode materials have been chosen for specific reasons at different locations on your sprayer to meet this goal. Unfortunately, there is no single material which is perfect for all foreseeable applications. Some chemicals are more aggressive than others and each chemical interacts differently with various materials. Some consistencies (e.g., wettable powders, charcoal) are more abrasive and lead to higher wear rates.
Guide for the Multi Pro 5800-D and 5800-G turf sprayer with ExcelaRate spray system. Note: When you move to a different job site, you need to select another sub-area screen to record the individual area and volume information. 6.
this case, turn the agitation switch to the OFF position. Alternatively, you can add anti-foaming agent to the tank. 10. When you are finished spraying, set the master section switch to the OFF position to turn off all sections, then set the spray-pump switch to the OFF position. Note: Return the sections to the transport position and drive the sprayer to the cleaning area.
5. Shut off the master section switch, set the throttle to the slow position, shut off the spray pump, and shut off the engine. 6. Set the graduated container on a level surface and note the fluid volume (Figure 47). Important: When you are reading the graduated container, you must set the container on a level surface. Important: When you are reading the graduated container, read the fluid volume in the graduated container at the lowest point of the fluid-surface curve.
2. 15-Second Catch Test Table (cont'd.) Blue 946 32.0 Green 1,419 48.0 8. Use the boom-section lift switches to raise the outer spray sections, until they have moved completely into boom-section transport cradles forming the “X” transport position, and the lift cylinders are fully retracted. Important: Release the boom-section lift switch(es) once the outer spray sections have reached the desired position.
To put the outer spray sections back into the transport cradle, lower the spray section(s) to the spray position and then raise the spray section(s) back to the transport position. Make sure that the lift cylinders are fully retracted to prevent damaging the actuator rod. Taking Proper Turf Care Precautions while Operating in Stationary Modes Set the master section switch to the OFF position and then set the sprayer-pump switch to the OFF position. 3.
Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage. Cleaning the Sprayer System Draining the Tank 1. Stop the sprayer, engage the parking brake, shut off the engine, and remove the key. 2. Locate the tank-drain valve at the left, rear fender of the machine (Figure 49). Note: The drain valve is attached to the drain-valve bracket that is mounted to the left, rear fender. g191083 Figure 50 1.
Cleaning the Suction Filter Clean the spray system and any installed spray accessories after each spraying session. To properly clean the spray system, perform the following: • Complete 3 separate rinse cycles. • Use the cleaners and neutralizers as recommended by your chemical manufacturers. • Use pure, clean water (no cleaners or neutralizers) for the final rinse. 1. Fill the tank with at least 190 L (50 US gallons) of clean water and close the cover. 2. 3. 4. 5. 6. 7. 8. 9. 10.
and housing with the retainer that you removed in step 2. 8. Install the pressure filter element into the filter head (Figure 53). Note: Ensure that the filter element is firmly Cleaning the Pressure Filter seated into the filter head. Service Interval: Before each use or daily—Clean the pressure filter. Clean the pressure filter (more often when using wettable powders). 1.
Conditioning the Spray System 4. Allow the spray system to spray until the nozzles discharge the conditioner. Service Interval: After each use—Condition the spray system at the end of each daily use. Note: Most propylene glycol RV antifreeze is Conditioner Specification colored pink. Use the catch container to sample the sprayer discharge at several of the nozzles. 5.
Towing the Sprayer In case of an emergency, the sprayer can be towed for a short distance after you open the tow valve. However, we do not recommend this as a standard procedure. WARNING Towing at excessive speeds could cause a loss of steering control, resulting in personal injury. g002213 Figure 58 Never tow the sprayer at faster than 4.8 kph (3 mph). 1. Front towing points Towing the sprayer is a 2-person job.
Maintenance Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual for additional maintenance procedures. Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety – Handle chemicals in a well-ventilated area.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Torque the wheel-lug nuts. • Check the fan/alternator belt. After the first 50 hours • • • • After the first 100 hours • To provide proper performance and long sprayer life, follow these guidelines for the first 100 operating hours: After the first 200 hours • Pack the front wheel bearings. Before each use or daily • Inspect the seat belt(s) for wear, cuts, and other damage.
Maintenance Service Interval Every 400 hours Every 800 hours Maintenance Procedure • • • • • • • • • • • • • Grease the actuator-rod bearings. Perform yearly engine maintenance. Check the fuel lines and connections. Service the fuel filter. Drain and clean the fuel tank. Pack the front wheel bearings. Check the planetary-gear-drive lubricant. Check the coolant (as directed by the manufacturer) and change if necessary. Inspect the O-rings in the valve assemblies and replace them if necessary.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Monday Tuesday Wednesday Thursday Check the brake and parking-brake operation. Check the neutral-lockout-switch operation. Check the fuel level. Check the engine-oil level. Check the hydraulic-fluid level. Check the coolant level. Inspect the air filter. Inspect the radiator and oil cooler for debris. Check for any unusual engine noises. Check for any unusual operating noises.
Pre-Maintenance Procedures CAUTION If you leave the key in the starter switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the starter switch before you do any maintenance. g203111 Figure 61 1. Rear jacking points Raising the Sprayer Whenever running the engine for routine maintenance and/or engine diagnostics, the rear wheels of the sprayer should be 25 mm (1 inch) off the ground with the rear axle supported on jack stands.
Removing the Undercarriage Shroud Installing the Forward Heat Shield 1. Align the rear flange of the forward heat shield over the forward flange of the rear heat shield (Figure 63). 1. Remove the 5 flange-head bolts (5/16 x 7/8 inch) and 5 washers (5/16 inch) that secure the rear of the undercarriage shroud to the chassis of the machine (Figure 64). Note: Retain the flange-head bolts and washers for installation in step 5 of Installing the Undercarriage Shroud (page 52). g028177 Figure 63 1.
Removing the Seat-Base-Access Panel 1. Remove the 2 flanged-head bolts that secure the seat-base-access panel to the seat base (Figure 66). g189583 Figure 65 1. Engine mount 4. Flange locknuts (5/16 inch) 2. Bolt—shown for clarity; do not remove 3. Mounting tabs (undercarriage shroud) 5. Front of the machine 3. Move the mounting tabs off the bolts that secure the undercarriage shroud to the engine-mount brackets. 4. Remove the undercarriage shroud from the machine (Figure 64 and Figure 65).
Lubrication Note: The grease fittings positions are illustrated in Figure 68. Greasing the Spray Pump Service Interval: Every 50 hours—Lubricate the pump. Every 50 hours/Yearly (whichever comes first) Grease Type: Mobil XHP 461. 1. Wipe the 2 remote grease fitting clean (Figure 67). g187456 Figure 68 1. Grease fitting g204693 Figure 67 1. Back of the machine 3. Grease point (2) 2. Spray pump 2. 3. Pump grease into the remote grease fitting (Figure 67).
g013780 Figure 71 g002014 Figure 70 Right Boom 1. Actuator 4. Hairpin 2. Actuator rod 5. Clevis pin 1. Grease fitting 3. Boom-pivot-pin housing 3. Wipe off excess grease. 5. 4. Repeat the procedure for each boom pivot. Swivel the rod-end bearing and apply grease into the bearing (Figure 72). Note: Wipe off excess grease. Greasing the Actuator-Rod Bearings Service Interval: Every 400 hours/Yearly (whichever comes first) Grease Type: No. 2 lithium grease. 1.
9. Engine Maintenance Repeat steps 2 through 8 to the actuator-rod bearing at the other side of the machine. Engine Safety Shut off the engine before checking the oil or adding oil to the crankcase. Checking the Air Cleaner Service Interval: Before each use or daily Service the air cleaner more frequently if operating conditions are extremely dusty or sandy. 1. Engage the parking brake, shut off the spray pump, shut off the engine, and remove the key. 2.
7. Check the air-filter element for excessive accumulation of dust, dirt, and debris (Figure 73). Note: Do not clean the air-filter element if it is dirty; replace the air-filter element if it is dirty. 8. Install the dust cap onto the air-cleaner body and secure the cap with the 2 latches (Figure 73). Note: Ensure that the dust valve aligns between the 5 to 7 o’clock position when viewed from the end. 9. Lower the passenger seat.
8. Install the cover onto the air-cleaner body and secure the cover with the 2 latches (Figure 74). Note: Ensure that the dust valve is aligned between the 5 to 7 o’clock position when viewed from the end (Figure 74). 9. Align the coolant-overflow tank to the tank-support bracket and seat the tank firmly (Figure 74). Important: Ensure that the pressure-relief hose is routed forward and down, and the tank-vent hose is routed rearward as shown in Figure 74. 10. g195363 Lower the passenger seat.
Changing the Engine Oil CAUTION Components under the seat will be hot if the sprayer has been running. If you touch hot components, you may be burned. Service Interval: After the first 50 hours Every 200 hours Change the oil more often when operating the machine under heavy load or in high temperatures. Allow the sprayer to cool before performing maintenance or touching components under the hood. 3. 1. Align a drain pan under the drain plug (Figure 76). 2.
8. Install the oil-filler cap into the filler neck and the dipstick into the dipstick tube (Figure 77). 9. Start the engine and check for oil leaks. Performing Yearly Engine Maintenance Shut off the engine, wait 2 to 3 minutes, remove the dipstick, and check the oil level in the engine.
Fuel System Maintenance DANGER Under certain conditions, fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. g323402 Figure 79 • Use a funnel and fill the tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. 1. Screws (#10 x 3/4 inch) 3. Fuel tank 2. Cover • Do not fill the fuel tank completely full.
connector of the fuel pump/sending unit (Figure 83). g323399 Figure 81 1. Hose clamps 4. Separate the hoses from the fittings (Figure 82). g323401 Figure 83 1. 2-socket connector (machine—wiring harness) 5. Nut (fuel pump/sending unit) 2. 2-pin connector (fuel pump/sending unit) 6. Seal 3. 2-pin connector (machine-wiring harness) 7. Fitting (fuel pump) 4. 2-socket connector (fuel pump/sending unit) 8. Fuel-hose coupling 2.
Replacing the Fuel Filter 1. Remove the pickup tube of the fuel filter from the fitting of the fuel pump (Figure 85). Note: Discard the fuel filter. g028351 Figure 85 g032543 Figure 84 1. Fuel-tank neck 4. Fuel pump/sending unit 2. Arm (sending-unit float) 5. Filter 3. Pickup tube (fuel filter) 6. Float 62 1. Fitting (fuel pump) 4. Float arm (empty position) 2. Float arm (full position) 5. Fuel filter (short leg) 3. Pickup tube 6. Fuel filter (long leg) 2.
Installing the Fuel Pump and Sending Unit 1. Support the float arm and pickup tube together and slip the float and fuel filter into the opening in the fuel tank (Figure 84). Important: Ensure that the float and the long leg of the filter are pointing forward in the tank and the fitting at the top of the fuel pump points 90° toward the centerline of the machine. g323402 Figure 86 1. Screws (#10 x 3/4 inch) 2. Seat the fuel pump/sending unit into the opening in the tank (Figure 84 and Figure 85). 2.
Draining the Fuel Tank Service Interval: Every 400 hours/Yearly (whichever comes first) Drain and clean the fuel tank if the fuel system becomes contaminated or if you plan to store the machine for an extended period. When cleaning the fuel tank, use fresh, clean fuel to flush out the tank. 1. g323413 Figure 88 1. Hose clamps 5. Transfer the fuel from the tank into an approved fuel container using a siphon pump.
Servicing the Battery Electrical System Maintenance Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Electrical System Safety • Disconnect the battery before repairing the • • machine. Disconnect the negative terminal first and the positive last.
Charging the Battery WARNING Important: Always keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 32°F (0°C). Battery terminals or metal tools could short against metal sprayer components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 1. Remove the battery from the chassis; refer to Removing the Battery (page 65).
Drive System Maintenance Inspecting the Wheels/Tires Service Interval: After the first 8 hours—Torque the wheel-lug nuts. Every 100 hours—Torque the wheel-lug nuts. Every 100 hours—Inspect the condition and wear of the tires. Torque the lug nuts at the front wheels to 75 to 102 N∙m (55 to 75 ft-lb) and the lug nuts at the rear wheels to 95 to 122 N∙m (75 to 90 ft-lb).
g238951 Figure 96 1. Fill plug 4. Drain-plug hole (planetary lubricant) 2. Fill-plug hole (planetary lubricant) 5. Drain plug 3. Check-plug hole (planetary lubricant) 6. Check plug g238948 Figure 95 1. Fill plug 3. Check plug 2. Fill-plug hole (planetary lubricant) 5. 3. Check the O-rings of the fill plug for the damage. If the O-ring is damaged, replace it. 6. Install the fill plug and the check plug (Figure 95). 7.
Planetary-Gear-Drive with Lubricant Quantity 0.62 L (21 fl oz); refer to Planetary-Gear-Drive Lubricant Specification (page 67) Filling the Planetary-Gear-Drive with Lubricant 1. Through the fill-plug hole, slowly add the specified gear lubricant; refer to Figure 95 in Checking the Planetary-Gear-Drive Lubricant (page 67). g002247 Figure 98 1. Tire center line—back 2. Tire center line—front You should see the lubricant level at the bottom of the threads in the check-plug hole. 3.
Cooling System Maintenance • Preferred: When mixing coolant from a concentrate, mix it with distilled water. • Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate. • Minimum requirement: If distilled water and Cooling System Safety pre-mix coolant are not available, mix concentrated coolant with clean drinkable water. • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.
Owner provided equipment: a handheld coolant thermometer 1. Position the sprayer on a level surface, engage the parking brake, shut off the spray pump, shut off the engine, and remove the key. 2. Wait until the engine is cool, then remove the radiator cap (Figure 100). 3. Place a large drain pan under the radiator. 4. Open the drain valve and drain the coolant into the pan (Figure 101). g028232 Figure 100 1. Radiator cap 3. Expansion-tank cap 2. Expansion tank 4. Full-line mark 4.
11. Open the expansion-tank cap and fill the tank with coolant to the Cold level (Figure 100). Brake Maintenance 12. Check the coolant levels after several engine startup and shut-down cycles. Adjusting the Brakes Note: Add coolant to the radiator and expansion If the brake pedal travels more than 2.5 cm (1 inch) before you feel resistance, adjust the brakes as follows: tank as needed. 1. Position the sprayer on a level surface, shut off the spray pump, shut off the engine, and remove the key. 2.
Belt Maintenance 5. When you achieve the proper tension, tighten the alternator and the bolts to secure the adjustment. Servicing the Alternator Belt 6. Tighten the locknut to secure the adjustment. Service Interval: After the first 8 hours Every 100 hours Check the condition and tension of the alternator/cooling fan belt. Replace the belt as necessary. 1. Position the sprayer on a level surface, engage the parking brake, shut off the spray pump, shut off the engine, and remove the key. 2.
Hydraulic System Maintenance High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) 140 or higher Hydraulic System Safety Viscosity Index ASTM D2270 • Seek immediate medical attention if fluid is injected Pour Point, ASTM D97 -37°C to -45°C (-34°F to -49°F) Industry Specifications: Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S) into skin. Injected fluid must be surgically removed within a few hours by a doctor.
filled the reservoir with an alternative fluid, replace the hydraulic filter. WARNING Hot hydraulic fluid can cause severe burns. Allow the hydraulic fluid to cool before performing any maintenance to the hydraulic system. Important: You may void the warranty on some components if you use any other filter. g014217 Figure 104 1. Hydraulic-fluid tank 3. Dipstick cap Use the Toro replacement filter (See your Parts Manual for the correct part number.) 2.
WARNING Hot hydraulic fluid can cause severe burns. Allow the hydraulic fluid to cool before performing any maintenance to the hydraulic system. Important: You may void the warranty on some components if you use any other fluid. 1. Replace the hydraulic-fluid filters; refer to Replacing the Hydraulic Filters (page 75). 2. Clean the area around a hydraulic-hose fitting on the bottom of the hydraulic-fluid tank (Figure 108). g013790 Figure 107 1. Rear filter 2. Rear wheels 3.
Sprayer System Maintenance Inspecting the Hoses Service Interval: Every 200 hours—Inspect all hoses and connections for damage and proper attachment. Every 400 hours/Yearly (whichever comes first)—Inspect the O-rings in the valve assemblies and replace them if necessary. g033578 Examine each hose in the spray system for cracks, leaks, or other damage. At the same time, inspect the connections and fittings for similar damage. Replace any hoses and fittings if damaged. Figure 110 1. Screen vane 5.
Changing the Nozzle Filter Note: Determine the appropriate nozzle filter mesh size that you need for your job; refer to Selecting a Nozzle-Tip Filter (Optional) (page 26). 1. Park the machine on a level surface, engage the parking brake, shut off the sprayer pump, shut off the engine, and remove the key. 2. Remove the nozzle from the spray turret (Figure 112). g028235 Figure 111 1. Filter head 2. O-ring (bowl) 4. Bowl 5. O-ring (drain plug) 3. Filter element 6. Drain plug 3.
g014220 g013780 Figure 114 Figure 113 1. Actuator 2. Actuator rod 3. Boom-pivot pin housing 4. Cotter 5. Pin 1. Flat on the actuator rod 5. Eyelet adjusted 2. Jam nut 6. Eyelet position for assembly 3. Eyelet 7. Jam nut tightened to lock new position 3. Lift up on the boom and remove the pin (Figure 113), and slowly lower the boom to the ground. 4. Jam nut loosened 4. Inspect the pin for any damage, and replace it if necessary. 6. 5.
2. Extend the outer-boom sections to the spray position and support the boom sections using stands or straps and lifting equipment. Pump Maintenance 3. Remove the bolt and nut that secure the pivot pin, and remove the pin (Figure 115). Inspecting the Pump Service Interval: Every 400 hours/Yearly (whichever comes first)—Inspect the pump diaphragms and replace if necessary (see an authorized Toro distributor).
Cleaning Cleaning the Flow Meter Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine. Service Interval: Every 200 hours/Yearly (whichever comes first) (more often when using wettable powders). Important: Do not use brackish or reclaimed 1. Thoroughly rinse and drain the entire spraying system. 2. Remove the flow meter from the sprayer and flush it with clean water. 3. Remove the retainer ring on the upstream side (Figure 116).
Cleaning the Agitation and Section Valves • To clean the agitation valve; refer to the following sections: 1. Removing the Valve Actuator (page 82) 2. Removing the Agitation-Manifold Valve (page 82) 3. Cleaning the Manifold Valve (page 84) 4. Assembling the Manifold Valve (page 86) 5. Installing the Agitation-Manifold Valve (page 87) 6.
2. 3. Removing the Section-Manifold Valve Remove the 3 flange clamps that secure the agitation-valve manifold to the flanges of the pressure-filter head and the coupling adapter (Figure 118). 1. Remove the 2 flange-head bolts (1/4 x 3/4 inch) and 2 flange locknuts (1/4 inch) that secure the agitation-valve manifold to the valve support (Figure 119). Remove the quick-connect pin that secures the quick-connect coupler for the section-bypass valve to the section-manifold valve (Figure 120).
5. Move the section-valve manifold and gaskets down to clear the section-bypass valve and then away from the machine (Figure 122). Note: If needed, loosen the mounting hardware for the left or right section-valve manifolds as needed to provide clearance. Note: Retain the flange clamps, gaskets and quick-connect pins for installation in Installing the Agitation-Manifold Valve (page 87). Cleaning the Manifold Valve 1. Position the valve stem so that it is in the closed position (Figure 123B).
g028243 Figure 124 Agitation Valve Manifold 1. Stem retainer 7. Back seating O-ring (0.676 x 0.07 inch) 2. Valve stem 8. Valve-seat ring 3. Stem port g028240 Figure 125 Section Valve Manifold 9. Manifold body 4. Stem-capture retainer 10. Ball valve 5. End-cap fitting 11. End-cap-fitting assembly 1. Valve-stem seat 7. End-cap O-ring (0.796 x 0.139 inch) 2. Valve-stem assembly 8. Back seating O-ring (0.676 x 0.07 inch) 3. Stem port 4. Stem retainer 6. End-cap seal O-ring (0.796 x 0.
Installing the Section-Manifold Valve Assembling the Manifold Valve Operator supplied material: Clear silicone grease. 1. Important: Use only silicone grease when assembling the valve. 1. Check the condition of the outlet fitting O-rings (section valve manifold only), end cap O-rings, back seating O-rings, and ball seat for damage or wear (Figure 124 and Figure 125).
Torque the flange-head bolts and flange locknuts to 1978 to 2542 N∙cm (175 to 225 in-lb). 7. Tighten the 2 flange clamps by hand (Figure 129). 8. Assemble the quick-connect coupler of the section hose onto the quick-connect fitting of the section-valve manifold with the quick-connect pin (Figure 128). 9. If you loosened the mounting hardware of the left or right section-valve manifolds, tighten the nut and bolt to 1978 to 2542 N∙cm (175 to 225 in-lb).
Installing the Valve Actuator g191301 Figure 131 1. Flange (pressure-filter head) 4. Quick-connect pin 2. Flange (coupling adapter) 5. Quick-connect coupler (agitation hose) 3. Flange clamp 6. Quick-connect fitting (agitation valve manifold) 2. Loosely secure the agitation-valve manifold to the agitation-bypass valve, pressure filter head, and coupling adapter (Figure 131) with the 3 flange clamps that you removed in Removing the Agitation-Manifold Valve (page 82). 3.
Storage 4. Storage Safety Prepare rust inhibiting, non-alcohol based, RV antifreeze solution; refer to Preparing the Conditioner (page 44). 5. Remove the tube from the back of the pressure gauge and place the end of the tube into a container (Figure 132). • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
4. Turn the master section switch to the OFF position. 2. Grease the sprayer; refer to Greasing the Spray Pump (page 53). 5. Turn the pump switch to the OFF position. 3. Check the condition of all spray hoses. 6. Use the boom-section lift switches to raise the outer boom sections. Note: Replace any hoses that are worn or damaged. Raise the boom sections until they have moved completely into boom-transport cradle forming the “X” transport position and the lift cylinders are fully retracted. 4.
Preparing the Machine for Service 1. Insert the pressure-gauge tube into the tube coupler at back of the pressure gauge (Figure 133). g276304 Figure 133 1. Pressure-gauge tube 3. Pressure gauge 2. Tube coupler 2. Close the spigot of the fresh-water tank. 3. Add fuel to the fuel tank. 4. Fully charge the battery; refer to Charging the Battery (page 66). 5. Install the battery into the chassis; refer to Installing the Battery (page 66).
Troubleshooting Troubleshooting the Engine and Vehicle Problem The starter does not rotate the engine. The engine cranks but does not start. Possible Cause 1. The electrical connections are corroded or loose. 1. Check the electrical connections for good contact. 2. A fuse is blown or loose. 3. The battery is discharged. 4. A broken starter or starter solenoid. 5. There are seized internal engine components. 2. Correct or replace fuse. 3. Charge or replace the battery. 4.
Problem The engine overheats. Possible Cause 1. The crankcase-oil level is incorrect. 1. Fill or drain to the Full mark. 2. The coolant level is low. 2. Check the coolant level and replenish it as needed. 3. Reduce load; use lower ground speed. 3. The engine is operated under excessive load. 4. The air-intake screens are dirty. 5. The cooling fins and air passages under the engine-blower housing and/or the rotating-air-intake screen are plugged. The engine loses power. Corrective Action 4.
Troubleshooting the Spray System Problem A spray section does not spray. Possible Cause Corrective Action 1. The electrical connection on the section valve is dirty or disconnected. 1. Turn the valve off manually. Disconnect the electrical connector on the valve and clean all leads, then connect it. 2. There is a blown (open) fuse. 2. Check the fuses and replace them as necessary. 3. Repair or replace the hose. 4. Adjust the section bypass. 3. There is a pinched hose. 4.
Schematics g034336 Sprayer System Schematic (Rev.
Notes:
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The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Parts Conditions and Products Covered The Toro Company warrants your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
