Residential and LCE Products 21 inch Aerator Service Manual
ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. For information specific to the engines used on this unit, refer to the appropriate engine manufacturer’s service and repair instructions.
ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
TABLE OF CONTENTS 1 - Safety Information General Information ������������������������������������������������������������������������������������������������������������������������������������� 1-1 Think Safety First ���������������������������������������������������������������������������������������������������������������������������������������� 1-1 2 - Specifications & Maintenance Specifications 2012-13 models (Serial 312000001 & up, Serial 313000001 & up) ������������������������������������� 2-1
TABLE OF CONTENTS 4 - Hydraulic & Engine Mounting Aerator Transaxle Subsystem �������������������������������������������������������������������������������������������������������������������������4-1 Transmission Replacement �����������������������������������������������������������������������������������������������������������������������������4-2 Transmission Removal ������������������������������������������������������������������������������������������������������������������������������4-2 Chan
SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because if has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro 30” Aerator.
SAFETY INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
SPECIFICATIONS & MAINTENANCE Specifications 2012-13 models (Serial 312000001 & up, Serial 313000001 & up) 21” Single Hydro Aerator Model: 23515 / 33515 Engine: 10.9 cu-in. (179cm³) Make Kawasaki Model FJ180V Hi-Idle 3600 RPM Low-Idle 1250-1550 RPM Spark Plug BPR6ES (NKG) Spark Plug Gap Oil Oil Capacity Starter Fuel Tank Volume 2 .030"/.76mm SAE 10W-30 0.6 Qt. (0.6 liters) Recoil Only 1.0 US gal (3.
SPECIFICATIONS & MAINTENANCE Specifications 2014 models (Serial 314000001 & up) 21” Single Hydro Aerator 2 Model: 23515 / 33515 Engine: 10.9 cu-in. (179cm³) Make Kawasaki Model FJ180V Hi-Idle 3700 + 50 RPM Low-Idle 1250-1550 RPM Spark Plug BPR6ES (NKG) Spark Plug Gap Oil Oil Capacity Starter Fuel Tank Volume .030"/.76mm SAE 10W-30 0.6 Qt. (0.6 liters) Recoil Only 1.0 US gal (3.
SPECIFICATIONS & MAINTENANCE Handle Adjustment (Serial 314000001 & up) The height of the handle can be adjusted for comfortable operation. Stand behind the handle to determine the appropriate height settings. 1. To adjust the handle height, position the hardware into one of three sets of holes on each side of the mainframe (Fig. 001, Fig. 002, and Fig. 003). C D B C C C D B A 2 A Fig. 002 fig. 8 G023052 Middle handle position C. Mounting bolt location A. Trunion bracket bottom hole D.
SPECIFICATIONS & MAINTENANCE C 2 C B Adjusting the Coring Depth (All Models) A A coring depth of 2-1/2” (6.35cm) is recommended, but you can change the depth as follows: 1. Stop engine, wait for all moving parts to stop. D Fig. 003 2. Disconnect the wire from the spark plug. 3. Loosen the nuts securing the wheel stop on the right side of the machine (Fig. 004). fig. 9 G023063 D Rear handle position - highest height A. Trunion bracket C. Mounting bolt location top hole D. Handle hardware B.
SPECIFICATIONS & MAINTENANCE 4. Lower the wheel stop to reduce the depth. Raise it to increase the coring depth and as required. Note: To ensure that the tines penetrate fully into the soil, weights can be added to the back of the machine. The machine has three weight pockets that hold the weights. When placing weight, ensure that the load is balanced; if using only one weight, place it in the center pocket and if using two, place them in the side pockets. Note: The removable weights are heavy.
SPECIFICATIONS & MAINTENANCE 5. The lower ball joint bolt, on the upper link rod, should be offset 1/4” (6mm) from the handle pivot bolt. If not, loosen the lock nuts on the lift link strap ball joints, adjust as necessary, and retighten locknuts (Fig. 006). 7. The ball joint on the tine-control lever should contact the handle firmly (Fig. 007); if not, proceed to step 8. B C B C A 2 6. Slide the oval locking rings upward on the handle and fold the handle towards the engine.
SPECIFICATIONS & MAINTENANCE Lift Drop Cable Adjustment 2012-13 models (Serial 312000001 & up, Serial 313000001 & up) 1. Adjust jam nut all the way to the end so no threads are showing. Adjust the yoke as far onto the rod as possible and re-tighten the jam against the yoke (A Fig. 009). 3. Adjust the lower nut all the way to the end so that one thread is showing at most. Tighten the internal nut to secure the cable to the bracket (C - Fig. 012). 4.
SPECIFICATIONS & MAINTENANCE Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil. Before each use or daily • • • • • • • • • • Check the engine oil level. Check the condition and tension of the tine drive chains. Check the condition of the front drive chains. Check the condition of the drive chain sprockets. Lubricate the tine drive chains.
SPECIFICATIONS & MAINTENANCE Accessing the Tines & Tipping the Machine The machine has a rear access panel that you can remove to access and maintain the tines (Fig. 014). If you need to work on the underside of the machine, you can tip it backward (Fig. 015). Do not tip the machine forward or you will foul the air cleaner with gasoline. Secure the machine with a jack stand before working under it. 2 A A Fig. 015 fig. 22 G017586 A. Jack stand ! Fig. 014 fig. 21 G023846 A.
SPECIFICATIONS & MAINTENANCE Greasing the Tine Shaft Bearings 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2. Remove the rear access panel. 2 3. Lubricate fittings with NGLI grade #2 multi-purpose gun grease. Refer to the following chart for fitting locations and lubrication schedule. Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval A. Tine Shaft A. Bearings 1 2 25 hours B. Tine B. Assembly B.
SPECIFICATIONS & MAINTENANCE 3. Rotate the front wheels and apply oil or chain lubricant onto the links of the lower spans of the front drive chains (Fig. 018). 4. Check the front drive chains (Fig. 018) for wear, damage, and proper tension. If chains pop or snap, replace the sprockets and chains. 5. Rotate tine shafts and apply oil or chain lubricant onto all the links of the lower spans of the tine drive chains (Fig. 018).
SPECIFICATIONS & MAINTENANCE Changing the Engine Oil 5. Remove the dipstick (Fig. 020). Oil Capacity 2 With oil filter 0.85 L (29 ounces) Without oil filter 0.65 L (22 ounces) 1. Run the engine to warm the engine oil. Note: Warm oil flows better and carries more contaminants. WARNING Fig. 020 Oil may be hot after engine has been run, and contact with hot oil can cause severe personal injury. fig. 25 G016924 6. Remove the drain plug (Fig. 021) and tip the machine so the oil flows to the pan.
SPECIFICATIONS & MAINTENANCE 7. Tip the machine upright again, clean the oil from the frame with a rag and replace the drain plug. 8. Slowly pour oil into the oil fill tube, periodically checking the level with the dipstick, until the dipstick indicates that the engine is full. Do not overfill. (Max. fill: 0.55 L (20 oz), type: SAE 10-w30 detergent oil with an API service classification of SH, SJ, SL, or higher.) Changing the Oil Filter 1. Drain the engine oil. 2. Place a rag under the oil filter (Fig.
SPECIFICATIONS & MAINTENANCE 3. Remove the oil filter. Servicing the Spark Plug 4. Use your finger to coat the gasket on the new filter with oil (Fig. 023). Use an NGK BPR6ES spark plug or equivalent. 1. Stop the engine and wait for all moving parts to stop. A 2 2. Disconnect the wire from the spark plug. 3. Clean around the spark plug. 4. Remove the spark plug from the cylinder head. Important: Replace a cracked, fouled, or dirty spark plug.
SPECIFICATIONS & MAINTENANCE Check the Spark Arrester (if equipped) ! WARNING ! Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage. DO NOT refuel or run engine unless spark arrester is installed. Emptying the Fuel Tank and Cleaning the Fuel Filter The fuel filter (screen) element is located inside the fuel tank. 1.
SPECIFICATIONS & MAINTENANCE 4. Disconnect the fuel line by loosening the tube clamp at the carburetor. 5. Open the fuel valve by turning the lever to the open position. 2 6. Drain the gasoline completely from the tank and fuel line into an approved fuel container. Replacing the Fuel Filter 1. Stop the engine and wait for it to cool down. Important: Drain gasoline from a cold engine only. 2. Disconnect the wire from the spark plug. 3. Close the fuel valve. 7. Remove the fuel tank from the machine. 8.
SPECIFICATIONS & MAINTENANCE Checking the Tire Pressure Maintain the air pressure in the tires as specified. Check the tires when they are cold to get the most accurate reading (Fig. 027). Pressure: 12-14 psi (83-97 kPa) A Adjusting the Tension of Tine Drive Chains 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2. Raise the front of the machine to gain access to the chains and block it in place.
SPECIFICATIONS & MAINTENANCE A. Loosen the nut securing the idler sprocket of the chain you are tensioning (Fig. 029). Checking the Hydrostatic Drive Belt 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2. Raise the front of the machine to gain access to the pump drive belt and block it in place. 2 ! A CAUTION ! If you do not securely block the up the front of the machine the machine could fall on you during service injuring you.
SPECIFICATIONS & MAINTENANCE 3. Push on a span of the drive belt with 20 pounds (9kg) of force (Fig. 030). If the belt flexes more than 1/8” (3mm), tighten it as follows: Adjusting the Machine Ground Speed 2012-13 models (Serial 312000001 & up, Serial 313000001 & up) 1. Loosen the 2 bolts securing the cable attachment bracket and slide it as far as possible to the left then tighten the 2 bolts (Fig. 031). A B A B Fig. 030 A. Pump drive belt B. Idler pulley C fig. 33 G013125 C. Idler pulley nut A.
SPECIFICATIONS & MAINTENANCE 2. Adjust the traction drive cable at the lower anchor by moving the nut to the end of the thread and tightening the jam nut (Fig. 032). 3. Adjust the traction drive cable at the handle as follows: • Loosen and remove the linkage adjustment from the bracket (Fig. 033). • Move the lower nut to the end of the thread (Fig. 033). 2 Note: Ensure that the bail will reach the handle after the transmission is engaged. AB Fig. 032 A. Nut A fig. 30 G020484 B. Jam nut Fig.
SPECIFICATIONS & MAINTENANCE 4. Adjust the reverse speed stop as follows: • Loosen the 2 nuts on the reverse speed stop (Fig. 034). • Move the stop down to the midpoint or slightly past it and tighten the 2 nuts (Fig. 034). Note: The reverse speed should be around 2.0 MPH (3.2km/h). Adjusting the Self-Propel Drive 2014 models (Serial 314000001 & up) 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2.
SPECIFICATIONS & MAINTENANCE Changing the Hydraulic Transmission Fluid See “Changing Transmission Oil” on page 4-5. Checking/Replacing Tines 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2. Remove the rear access panel. 2 3. Manually rotate the tines on the shaft, inspecting them for wear or damage. 4. If any are damaged or broken, remove the nut and bolt securing the tine to the tine assembly (Fig. 036). A C B Fig. 036 A. Tine assembly B. Tine fig.
SPECIFICATIONS & MAINTENANCE Troubleshooting Problem Possible Cause Engine will not start. 1. Move the throttle lever to the 1. The throttle lever is in the Off Choke position. position. 2. Connect the spark plug. 2. The spark plug is disconnected. 3. Open the fuel valve. 3. The fuel is turned off. 4. Release the traction lever so it 4. The traction lever is not in neutral. returns to neutral. The machine vibrates abnormally. 1. Loose bolts and/or broken parts. 1.
SPECIFICATIONS & MAINTENANCE 2 THIS PAGE INTENTIONALLY LEFT BLANK.
CHASSIS Handle Subsystem – 2012 (Serial 312000001 & up), 2013 (Serial 313000001 & up) (Fig. 037) C G 3 B D E F A Fig. 037 A. B. C. D. Toro 21” Aerator Service Manual Mount - Handle Handle - Assembly Tube - Control Tube - Lift, Handle subsystem handles 2012 E. Control - Throttle F. Cable - Lift, Lower G.
CHASSIS Handle Subsystem – 2014 (Serial 314000001 & up) (Fig. 038) A 3 1 B C 2 J 7 D E G I 9 G. Lower Handle Asm H. Link - Lift I. Ball Joint subsystem handles 1 J. Handle - Lower K. Rod - Upper Link 1 Do not overtighten leave 1 or 2 threads showing. Handle must still be able to pivot. 2 Push angle stop down as far as possible. 4 7 With the handle folded, adjust linkage (K) by hand until the ball join on the tine ground engagement lever is tight against the handle.
CHASSIS Engine Frame Subsystem – 2012 (Serial 312000001 & up), 2013 (Serial 313000001 & up) (Fig. 039) C L 3 F D A B K G H I E J Fig. 039 A. Frame - aerator 21” B. Stop-depth C. Cover - assembly D. Brackt-mount, cable E. Sprocket - idler F. Guard Toro 21” Aerator Service Manual J. G. Cover - transaxle H. Bracket - mount axle, K. RH I. Brocket - mount axle, L.
CHASSIS Engine Frame Subsystem – 2014 (Serial 314000001 & up) (Fig. 040) G 3 B A I H D E F C Fig. 040 A. Frame - service D. B. Stop - depth C. Sprocket - idler E. 3-4 Bracket - mount axle, RH Bracket - mount axle, LH subsys eng frame 2014 F. Pulley H. Cover, transaxle G. Weight - areator I.
CHASSIS Height Linkage Subsystem – Height Linkage - 2012 (Serial 312000001 & up), 2013 (Serial 313000001 & up) (Fig. 041) 3 F A G F E B C D Fig. 041 A. Shaft - pivot B. Arm - wheel C. Link - connecting D. Wheel - transport Toro 21” Aerator Service Manual E. Arm - lift F. Key - woodruff subsys ht linkage 2012a G.
CHASSIS Subsystem – Height Linkage - 2014 (Serial 314000001 & up) (Fig. 042) E F H 3 G B 4 2 6 D C 5 3 A 2 Fig. 042 A. B. C. D. Wheel - arm asm, LH Wheel - arm asm, RH Shaft - pivot Wheel - transport E. F. G. H. Arm - lift RH Foot guard Arm - guard, LH Arm - guard, RH 2 Wheel pivot arms must rotate freely on frame pivot pins (2x). 3 Pivot shaft assembly must rotate freely in frame bushings.
CHASSIS Drive Cable Removal & Installation 1. Remove the cotter key and pin from the drive handle. Loosen the lock nuts on the handle and remove cable (Fig. 043). 3. Install new cable. Install the linkage to the trans mission and install all of the lock nuts and tighten. Adjust the cable as follows: 4. Adjust the traction drive cable at the lower anchor by moving the nut to the end of the thread and tightening the jam nut (Fig. 045). 3 Fig. 043 drive cable 1 2.
CHASSIS 5. Adjust the traction drive cable at the handle as follows: • Loosen and remove the linkage adjustment from the bracket (Fig. 046). • Move the lower nut to the end of the thread (Fig. 046). Note: Ensure that the bail will reach the handle after the transmission is engaged. 6. Adjust the reverse speed stop as follows: • Loosen the 2 nuts on the reverse speed stop (Fig. 047). • Move the stop down to the midpoint or slightly past it and tighten the 2 nuts (Fig. 047).
CHASSIS Tine Control Cable Removal & Installation - Serial 312000001 & up, Serial 313000001 & up 1. Remove the cotter key and pin from tine control handle. Loosen the lock nuts that connects the cable to the handlebar and remove cable (Fig. 048). 3. Install new cable. Insert all pins and cotter keys, and finger tighten lock nuts into brackets. 4. Adjust the jam nut on the tine control bracket yoke so that no threads are showing then adjust the yoke as far onto the rod as possible.
CHASSIS 6. Adjust the jam nut on the handle bracket yoke so no threads are showing, then adjust the yoke as far onto the rod as possible and tighten the jam nut against the yoke (Fig. 052). 3 Fig. 052 upper jam nut 1a 7. Adjust the cable housing jam nuts so there are an equal number of threads on each side. Tighten the jam nuts (Fig. 053). Fig.
CHASSIS Adjusting Handle - Serial 314000001 & up The height of the handle can be adjusted for comfortable operation. Stand behind the handle to determine the appropriate height settings. C C D B A 1. To adjust the handle height, position the hardware into one of three sets of holes on each side of the mainframe as shown in Fig. 054, Fig. 055, and Fig. 056. C B C D A 3 Fig. 055 fig. 8 G023052 Middle handle position A. Trunion bracket C. Mounting bolt location bottom hole D. Handle hardware B.
CHASSIS Adjusting the Tine Control Lever Serial 314000001 & up 1. Stop engine, wait for all moving parts to stop. 5. The lower ball joint bolt, on the upper link rod, should be offset 1/4” (6mm) from the handle pivot bolt. If not, loosen the lock nuts on the lift link strap ball joints, adjust as necessary, and retighten locknuts (Fig. 058). 2. Disconnect the wire from the spark plug. 3. Raise the tines to the transport position. 3 4.
CHASSIS 6. Slide the oval locking rings upward on the handle and fold the handle towards the engine. 7. The ball joint on the tine-control lever should contact the handle firmly (Fig. 059); if not, proceed to step 8. BC A DE C B Replacing Pivot Shaft - Serial 312000001 & up, Serial 313000001 & up 1. Lower the tines to the ground to take pressure of the lift system. 2. Remove the tine control cable from the tine control bracket (Fig. 060). 3 F A Fig. 060 lift lower cable 2 3.
CHASSIS 4. Remove the snap ring and washer from the lift arm (Fig. 062). 6. Slide the wheel arm and lift arm off of the shaft (Fig. 064). 3 Fig. 062 lift arm snap ring_a 5. Loosen the set screws on the lift arm. Fig. 064 7. On the opposite side, remove the snap rings and washers from the wheel arm and lift arm (Fig. 065). Note: There are two set screws (Fig. 063). Fig. 065 Fig.
CHASSIS 8. Slide the pivot shaft out of the chassis by pulling on the wheel and lift arm assembly (Fig. 066). 10. Insert the shaft and wheel and lift arm assembly into the chassis (Fig. 068). 3 Fig. 066 remove pivot shaft_a 9. Once the pivot shaft is out, loosen the set screws on the lift arm and remove the wheel and lift arm assembly from the shaft. Replace the shaft with new, inserting it into the wheel and lift arm assembly (Fig. 067). Fig. 068 11.
CHASSIS 12. Once the shaft is through the chassis, re-install the wheel and lift arm assembly. Apply Loctite® 242 to the threads of the set screws and tighten them to 12-14 ft-lbs. (16-19 Nm). 13. Install all snap rings and washers (Fig. 070). Replacing Pivot Shaft - Serial 314000001 & up 1. Lower the tines to the ground to take pressure off the lift system. 2. Remove the two bolts from the right hand lift arm (Fig. 071). 3 Fig. 070 install snap rings_a Fig. 071 RH lift arm 3.
CHASSIS 4. Disengage the right hand lift arm (Fig. 073). 6. Remove the nut and bolt that connects the wheel arm assembly to the lift link (Fig. 075). 3 Fig. 073 RH arm remove Fig. 075 5. Remove the jam nut that is connected from the ball joint to the lift link (Fig. 074). Fig. 074 7. Remove the pivot shaft from the left side of the machine (Fig. 076). ball joint nut Fig.
CHASSIS 8. The pivot shaft and lift arm are one complete unit (Fig. 077). 10. Guide the shaft through the pivot shaft hole on the right hand side (Fig. 079). 3 Fig. 077 pivot shaft unit_a 9. Insert new shaft through LH side of machine (Fig. 078). Fig. 078 3-18 pivot shaft asm Fig. 079 RH side hole_a 11. Install the RH lift arm (Fig. 080). Fig.
CHASSIS 12. Install the snap ring (Fig. 081). 14. Install the nut and bolt that connects the wheel arm assembly to the lift link (Fig. 083). 3 Fig. 081 PS snap ring Fig. 083 13. Install the two bolts on the right hand lift arm (Fig. 082). Fig. 082 15. Install the jam nut that is connected from the ball joint to the lift link (Fig. 084). RH lift arm Fig.
CHASSIS Replacing the Front Drive Axle - All Models 4. With an Allen wrench, loosen the set screws on the lock collars on both sides (Fig. 087). 1. Jack the front of the unit up and place jack stands under the front frame. 2. Remove the snap rings and remove the front wheels (Fig. 085). 3 Fig. 087 lock collar 1_a 5. Insert a punch into the recess on the lock collar. Tap the punch with a hammer to loosen the lock collar. Remove lock collar (Fig. 088). Fig. 085 wheels_a 3.
CHASSIS 6. Remove the bolts securing the bearings and bearing flanges. Remove the bearings and flanges (Fig. 089). 8. Loosen the transmission mounting bolts as outlined in the “Transmission Removal” section on page 4-2. Loosen transmission enough to gain clearance to get the sprocket past the transmission. Pull the axle out. 9. Insert new axle into the chassis. 10. Tighten the transmission mounting bolts. 11. Reinstall the chain onto the transmission sprocket and the drive shaft sprocket.
CHASSIS 14. Install the lock collars onto the flange bearings. With a punch, tap the recess to securely lock the collar onto the bearing. Apply Loctite® 242 to the set screws and tighten to 12-14 in-lbs. (1.4-1.6 Nm) (Fig. 092). 3 Fig. 092 lock collar 3_a 15. Install the bushings and keys. 16. Install the wheels and snap rings.
HYDRAULICS & ENGINE MOUNTING Aerator Transaxle Subsystem (Fig. 093) C B 3 I H G 4 1 E 2 CK 4 4 A J 2 D J D 4 F C H C 4 C Fig. 093 A. Transaxle asm B. Shaft - wheel C. Bearing - lock, collar D. Sprocket E. Angle - control F. Wheel asm subsys_aerator transaxle G. Belt drive J. Chain - drive, wheel H. Sprocket asm K. Shaft - jack I. Bracket - support, shaft 1 Ensure belt is properly tensioned with no more than 1/4” deflection witih moderate 20 - 30 lbs. pressure.
HYDRAULICS & ENGINE MOUNTING Transmission Replacement 5. Disconnect the self-propel drive bail cable from the transmission (Fig. 095). Transmission Removal 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2. Drain the fuel from the fuel tank. Dispose of fuel in an approved container. 3. Slide the oval locking rings on the handle upward, and fold the handle towards the engine. 4.
HYDRAULICS & ENGINE MOUNTING 7. Remove the belt from the pulley by working it around the pulley (Fig. 097). Fig. 097 3a 8. Remove and retain the connecting link from the front axle chain sprocket. Remove chain (Fig. 098). Fig. 098 9. Loosen the drive chain idler sprockets on each side of the unit (Fig. 099). Fig. 099 4 10. Remove and retain the connecting link from the drive chains. Remove the drive chains from the transmission sprockets (Fig. 100). 4 Fig.
HYDRAULICS & ENGINE MOUNTING 11. Remove the bolts securing the bearing plate to the top of the deck (Fig. 101). Fig. 101 4 13. Remove the transmission from the chassis (Fig. 103). 7a Fig. 103 9 12. Remove the four bolts holding the transmission to the support brackets (Fig. 102). Fig.
HYDRAULICS & ENGINE MOUNTING Changing Transmission Oil 4. Remove the expansion tank and drain the oil. Service Interval: Every 100 hours Note: Do not remove the vent cap from the tank. 1. Carefully clean the area around the expansion tank and oil-fill port. It is important that no dirt or contamination enter the hydraulic system. Note: Do not remove the tank hose or O-ring unless a replacement is needed. 2.
HYDRAULICS & ENGINE MOUNTING 7. Fill the transmission at the oil-fill port until the oil level is 1/2 - 1 1/4 inches (13 - 32mm) below the top of the fill port (A) (Fig. 108). Servicing the Jack Shaft & Output Shaft Note: Toro Premium Hydro Oil is recommended. Mobil 1 15w-50 is an acceptable alternative. Jack Shaft & Output Shaft Removal 2. Remove the bolts that secure the bearings to the bearing plate. Remove the bolts that secure the bearing plate to the transmission (Fig. 109). A 4 Fig. 108 1.
HYDRAULICS & ENGINE MOUNTING 4. Loosen the set screws on the lock collar of the output shaft (Fig. 111). 6. Remove the lock collar (Fig. 113). Fig. 113 Fig. 111 5. Insert a pin punch into the recessed hole in the lock collar. Tap the punch to turn the collar to loosen the collar (Fig. 112). 7. Remove the bearing from the shaft and the output shaft from the transmission (Fig. 114). Fig. 114 Fig.
HYDRAULICS & ENGINE MOUNTING 10. Loosen the set screws on the large sprocket (Fig. 117). 8. Remove the lock collar and bearing from the jack shaft the same way as the output shaft (Fig. 115). Fig. 115 4 20a 9. Loosen the inner lock collar set screw. Insert a pin punch into the recessed hole of the lock collar and tap the collar to loosen it from the bearing (Fig. 116). Fig. 116 Fig. 117 11. Remove the jack shaft from the transmission. The sprocket is keyed.
HYDRAULICS & ENGINE MOUNTING Jack Shaft & Output Shaft Installation 1. Replace the needed parts. Re-install the output shaft and the jack shaft and install the chain. Leave the lock collars loose (Fig. 119). 3. The bearing plate to bracket support assembly dimension should be 5 inches from center-to-center on the mounting holes (Fig. 121). Fig. 121 Fig. 119 24a 4. The sprockets should be exactly aligned with one another (Fig. 122). 2. Install the bearing plate, bearings, and bearing retainers (Fig.
HYDRAULICS & ENGINE MOUNTING 5. Once the sprockets are aligned, apply Loctite® 242 to the set screws on the large sprocket. Tighten the set screws on the large sprocket to 100 in-lbs (11.5 Nm) (Fig. 123). 4 Fig. 123 1. With the transmission belt on the engine pulley and the idler pulley, loosely install the transmission using the previously removed mounting hardware (Fig. 125). 28a 6. Insert a pin punch into the recessed hole in the inner jack shaft lock collar.
HYDRAULICS & ENGINE MOUNTING 3. Install the drive chains onto the idler and trans mission sprockets. Insert the master link so that the spring clip is toward the outside of the machine and the opening is to the back of forward rotation. Do not tighten the chains at this time (Fig. 127). 5. Tighten the seven transmission mounting bolts. Torque to 17 ft-lbs. (23 Nm) (Fig. 129). A A Fig. 127 6a 4. Install the chain on the front axle sprocket.
HYDRAULICS & ENGINE MOUNTING 7. Tension the drive chains. Pull down on the idler sprocket until the slack is taken out of the chain. Tighten the idler sprocket nut and torque it to 30 ftlbs. (40.6 Nm) (Fig. 131). 9. Connect the self-propel drive bail cable (Fig. 133). A B Fig. 133 4 32a 10. Carefully remove the hoist hooks and lower the machine to the ground. Raise and lock the handle into the operating position. Fig. 131 A. Idler sprocket fig. 32 G023852 B. Nut 8. Inspect the flex in the chain.
HYDRAULICS & ENGINE MOUNTING Engine Subsystem (Fig. 135) C 4 B A 4 G F 3 D 6 3 1 E E 1 3 Fig. 135 A. Engine B. Tank mount assembly C. Tank assembly D. Pulley - driver E. Screw - set F. Valve - fuel 1 Torque to 114 + 12 in-lbs. (13 Nm) 3 Apply Loctite® 242 prior to tightening. Torque to 30 ft-lbs. (40 Nm). 4 6 subsystem_engine G.
HYDRAULICS & ENGINE MOUNTING Engine Replacement Engine Installation Engine Removal 1. Mount engine to chassis. Apply Loctite® 242 to engine mount bolts and insert bolts. Torque bolts to 30 ft-lbs. (40 Nm). 1. Drain the fuel from the fuel tank. Make sure fuel is disposed of in an approved container. 2. Disconnect the throttle cable from the engine (Fig. 136). 2. Re-install transmission as outlined in “Transmission Installation” in this chapter. 3. Connect the throttle cable to the engine. a.
TINE SYSTEM Tines Subsystem (Fig. 139) 7 D A 8 7 C E 3 4 G F B 5 2 5 Fig. 139 A. Tine - coring B. Sprocket - #40 C. Tine - wheel, LH D. Tine - wheel, RH subsystem_tines E. Asm - chain guard, RH G. Chain - drive F. Asm - chain guard, LH 2 Adjust idler position so chain is tight with 1/8” max deflection with 20 lbs. of force. 3 Zerk on tine shaft bearings must face top of unit. 4 Grease location.
TINE SYSTEM Checking/Replacing Tines 3. Manually rotate the tines on the shaft, inspecting them for wear or damage. 1. Raise the tines, stop the machine, stop the engine and disconnect the spark plug wire. 4. If any are damaged or broken, remove the nut and bolt securing the tine to the tine assembly. 2. Remove the rear access panel (Fig. 140). Fig. 140 5. Remove the tine and replace it with a new one. Ensure that the new tine is facing the same direction as the other tines on the assembly (Fig. 141).
TINE SYSTEM Tine Assembly Replacement 5. Loosen the drive chain idler sprockets on each side of the unit (Fig. 143). Tine Assembly Removal 1. Raise the tines, stop the machine, stop the engine, and disconnect the spark plug wire. 2. Drain the fuel from the fuel tank. Dispose of fuel in an approved container. 3. Slide the oval locking rings on the handle upward, and fold the handle towards the engine. 4.
TINE SYSTEM 7. Loosen the set screws on the lock collars (if applic able) on both sides of the machine. Insert a pin punch into the recess in the lock collars and tap until lock collars come loose (Fig. 145). 9. Remove all of the chain guard bolts (Fig. 147). Fig. 147 Fig. 145 5 38 40 10. Slide the snap rings on the tine shaft all the way to the outer stationary spyder (Fig. 148). 8. Loosen and remove the two nuts and bolts, then remove the lock collar bearings from both sides of the unit (Fig.
TINE SYSTEM 11. Loosen the flange bearing bolts and remove the nuts (Fig. 149). Fig. 149 42 13. Remove the tine assembly and chain guard (Fig. 151). Fig. 151 44a 12. Slide the inner spyder toward the outer stationary spyder (Fig. 150). 5 Fig.
TINE SYSTEM Tine Assembly Installation 3. Install the bearings and bearing flanges onto both tines using bolts and nuts. Torque bolts to 17 ft-lbs. (23 Nm) (Fig. 154). 1. Place the chain guard on the tine assembly and install into the chassis (Fig. 152). Fig. 154 Fig. 152 5 4. Position the chain guards and install all the bolts. Torque to 17 ft-lbs. (23 Nm) (Fig. 155). 2. Place the chain guard on the opposite side tine assembly and install into chassis.
TINE SYSTEM 5. Tighten the flange bearing bolts. Torque to 30 ft-lbs. (40 Nm) (Fig. 156). Fig. 156 7. If the unit has bearing lock collars, install the collar onto the bearing. Insert a pin punch into the recessed hole in the lock collar and tap it with a hammer in the forward motion of direction until snug. Apply Loctite® 242 to the set screw and tighten to 12-14 ft-lbs (16-19 Nm) (Fig. 158). 49a 6. Move the inner spiders all the way toward the flange bearings.
TINE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
21 inch Aerator Service Manual Form Number 492-9335
