Toro 41107 User manual

1
©The TORO Company - 2001
All Rights Reserved
To assure maximum safety, optimum
performan e, and to gain knowledge of
the produ t, it is essential that you or any
other operator of this vehi le read and
understand the ontents of this manual
before the engine is ever started. Pay
parti ular attention to the SAFETY
INSTRUCTIONS highlighted by the
triangular safety alert symbol.
The safety alert symbol means
CAUTION, WARNING, or DANGER
- personal safety instru tion. Failure to
omply with the instru tion may result in
personal injury.
FORM NO. 104-8942
MODEL NO. 41107-210000235 and UP OPERATOR'S &
SETUP
MANUAL
MULTI PRO® 1200
TURF SPRAYER

2
When the ma hine is used or operated on any California forest, brush, or grass overed land, a
properly operating Spark Arrester must be obtained and installed to the Muffler. The operator is
violating state law, Se tion 4442 Publi Resour es Code if a Spark Arrester is not used.
IDENTIFICATION AND ORDERING
VEHICLE: ENGINE:
The MULTI PRO® 1200 has two identification
numbers: a model number and a serial number
These numbers are stamped into a plate located
on floor board of the vehicle In any
correspondence concerning the unit, supply the
model number and serial number to ensure
correct information and replacement parts are
obtained Record your Vehicle Identification
numbers on the illustration below for future
reference
This vehicle is not a motor vehicle as defined by
the National Traffic Motor Vehicle Safety Act It is
not designed or manufa tured for use on roads,
streets, or highways, and is not to be li ensed
as a motor vehi le.
FOREWORD
Safety, mechanical, and some general information in this manual are emphasized DANGER, WARNING,
and CAUTION identify safety messages Whenever the triangle safety symbol appears, it is followed by
a safety message that must be read and understood For more details concerning safety, read the safety
instructions on pages 4 through 6 IMPORTANT identifies special mechanical information and NOTE
identifies general information worthy of special attention
SPARK ARRESTER
In some places a Spark Arrester muffler must be used because of local, state, or federal regulations The
Spark Arrester available from your local TORO Distributor is approved by the United States Department
of Agriculture and the United States Forest Service
All information, illustrations and specifications in this manual are based on the latest product information available at the time of
publication The right is reserved to make any changes at any time without notice
DATE PURCHASED: _______________________
You have purchased a vehicle from the industry leader in maintenance excellence Its future performance
and dependability are of prime importance TORO is also concerned about future use of the vehicle
and safety of the user Therefore, this manual must be read by you and those involved with the MULTI
PRO® 1200 to assure that safety, proper setup, operation, and maintenance procedures are followed at
all times The major sections of the manual are:
MOD.
SER.
THE TORO CO.
MINNEAPOLIS, MN. 55420
1. SAFETY INSTRUCTIONS 2. SETUP INSTRUCTIONS 3. BEFORE OPERATING
4. OPERATING INSTRUCTIONS 5. MAINTENANCE 6. SPRAYING SYSTEM
WARNING
The engine exhaust from this produ t
ontains hemi als known to the State
of California to ause an er, birth
defe ts, or other reprodu tive harm.
The engine has three identification numbers: a
model number, a specification number and a serial
number These numbers appear on a decal affixed
to the engine shrouding When ordering parts or
in any communication involving the engine, it will
be necessary to supply the engine manufacturer
with these numbers, to ensure correct information
and replacement parts are obtained Record the
engine identification numbers on the illustration
below for future reference

3
5-7
5
5-6
6-7
7
7
8-9
10
11-14
11
12-14
15-19
15
16
17
18
18
19
19
19
19
20-21
22-25
22
22
22
23
23
23-24
24
24
24
24
25
25
26
26
27
28
29
29-30
31-32
33
34-37
34
34
35
35
36
37
38
38
TABLE OF CONTENTS
SAFETY INSTRUCTIONS................................................................................................................
SUPERVISOR'S RESPONSIBILITES
BEFORE OPERATING
WHILE OPERATING
SAFETY AND INSTRUCTIONS.................................................................................................
MAINTENANCE
SAFETY AND INSTRUCTION DECALS...................................................................................
SPECIFICATIONS......................................................................................................................
SETUP INSTRUCTIONS..................................................................................................................
ACTIVATE AND CHARGE BATTERY
SPRAY SYSTEM
BEFORE OPERATING....................................................................................................................
CHECK ENGINE CRANKCASE OIL
FILL FUEL TANK
CHECK AIR CLEANER/AIR INTAKE
CHECK TRANSAXLE/HYDRAULIC FLUID
CHECK BRAKE FLUID/MASTER CYLINDER
CHECK TORQUE OF WHEEL NUTS
CHECK TIRE PRESSURE
INSPECT TIRES
NEUTRAL INTERLOCK SWITCH
VEHICLE CONTROLS...............................................................................................................
OPERATING INSTRUCTIONS........................................................................................................
PRE-STARTING CHECKS
STARTING ENGINE
DRIVING VEHICLE
STOPPING VEHICLE
NEW VEHICLE BREAK-IN
OPERATING CHARACTERISTICS
SPEED
TURNING
BRAKING
TIPOVERS
HILLS
TOWING VEHICLE
MAINTENANCE.................................................................................................................................
SERVICE INTERVAL CHART
DAILY MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
JACKING VEHICLE
NEUTRAL INTERLOCK SWITCH
LUBRICATION............................................................................................................................
AIR CLEANER MAINTENANCE................................................................................................
ENGINE MAINTENANCE..........................................................................................................
AIR INTAKE/COOLING AREAS
ENGINE CRANKCASE OIL
OIL FILTER
IGNITION SYSTEM
SPARK PLUG
IN-LINE FUEL FILTER
CLUTCH SYSTEM AND CVT BELT
STEERING PUMP BELT TENSION
DESCRIPTION PAGE

4
TABLE OF CONTENTS
39-40
39
39
40
40
40
41
41
42
43-44
43
43
44
45
46
47-48
49
50
51-59
60
61
62
63
63
63
63
64
64
64
64
64
64
65
65
66
66
67-68
69
70-71
72
73
73
74
74
DESCRIPTION PAGE
HYDRAULIC SYSTEM MAINTENANCE..................................................................................
CHANGING TRANSAXLE/HYDRAULIC FLUID
REPLACING TRANSAXLE/HYDRAULIC FILTER
CHECKING HYDRAULIC LINES AND HOSES
CLEANING TRANSAXLE/HYDRAULIC STRAINER
PRESSURE SETTINGS
TRANSAXLE MAINTENANCE..................................................................................................
HYDRAULIC SYSTEM DIAGRAM...........................................................................................
TIRE & BRAKE MAINTENANCE.............................................................................................
ELECTRICAL MAINTENANCE................................................................................................
JUMP STARTING PROCEDURE
FUSES
BATTERY CARE & STORAGE
VEHICLE ELECTRICAL DIAGRAM.........................................................................................
SPRAYING SYSTEM.......................................................................................................................
SPRAY CONTROLS AND OPERATION..................................................................................
SPRAY PRO  MONITOR MAIN FUNCTIONS......................................................................
QUICK START SPRAY GUIDE.................................................................................................
BEFORE SPRAYING.................................................................................................................
SPRAY PRO  MONITOR FUNCTION...................................................................................
SPRAY PRO FINE TUNING..................................................................................................
SPRAY PRO  OPERATION AND SPRAYER OPERATION.................................................
PREVENTIVE MAINTENANCE................................................................................................
SUCTION STRAINER
AFTER SPRAYING
FLUSH PUMP AFTER USE
PUMP MAINTENANCE.............................................................................................................
CHANGING OF VALVES AND DIAPHRAGMS
VALVES
DIAPHRAGM
PUMP LUBRICATION
SUCTION AND PRESSURE DAMPENER MAINTENANCE
MAINTENANCE.........................................................................................................................
BOOM BYPASS VALVE
FLOWMETER
BOOM CONTROL VALVE
SPRAY SYSTEM FLOW & ELECTRICAL DIAGRAM.............................................................
MAINTENANCE TROUBLESHOOTING.................................................................................
SPRAY PRO  TROUBLESHOOTING...................................................................................
STORAGE..................................................................................................................................
PERFORMANCE VERIFICATION............................................................................................
OPTIONAL RATE CHECK........................................................................................................
NOZZLE CHECK.......................................................................................................................
CALCULATE RANGE................................................................................................................
TORO® WARRANTY...................................................................................................... BACK COVER

5
SAFETY INSTRUCTIONS
BEFORE OPERATING:
1. Operate the vehicle only after reading and
understanding the contents of this manual A
replacement manual is available by sending
complete model and serial number to: Hahn
Equipment Co., A subsidiary of The TORO
Company, 1625 N Garvin, Evansville, Indiana
47711-4596
Read and understand the Engine Manufacturer's
Operator's Manual Follow the safety alert
messages
1. Make sure operators are thoroughly trained
and familiar with the Operator's Manual and all
labels on the vehicle
2. Be sure to establish your own special
procedures and work rules for unusual operating
conditions (e g slopes too steep for vehicle
operation)
The MULTI PRO® 1200 Turf Sprayer was
designed and tested to offer safe servi e when
operated and maintained properly. Although
hazard ontrol and a ident prevention
partially are dependent upon the design and
onfiguration of the vehi le, these fa tors are
also dependent upon the awareness, on ern,
and proper training of the personnel involved
in the operation, maintenan e, and storage of
the vehi le. Improper use or maintenan e of
the vehi le an result in injury or death.
This is a spe ialized Turf Sprayer designed for
off road use. Its ride and handling will have a
different feel than what drivers experien e with
passenger ars or tru ks. So take time to
be ome familiar with your MULTI PRO® 1200.
The atta hments that adapt to the MULTI PRO®
1200 are not overed in this manual. See the
spe ifi Operator's Manual provided with the
atta hment for additional safety instru tions.
READ THESE MANUALS.
TO REDUCE THE POTENTIAL FOR INJURY
OR DEATH, COMPLY WITH THE FOLLOWING
SAFETY INSTRUCTIONS:
3. This vehicle is designed to carry Only You,
the Operator. Never carry passengers on the
vehicle
4. Never operate the vehicle when under the
influence of drugs or alcohol
5. Become familiar with the controls and know
how to stop the engine quickly
6. Keep all shields, safety devices, and decals
in place If a shield, safety device, or decal is
malfunctioning, illegible, or damaged, repair or
replace it before operating the vehicle
7. Always wear substantial shoes Do not
operate vehicle while wearing sandals, tennis
shoes, or sneakers Do not wear loose fitting
clothing or jewelry which could get caught in
moving parts and cause personal injury
8. Wearing safety glasses, safety shoes, long
pants, and a helmet is advisable and required by
some local safety and insurance regulations
9. Keep everyone, especially children and pets,
away from the areas of operation
10. Before operating the vehicle, always check
all parts of the vehicle and any attachments If
something is wrong, stop using the vehi le
Make sure the problem is corrected before vehicle
or attachment is operated again
11. Since gasoline is highly flammable, handle
it carefully
A. Use an approved gasoline container
B. Do not remove cap from fuel tank when
engine is hot or running
C. Do not smoke while handling gasoline
D. Fill fuel tank outdoors and to
approximately one inch below top of tank,
(bottom of filler neck) Do not overfill
E. Wipe up any spilled gasoline
12 Entering tank is prohibited Some spray
chemicals could be hazardous Entering tank
could increase exposure to hazardous chemicals
SUPERVISOR'S RESPONSIBILITIES:
2. Never allow children to operate the vehicle
or adults to operate it without proper instructions
Only trained and authorized persons should
operate this vehicle Anyone who operates the
vehicle should have a motor vehicle license

6
SAFETY INSTRUCTIONS
5. The vehicle is designed with safety in mind
This vehicle is not a passenger car It is a Turf
Sprayer and is not designed for use on roadways
Above all, use good judgement when operating
this vehicle Failure to operate vehicle safely may
result in an accident, tip over of vehicle and
serious injury or death Drive carefully To
prevent tipping or loss of control:
A. Use extreme caution, reduce speed and
maintain a safe distance around sand traps,
ditches, creeks, ramps, and any unfamiliar
areas, or other hazards
B. Watch for holes or other hidden
hazards
C. Always reduce speed before starting up
or down a hill Do not start or stop suddenly when
traveling uphill or downhill Do not operate
vehicle on a steep slope Travel straight up and
down normal slopes Avoid turning on hillsides
whenever possible Reduce speed when making
sharp turns or when turning on hillsides
D. If engine stalls or loses power and cannot
make it to the top of a slope, apply brakes and
do not turn vehicle around Always back slowly
straight down the slope
E. Use extra caution when operating vehicle
on wet surfaces, at higher speeds or with a full
load Stopping time will increase with a full load
F. Operate vehicle with extra caution when
handling off-center loads that cannot be
centered
G. Avoid sudden starts and stops Do not
go from reverse to forward or forward to reverse
without first coming to a complete stop
H. Do not attempt sharp turns or abrupt
maneuvers or other unsafe driving actions that
may cause a loss of vehicle control
I. Before backing up, be sure no one is
behind the vehicle Back up slowly
J. Watch out for traffic when near or crossing
roads Always yield the right of way to
pedestrians and other vehicles This vehicle is
not designed for use on streets or highways
Always signal your turns and stops early enough
to let other people know what you plan to do
Obey all traffic rules and regulations
K. Never operate vehicle in or near an area
where dust or fumes, which are explosive, are in
the air The electrical and exhaust systems of the
vehicle can produce sparks capable of igniting
explosive materials
13. The MULTI PRO® 1200 is equipped with a
Neutral Interlock Switch The purpose of this
switch is to insure that the vehicle will not start
unless the Range Selector is in the NEUTRAL
position and/or the Neutral Engine Speed Control
will not engage unless the Range Selector is in
the neutral position Should any of the following
occur:
A Vehicle will not start with Range Selector
in neutral
B Vehicle will start with Range Selector in
gear
C Neutral Engine Speed Control will engage
with Range Selector in gear
D Neutral Engine Speed Control will not
engage with Range Selector in neutral
See the Maintenance section for the Neutral
Interlock Switch, page 29
WHILE OPERATING:
WARNING: Do not run engine in a onfined
area without adequate ventilation. Exhaust
fumes are hazardous, and ould possibly be
deadly.
1. Operator should remain seated whenever the
vehicle is in motion Operator should keep both
hands on steering wheel whenever possible
Keep arms and legs within the vehicle body at all
times
2. Sit on seat when starting and operating the
vehicle
3. When starting the engine:
A. Engage the Parking Brake
B. Turn Key Switch to the "ON" position
C. Apply Service Brake
D. Put the Range Selector in the Neutral
Position and start the engine
E. After engine is started, select the
appropriate range
F. Release the Parking Brake
4. Operator must be skilled and trained in how
to drive on hillsides Failure to use caution on
slopes or hills may cause loss of control and
vehicle to tip or roll, possibly resulting in personal
injury or death

7
6. Do not touch Engine, Muffler, or Muffler
Shield while engine is running or soon after it has
stopped because these areas may be hot
enough to cause burns
7. If the vehicle ever vibrates abnormally, stop
immediately, turn off engine, wait for all motion
to stop, and inspect for damage Repair all
damage before commencing operation
8. Before getting off the seat:
A. Stop movement of the vehicle
B. While braking, set Parking Brake and
place Range Selector in the Neutral position
C. Shut engine off and wait for all movement
to stop
D. Remove Key from Ignition Switch
E. Do not park on slopes unless wheels are
chocked or blocked
SAFETY AND INSTRUCTIONS
6. Before disconnecting or performing any
work on the hydraulic system, all pressure in the
system must be relieved by stopping the engine
7. If major repairs are ever needed or assistance
is required, contact an Authorized TORO
Distributor
8. Disconnect battery before servicing the
vehicle If battery voltage is required for
troubleshooting, temporarily connect the battery
9. If the engine must be running to perform
maintenance, or an adjustment, keep hands, feet,
clothing, and any parts of the body away from
the engine and any moving parts Keep everyone
away
10. Do not over-speed engine by changing
Governor settings Maximum engine speed is
3350 no-load rpm To assure safety and
accuracy, have an Authorized TORO Distributor
check maximum engine speed with a tachometer
11. Shut engine off before checking or adding
oil to the crankcase
12. To assure optimum performance and
continued safety of the vehicle, always use
genuine TORO replacement parts and
accessories Replacement parts and accessories
made by other manufacturers could be
dangerous Altering this vehicle in any manner
may affect the vehicle's operation, performance,
durability, or its use may result in injury or death
Such use could also void the product warranty
of the TORO Company
13. This vehicle should not be modified without
The TORO Company's authorization Direct any
inquiries to:
Hahn Equipment Co.
A subsidiary of The TORO Company
1625 N Garvin Street
Evansville, IN 47711-4596
MAINTENANCE:
1. Before servicing, lubricating or making
adjustments to the vehicle, stop engine, set
Parking Brake and remove Key from Ignition
Switch to prevent someone from accidentally
starting the engine
2. Make sure the vehicle is in safe operating
condition, keeping all nuts, bolts, and screws
tight
3. To reduce potential fire hazard, keep the
engine area free of excessive grease, grass,
leaves, and accumulation of dirt Do not wash a
warm engine or electrical components
4. Make sure all hydraulic line connectors are
tight, and all hydraulic hoses and lines are in
good condition before applying pressure to the
system
5. Keep body and hands away from any pin
hole leaks in hydraulic lines that may eject high
pressure transaxle fluid Use cardboard or paper
to find hydraulic leaks Transaxle fluid escaping
under pressure can penetrate skin and cause
injury Fluid accidentally injected into the skin
must be surgically removed within a few hours
by a doctor familiar with this form of injury, or
gangrene may result
L. Watch out for and avoid low overhangs
such as tree limbs, door jambs, overhead
walkways, etc Make sure there is enough room
overhead to easily clear the vehicle and your
head
M. If ever unsure about safe operation,
STOP WORK and ask your supervisor

8
Part No 87-0570: Located on Rear
Tank Band
SAFETY AND INSTRUCTION DECALS
The following safety and instru tion de als are installed on the vehi le. If any be ome damaged
or illegible, repla e them. De al part numbers are listed below and in the parts atalog. Order
repla ements from your Authorized TORO Distributor.
Part No 93-0688: Located on
Spray Tank Lid
Part No 100-6775: Located on
Top of Fuel Tank
Part No 104-8750: Located on Lower
Front of Front Console
Part No 104-8882: Located On
Spray Valve Console Top
Part No 104-8749: Located On
Spray Valve Console Panel
Part No 100-8470: Located on
Upper Left Console
Part No 104-7628: Located on Left
Side of Dash Panel
THE TORO CO., 8111 LYNDALE AVE. S.
BLOOMINGTON, MN 55420-1196
104-7628
87-0570
93-0688
100-8470

9
SAFETY AND INSTRUCTION DECALS
The following safety and instru tion de als are installed on the vehi le. If any be ome damaged
or illegible, repla e them. De al part numbers are listed below and in the parts atalog. Order
repla ements from your Authorized TORO Distributor.
Part No 62-5550: Located on Front of
Front Console
Part No 100-8621:
Located on Dash Panel
Part No 100-8620: Located On Seat Mount Box Part No 100-8454: Located on
Lower Left Console
Part No 100-8577: Located on
Agitation Valve
Part No 100-6836: Located on
Tank by Tank Drain Handle
100-6836
N
100-8454
1. 3.
6. 7.
2.
4. 5.
1. 3.
2. 4.
2
31
R
N
N
2
31
R
N
100-8577
4
1
2
3
5
6
N
1260 lb
572 kg <1290 lb
<585 kg
350 lb
158 kg
<3500 lb
<1589 kg
100-8621
104-8902
Part No 104-8902: Located on Right Fender

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SPECIFICATIONS
Operator Ear Sound Level Measurement:
85 dBA
Noise: This unit has a continuous A weighted
sound pressure level at the operator ear of 85
dBA based on measurements of identical
machines per Directive 98/37/EC
Vibration: This unit does not exceed a vibration
level of 2 5 m/s2 at the hands based on
measurements of identical machines per ISO
5349 procedures
This unit does not exceed a vibration level of 0 5
m/s2 at the posterior based on measurements of
identical machines per ISO 2631 procedures
Vehi le: 4 Wheel, rear wheel drive, front steer,
single operator turf sprayer
Engine: 20HP Kohler V Twin horizontal shaft
governed to 3350 rpm, w/30 amp alternator,
accel pump carburetor
Battery: 12 volt with 360 cold cranking amps
@ 0° F
Fuel Capa ity: 5 gallon
Front Suspension: Full independent rubber
torsion swingarm
Rear Suspension: Rigid
Steering: Hydraulic power, center pivot
linkage
Tires:
Front: 18 x 9 5-8 slick
Rear: 24 x 13-12 Multi Trac
Brakes: 4 wheel hydraulic with dual chamber
master cylinder
ROPS: 2 Post Rollover Protection Structure
with Lap Safety Belt (optional)
Lights: Twin halogen headlights
Transmission: Integrated transaxle with 3
forward speed ranges and reverse
Ground Speed:
1st range: 0-3 1 mph
2nd range: 0-5 0 mph
3rd range: 0-11 0 mph
Sprayer Tank: 160 gallon tank, Inductive
Agitation, polyethylene material, large sump,
top controlled drain valve
Spray Pump: Diaphragm pump, proportional
ground speed control system 30 GPM @ 0 psi,
dry crankcase Can operate dry Self priming
Polyurethane diaphragms
Pressure Relief: Poppet style, 220 psi max
Su tion Filter: Top mounted for easy access,
50 mesh stainless steel
Control Valve: Manual rate adjustment, volu-
metric control for constant application rate
Boom Control Valves: Manual ON/OFF,
constant application rate with individual sec-
tions off
Agitation Control: Active agitation or return to
pump suction
Spray Appli ations Rate: Fast and accurate
response to ground speed changes
General Spe ifi ations (approx.):
Base Weight: Base unit 1260lbs
With standard spray sys
Without operator: dry 1610lbs
full 2900lbs
Maximum Gross Vehicle Weight: 3,500lbs
Measurements with Spray System:
Overall Width: 56
Overall Length: 120 with spray system
Height: Top of Tank 43"
Top of Boom "X" Pattern 74"
Ground Clearance: 4 5"
Wheel Base: 62
Inside Rear Tire Turning Diameter: 96"
Center of Gravity: 35" rear of the front axles
with unit empty and without booms or operator
Clut h: Centrifugally engaged variable belt
drive (CVT)