Service Manual

ManualsBrandsToro ManualsAeratorsToro 29518

Table Of Contents

30 inch

Stand-On Aerator

Service Manual

Residential and

LCE Products

Summary of content (118 pages)

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Residential and LCE Products 30 inch Stand-On Aerator Service Manual
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ABOUT THIS MANUAL This service manual was written expressly for Toro and Lawn-Boy 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 additional information on the electrical system, please refer to the Toro Electrical Demystification Guide (4924761) and subsequent.
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ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
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TABLE OF CONTENTS 1 - Safety Information General Information �� 1-1 Think Safety First �� 1-1 2 - Specifications & Maintenance Torque Specifications ��
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TABLE OF CONTENTS 3 - Chassis Chassis ��3-1 Exploded View - Mainframe ��3-1 Lubricate Caster Wheel Hubs ��3-2 Caster Wheel
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TABLE OF CONTENTS 5 - Ground Drive & Tine Systems Ground Drive ��5-1 Subsystem Ground Drive ��5-1 Chains ��
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TABLE OF CONTENTS 6 - Electrical cont.
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SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because it 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.
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SAFETY INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
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SPECIFICATIONS & MAINTENANCE Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
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SPECIFICATIONS & MAINTENANCE Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 2 Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2
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SPECIFICATIONS & MAINTENANCE Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.
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SPECIFICATIONS & MAINTENANCE 30” Aerator Specifications 30” Stand-On Aerator 2 Models: 23518 / 33518 Engines: 36.8 cu-in. (603cm³) Make Kawasaki Model FS481 V-Twin Hi-Idle 3600 RPM Low-Idle 1250-1550 RPM Spark Plug BPR4ES (NKG) Spark Plug Gap Oil Oil Capacity Starter Fuel Tank Volume .030"/.76mm SAE 10W-30 1.8 Qt. (1.7 liters) Electric Only 5.0 US gal (18.9 L) Power System: Transmission Hydro-Gear ZT3400 Hydraulic Fluid Toro Hydro Oil Hydraulic Fluid Capacity 70.3 oz.(2.
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SPECIFICATIONS & MAINTENANCE Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil. After the first 100 hours • Change the auxiliary hydraulic reservoir filter and fluid. • Change the hydraulic transmission filter and fluid. Before each use or daily • Check the engine oil level. • Check the safety interlock system. • Check for loose hardware. • Lubricate the chains. • Check the condition and tension of the chains.
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SPECIFICATIONS & MAINTENANCE Premaintenance Procedures Lubrication Note: Shut off engine, wait for all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit. Lubricate Chains 2 Service Interval: Before each use or daily Important: Do not lubricate chains with penetrating oil or solvents. Use oil or chain lubricant.
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SPECIFICATIONS & MAINTENANCE Lubricate Grease Fittings A Note: See chart for service intervals. B C D 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Lubricate fittings with NGLI grade #2 multi-purpose gun grease. 2 H Refer to the following chart for fitting locations and lubrication schedule. Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval A. Front Caster Pivots *0 2 Yearly B.
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SPECIFICATIONS & MAINTENANCE Lubricate Caster Wheel Hubs 5. Pry out seals, and inspect bearings for wear or damage and replace if necessary. Service Interval: Yearly 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2 2. Remove caster wheel from caster forks. 3. Remove seal guards from the wheel hub (Fig. 002). 4. Remove one of the spacer nuts from the axle assembly in the caster wheel (Fig. 002).
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SPECIFICATIONS & MAINTENANCE Engine Maintenance Service Air Cleaner Service Interval: Every 250 hours - Replace the primary air cleaner element - check secondary air cleaner element; replace if dirty. (May need more often under severe conditions. See the Engine Owner’s Manual for additional information.) Every 500 hours - Replace the secondary air cleaner element. (May need more often under severe condi tions. See the Engine Owner’s Manual for additional information.) 1.
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SPECIFICATIONS & MAINTENANCE 2 Fuel System Maintenance Electrical System Maintenance Change Fuel Filter Check Battery Charge A fuel filter is installed in the fuel line between the fuel tank and the engine. Replace when necessary. Service Interval: Monthly Note: It is important to reinstall the fuel line hoses and secure in place, the same way as originally installed at the factory, to keep the fuel line away from components.
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SPECIFICATIONS & MAINTENANCE Drive System Maintenance Check Condition Of Chains Check Tire Pressures Service Interval: Before each use or daily Service Interval: Every 50 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Check tire pressure in drive tires. 2. Check the chains on both sides of the unit for proper tension.
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SPECIFICATIONS & MAINTENANCE Jackshaft Drive Chain Tension Adjustment 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2 2. Lift the rear of the unit and support using jack stands or equivalent support. 3. Check the chains on both sides of the unit for proper tension. The chains should be able to move up and down 6-12mm (1/4”-1/2”). 5. Turn the adjustment bolt to move transmission adjustment plates and hydros.
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SPECIFICATIONS & MAINTENANCE Drive Wheel Chain Tension Adjustment Brake Maintenance 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Adjusting the Parking Brake 2. Lift the rear of the unit and support using jack stands or equivalent support. 3. Check the chains on both sides of the unit for proper tension. The chains should be able to move up and down 1/4”-1/2” (6-12mm). If the parking brake does not hold securely, an adjustment is required. 1.
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SPECIFICATIONS & MAINTENANCE 2 Adjusting the Brake Switch Belt Maintenance 1. Park the machine on a level surface. Check Condition & Tension Of Belts 2. Shut off the engine and wait for all moving parts to stop. Service Interval: Every 50 hours 3. Prior the adjusting the brake switch ensure the parking brake is properly adjusted. See “Adjusting the Parking Brake” on page 3-13. 4. Engage the parking brake. 5. Check the distance from the parking brake switch bracket to the hydro brake arm.
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SPECIFICATIONS & MAINTENANCE Controls System Maintenance Motion Control Linkage Adjustment 1. Park the machine on a level surface. 2. Shut off engine and wait for all moving parts to stop. 3. Push the control levers all the way forward to the front reference bar. • If the control levers contact the reference bar, allow the control levers to return to neutral. Remove the spring clevis pin on the turnbuckle of the motion control linkage.
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SPECIFICATIONS & MAINTENANCE Hydraulic System Maintenance Change Auxiliary Hydraulic Reservoir Fluid and Filter Check Auxiliary Hydraulic Oil Level Service Interval: After the first 100 hours Every 250 hours thereafter Service Interval: Every 50 hours 2 1. Lower the tines to the ground. 2. Stop engine and wait for all moving parts to stop, and remove key. Engage parking brake. 3. Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the baffle inside the tank.
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SPECIFICATIONS & MAINTENANCE Change Hydraulic Transmission Filters and Fluid Service Interval: After the first 100 hours Every 250 hours thereafter 1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake. 2. Locate the two filters under the transmissions. Remove filter guards. 3. Carefully clean area around filters. It is important that no dirt or contamination enter hydraulic system. 4.
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SPECIFICATIONS & MAINTENANCE Tine Maintenance Check Tines Service Interval: Before each use or daily 2 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Lift the rear of the unit and support using jack stands or equivalent support. Caution Raising the unit for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous.
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CHASSIS Chassis Exploded View - Mainframe (Fig. 008) E D K F H A B HI 3 J G C 1 Fig. 008 A. B. C. D. Main frame assembly Front caster assembly Weight Access cover 1 E. F. G. H. Muffler guard Guard - chain, RH Guard - chain, LH Plate, serial no. (1x5) subsystem mainframe_smr I. Plate, serial no. (1x2.88) J. Tube, manual K. Platform assembly Bolt installed from the bottom in this location only.
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CHASSIS Lubricate Caster Wheel Hubs 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove caster wheel from caster forks. 3. Remove seal guards from the wheel hub (Fig. 009). 8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do not thread spacer nut all of the way onto the end of the axle.
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CHASSIS Caster Wheel Assembly Replacement 3. Remove the caster fork and wheel assembly. Caster Wheel Assembly Removal 4. Remove the three Belleville washers from the caster wheel pivot tube (Fig. 012). 1. Remove the grease cap from the top of the caster wheel pivot tube (Fig. 010). 3 Fig. 012 Fig. 010 DSC-00139 DSC-00142 5. Remove the upper tapered roller bearing from the caster wheel pivot tube (Fig. 013). 2. Remove the nut from the caster fork shaft (Fig. 011). Fig. 013 Fig.
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CHASSIS 6. Remove the grease seal from the bottom of the caster wheel pivot tube (Fig. 014). 8. If replacing the wheel bearings, use a blunt punch to remove the upper and lower bearing cups from the caster wheel pivot tube (Fig. 016). 3 Fig. 014 DSC-00146a Fig. 016 7. Remove the lower tapered roller bearing (Fig. 015). Fig. 015 9. Remove the nut securing the caster wheel axle bolt, then remove the axle bolt (Fig. 017). DSC-00149 Fig.
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CHASSIS 10. Remove the caster wheel assembly from the caster fork. 12. Remove the spacer nut from the caster axle (Fig. 019). 11. Remove the seal guard from both sides of the wheel hub (Fig. 018). 3 Fig. 019 Fig. 018 DSCN-0377a Note: The spacer nuts are both threaded onto the caster axle. One of the spacer nuts will need to be removed after it has been removed from the caster wheel (Fig. 020). Fig.
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CHASSIS 13. Remove the grease seal from both sides of the caster wheel (Fig. 021). Caster Wheel Assembly Installation 1. Pack the caster wheel tapered roller bearing with high temperature grease (Fig. 023). 3 Fig. 021 DSCN-0387a 14. Remove the LH and RH tapered bearings (Fig. 022). Fig. 023 DSCN-0407a 2. Install the bearing into the wheel hub (Fig. 024). Fig. 022 DSCN-0389a Fig.
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CHASSIS 3. Install grease seal into the wheel hub (Fig. 025). 6. Position the caster axle through the bearing and seal assembly (Fig. 027). 3 Fig. 025 DSCN-0393a Fig. 027 4. Repeat steps 1, 2, and 3 on the other side of the caster wheel. 5. Fill the center of the wheel hub with high tempera ture grease (Fig. 026). Fig. 026 7. Install a spacer nut onto both ends of the caster axle (Fig. 028).
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CHASSIS 8. Position the seal guard onto both sides of the caster wheel hub (Fig. 029). 10. Install the upper and lower bearing cups into the pivot tube (Fig. 031). 3 Fig. 029 DSCN-0377a 9. Secure the caster wheel assembly to the caster fork using the axle bolt and nut (Fig. 030). Fig. 030 3-8 DSCN-0376a Fig. 031 DSCN-0410a Note: A socket can be used as a driver. Take care not to scar the race surface (Fig. 032). Fig.
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CHASSIS 11. Pack the pivot tube tapered roller bearings with high temperature grease (Fig. 033). 13. Install grease seal into the base of the pivot tube (Fig. 035). 3 Fig. 033 DSCN-0407a 12. Install the lower bearing into the pivot tube (Fig. 034). Fig. 034 Toro 30” Aerator Service Manual DSCN-0416a Fig. 035 DSCN-0414a 14. Install the upper bearing into the pivot tube (Fig. 036). Fig.
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CHASSIS 15. Install the 3 Belleville washers into the pivot tube (Fig. 037). 16. Insert the caster wheel and fork assembly through the pivot hub (Fig. 039). 3 Fig. 037 washers Note: Bottom: Crown Up / Middle: Crown Down / Top: Crown up (Fig. 038). Fig. 038 3-10 DSCN-0423a Fig. 039 insert wheel 17. Secure the caster wheel and fork assembly with the nut (Fig. 040). Fig.
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CHASSIS 18. Tighten locknut until spring washers are flat (15 ftlbs./20 Nm) and then back off a 1/4 turn to properly set the pre-load on the bearings. 21. Fill the pivot hub cavity until grease is purging out through the upper bearing (Fig. 043). 19. Remove the plug from the side of the pivot hub (Fig. 041). 3 Fig. 043 DSCN-0438a 22. Replace the grease zerk with the plug (Fig. 044). Fig. 041 DSCN-0436a 20. Install a grease zerk into the port on the side of the pivot hub (Fig. 042). Fig.
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CHASSIS Exploded View – Tower (Fig. 046) C E 3 B D G F A Fig. 046 A. B. C. D. 3-12 LH side panel assembly RH side panel assembly Assembly - console Cushion subsystem tower E. Control - choke F. Cable - brake G.
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CHASSIS Adjusting the Parking Brake Adjusting the Brake Switch If the parking brake does not hold securely, an adjust ment is required. 1. Park the machine on a level surface. 1. Park the machine on a level surface. 2. Shut off engine and wait for all moving parts to stop. 3. Check the air pressure in the drive tires. If needed, adjust to the recommended inflation. 4. Disengage the parking brake. 5. Loosen the adjustment nut on the brake cable under the console. 2.
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CHASSIS Fuel System Engine Fuel Line Routing (Fig. 049) (Fig. 050) A B B 2 D 3 A 1 C C Fig. 050 A. Emissions hose B. Fuel hose Fig. 049 A. Support, fuel tank B. Fuel tank assembly 1 2 3-14 subsystem fuel C. Emissions filter fuel tank C. Clamp D. Valve, fuel Torque fuel tank clamp bolts to 200 + 25 in-lbs. (27.5 + 2.8 Nm). Install filter matching flow direction ( ).
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CHASSIS Motion Control System (Fig. 051) I A B 3 F G E C D H 1 Fig. 051 A. RH control handle assembly B. LH control handle assembly C. Bell crank with arm 1 D. Link, hydro control E. Link, bell crank control F. Link, bell crank control subsystem motion control G. Yoke, linkage, brake H. Damper, control, motion I. Grip, lever, control Apply grease to bell crank. Note: use Mobil™ high temperature XHP 222 grease (or equivalent).
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CHASSIS Motion Control Linkage Adjustment 4. Once there is a minimal gap or contact between the control lever and front reference bar, remove clevis spring and rotate the turnbuckle clockwise (as viewed from the top of the machine) one full turn. 1. Park the machine on a level surface. 2. Shut off engine and wait for all moving parts to stop. 3. Push the control levers all the way forward to the front reference bar (Fig. 052). 5.
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CHASSIS Axle Bearing Assembly Replacement 4. Remove the four nuts securing the axle sub assembly to the frame (Fig. 056). Axle Bearing Assembly Removal 1. Position the unit in the work area, raise and secure the back of the unit as high as possible using two jack stands to support the unit (Fig. 054). 3 Fig. 056 Fig. 054 IMG-1044 IMG-1048a 5. On the underside of the unit, loosen the nut for the chain tensioner and slide the tensioner to the top of the slot (Fig. 057). 2.
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CHASSIS 6. Remove two tines from the outside spider that are in-line to each other (Fig. 058). It is not necessary to remove the connector link from the chain if it is not being replaced. Work the chain off the sprocket and let it drop down. 3 Axle Bearing Assembly Installation 1. If installing an axle and bearing assembly, proceed to step 3. Replacing a damaged wheel axle first remove it from the wheel bearing mount. Check to make sure the grease seals are not damaged.
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CHASSIS 3. Slide the axle assembly inward (it will be necessary to cock the unit at an angle to get the rear tine stub shaft hooked behind the sprocket). As you rotate the tines clockwise to install the unit (Fig. 061). 5. Install the four screws securing the axle assembly back in position, install the four nuts and tighten securely (Fig 063). 3 Fig. 063 Fig. 061 4. Reinstall the chain onto the sprocket and replace the two tines that were previously removed (Fig. 062). Fig.
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CHASSIS 7. Re-install the wheel hub to the axle and torque the lock nut to 310-325 ft-lbs. (420-440 Nm) (Fig 065). 3 Fig. 065 IMG-1045a 8. Install the tire and torque the lug nuts to 125-130 ftlbs. (169-176 Nm). 9. Lower the unit to the ground, test drive and re-check the chain tension.
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HYDRAULICS & ENGINE MOUNTING Hydraulics (Fig. 066) See engine “Hydraulic Pump Belt Removal and Installation” as shown in this chapter. Hydraulic Subsystem D B 10 4 A C E 5 3 4 F G 7 Fig. 066 subsystem hydraulic Bottom view engine pump pulley & idler A. Reservoir assembly B. Valve manifold with check & relief C. Hyd cylinder assembly D. Gauge, pressure E. F. G. H. Pump, hydraulic Belt Pulley Filter 3 Apply film of hydraulic oil to hydraulic oil gasket prior to installation.
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HYDRAULICS & ENGINE MOUNTING Valve Manifold Bottom view engine pump pulley and idler (Fig. 067) A B D 4 C Fig. 067 A. B. C. D.
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HYDRAULICS & ENGINE MOUNTING Auxiliary Hydraulic Subsystem (Fig. 068) 4 Fig.
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HYDRAULICS & ENGINE MOUNTING Checking the Transmission Expansion Tank Hydraulic Oil Servicing the Auxiliary Hydraulic Oil Service Interval: Every 50 hours Service Interval: Every 50 hours 1. Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system. 2. Let the unit cool. With the unit cold, check the expansion tank and if necessary add Toro Hydro Oil to the Full Cold line. DO NOT OVERFILL. 3. Replace the hydraulic reservoir cap and tighten until snug.
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HYDRAULICS & ENGINE MOUNTING 4. Check the hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Toro Hydro Oil (Fig. 071). Note: Hydraulic oil fill level to be between “COLD” baffle and down a 1/4” below. Check with the aerator tines down (resting on the ground) and fluid temperature at 71o + 10oF (21.6 + 6.6oC). 5. Replace the hydraulic reservoir cap and tighten until snug. DO NOT OVERTIGHTEN. 6.
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HYDRAULICS & ENGINE MOUNTING Changing Auxiliary Hydraulic Reservoir Fluid and Filter 4. Unscrew the filter to remove and allow oil to drain. Service Interval: After the first 100 hours, every 250 hours thereafter 1. Stop engine, wait for all moving parts to stop. Remove key and spark plug wires. Engage parking brake. 5. Apply a thin coat of Toro Hydro Oil to the surface of the rubber seal on the new oil filter.
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HYDRAULICS & ENGINE MOUNTING Changing Hydraulic Transmission Filters and Fluid Service Interval: After the first 100 hours, every 250 hours thereafter Hydraulic Transmission Filter Removal 1. Stop engine, wait for all moving parts to stop. Remove key and spark plug wires. Engage parking brake. Hydraulic Transmission Filter Installation 1. Apply a thin coat of Hydro Oil to the surface of the rubber seal on the new oil filter.
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HYDRAULICS & ENGINE MOUNTING 4. Raise the rear of the machine up and support with jack stands (or equivalent support). Raise just high enough to allow the drive wheels to turn freely. Transmission Belt Replacement Transmission Belt Removal 1. Blow dirt and debris off unit especially in the drive belt area. CAUTION Raising the unit for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous.
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HYDRAULICS & ENGINE MOUNTING 5. Remove the stationary idler on the RH side of the unit completely and set aside (Fig. 079 and Fig. 080). 6. Remove the front two transmission support plate bolts. Install the two nuts, finger tight (Fig. 081 and Fig. 082). Fig. 079 IMG-0012 Fig. 081 IMG-0017 Fig. 080 IMG-0011 Fig.
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HYDRAULICS & ENGINE MOUNTING 7. Position the floor jack under the front of the trans mission skid plate and apply slight upward pressure (Fig. 083). Fig. 083 4 4-10 IMG-0019 8. Remove the tension on the drive chains on both sides (Fig. 084 and Fig. 085). Fig. 084 IMG-0020a Fig.
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HYDRAULICS & ENGINE MOUNTING 9. Remove the front two nuts on each of the chain tensioner plates on the top side and loosen the back one until the nut is free from the nyloc portion (Fig. 086). Fig. 086 Transmission Belt Installation 1. Install the new belt around the engine and LH pump drive sheave and hook it on the lip of the idler arm pulley. Slowly raise the floor jack. The last pulley the belt will slip on, is the RH pump drive sheave (Fig. 088). 4 IMG-0022a 10.
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HYDRAULICS & ENGINE MOUNTING 4. Reinstall the stationary idler (Fig. 090). 6. Adjust the chain tension on both sides with the tensioner so chains have 1/4 - 1/2” deflection. Do not over tighten the chains. Do a final check for equal tension on both sides before tightening the 6 nuts (three on each side) and the two in front. See “Transaxle Chain Tensioning” as shown in this chapter. 7. Recheck chains one more time and set the jam nuts on the tensioners. 8.
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HYDRAULICS & ENGINE MOUNTING Transmission Replacement 3. Loosen the two transmission support plate bolts at the front of the machine (Fig. 095). Transmission Removal 1. Raise the front of the unit and support with jack stands (Fig. 093). Fig. 095 Fig. 093 IMG-0004 2. Remove the parking brake cable by loosening the jam nuts and feeding cable through opening (Fig. 094). front mount bolts 4. Loosen the chain tensioners on both sides of the machine. a.
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HYDRAULICS & ENGINE MOUNTING b. Loosen the three mounting bolts on each side of the machine (Fig. 097). 6. Rotate the rear wheels until the transaxle chain master link is accessible (Fig. 099). IMPORTANT: Do not remove the bolts at this time. Fig. 099 4 Fig. 097 tightener bolt 5. Remove the right and left side chain guards (Fig. 098). Fig. 098 7. Remove the master link and remove chain. Repeat for the opposite side of the machine. 8.
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HYDRAULICS & ENGINE MOUNTING 9. Remove the two bolts securing the pivot arm tensioner and remove tensioner and spring (Fig. 101). Fig. 101 11. Disconnect hydro hoses from the overflow tank and plug the openings (Fig. 103). Ensure shop towels or rags are available to wipe up any fluid spills. Dispose of used towels properly (Fig. 104). tensioner Fig. 103 hose Fig. 104 towel 10. Remove the stationary idler on the RH side of the unit (Fig. 102). Fig.
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HYDRAULICS & ENGINE MOUNTING 12. Disconnect the parking brake switch wire connector (Fig. 105). Fig. 105 4 14. Remove the two front mount bolts and the three mounting bolts on each side of the machine (Fig. 107). connector Fig. 107 13. Support transaxle with a jack (Fig. 106). Fig. 106 15. Slowly lower the jack to gain access to the drive belt. While lowering, work the belt off the PTO shaft of the engine (Fig. 108). Once the belt is off, lower the transaxle out of the chassis. IMG-0019 Fig.
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HYDRAULICS & ENGINE MOUNTING Transmission Installation 1. Place transaxle on a floor jack and position it under the frame so that the bolts line up through the slotted mounting holes (Fig. 109). 3. Raise the transaxle up through the mounting holes. Install the front mounting bolts, the transmission adjuster plates, bolts and nuts. Tighten the bolts finger tight (Fig. 111). Fig. 111 Fig. 109 IMG-0019 2. Slowly raise the transaxle until the bolts are almost to the frame.
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HYDRAULICS & ENGINE MOUNTING 5. Install the pivot arm tensioner (Fig. 113). Torque bolts to 20 ft-lbs. (27 Nm). Tighten the compression spring until the spring measures 2-3/8” with a new belt. After run-in, recheck the spring and it should not be more than 2-5/8”. A 4 Fig. 113 7. Install the park brake cable (Fig. 115). Fig. 115 tensioner A. 2-3/8” park brake 8. Insert the ball of the park brake cable thriough the park brake yoke and install yoke as shown between the two transaxles (Fig. 116). 6.
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HYDRAULICS & ENGINE MOUNTING 9. Reconnect the parking brake switch wire connector (Fig. 117). Fig. 117 11. Install both chains. Install the connecting link so the cover plate and spring clip are to the OUTSIDE of the machine. The split end of the chain clasp MUST be oriented AWAY from the forward direction of chain travel (Fig. 119). connector Fig. 119 10. Reconnect the hydro hoses to the overflow tank (Fig. 118). chain install (Fig. 120) Fig. 118 hose Fig.
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HYDRAULICS & ENGINE MOUNTING Transaxle Chain Tensioning 3. Tighten until the chain has between 1/4” and 1/2” deflection (Fig. 122). 1. Tighten the front mounting bolts and the trans mission adjustment plate bolts on both sides of the unit tight, then loosen them one turn. 2. Turn the adjustment bolt to move the transmission adjustment plates and hydros (Fig. 121). A B C 4 Fig. 121 trans adj plate E D Fig. 122 fig. 16 G020261 A. Hydro mounting bolts D. 6-12mm (1/4”-1/2”) & nuts E.
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HYDRAULICS & ENGINE MOUNTING 4. When the correct deflection is achieved, tighten the front mounting bolts and transmission adjustment plate bolts on both sides to 35 ft-lbs. (48 Nm). Hydraulic Pump Belt Removal & Installation 5. Check the deflection on the chains again. If they are too tight, loosen the mounting bolts one turn and loosen the chains using the adjustment bolt. Retorque the mounting bolts to 35 ft-lbs. (48 Nm) and check deflection again. 1.
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HYDRAULICS & ENGINE MOUNTING 5. Reinstall the fixed idler. The idler needs to be pushed into the belt hand tight when the fastener is tightened (minimum 15 lbs.) (Fig. 126). (bottom view) Idler Arm Removal & Installation 1. Lower the transaxle as outlined in the “Transmission Belt Replacement” section of this chapter. 2. Remove the idler arm mounting nut (Fig. 127). Note: The transaxle has been removed for picture clarity. 4 Fig. 127 Fig. 126 engine pump pulley & idler tensioner idler 3.
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HYDRAULICS & ENGINE MOUNTING Return to Neutral Setting ! WARNING 3. Start the engine and increase the throttle to full engine speed. ! Potential for Serious Injury Inattention to proper safety, operation, or main tenance procedures could result in personal injury, or damage to the equipment. Berfore ser vicing or repairing the transaxle, fully read and understand the safety precautions described in this section.
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HYDRAULICS & ENGINE MOUNTING Hydraulic Pump Rebuild (Fig. 129) DE B A 4 K G M N H F C J L I Fig. 129 A. B. C. D. Snap ring Shaft seal Front cover Antiextrusion 4-24 E. F. G. H. Upper seal Thrust plate Key Drive shaft I. J. K. L. Driven gear Thrust plate Seal Antiestrusion hyd pump asm M. Body N.
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HYDRAULICS & ENGINE MOUNTING 1. Ensure you have all the parts necessary to rebuild pump (Fig. 130). Fig. 130 0001_a 2. Remove the rear cover (Fig. 131). Fig. 131 3. Remove the body and thrust plate assembly (Fig. 132). Fig. 132 4. Remove the O-ring from one side of the body (Fig. 133). 0002_a Fig.
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HYDRAULICS & ENGINE MOUNTING 5. Replace the O-ring with new (Fig. 134). Fig. 134 4 8. Replace with new seal and antiestrusion (Fig. 136). 0005_a 6. Remove and replace the O-ring on opposite side. 7. Remove the seal and antiestrusion from the thrust plate assembly (Fig. 135). Fig. 136 9. Remove the key from the drive shaft and remove drive shaft and thrust plate from the front cover (Fig. 137). Fig. 137 Fig.
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HYDRAULICS & ENGINE MOUNTING 10. Remove the upper seal and antiextrusion and replace with new (Fig. 138). Fig. 138 12. Remove the seal (Fig. 140). 0009_a Toro 30” Aerator Service Manual 0011_a 4 13. Install new seal (Fig. 141). 11. Remove the snap ring (Fig. 139). Fig. 139 Fig. 140 0010_a Fig.
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HYDRAULICS & ENGINE MOUNTING 14. Install the snap ring (Fig. 142). Fig. 142 4 0010_a 15. Reassemble pump. Hydraulic Pump Assembly (Fig. 143) Torque bolts to 14-18 ft-lbs. (19-25 Nm). Fig.
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HYDRAULICS & ENGINE MOUNTING Hydraulic Cylinder Rebuild (Fig. 144) B C 4 A Fig. 144 Hyd cyl removal A. Hydraulic cylinder assembly B. Assembly, hydraulic hose C.
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HYDRAULICS & ENGINE MOUNTING 1. Remove the hydraulic cylinder from the chassis. Make sure to wipe up any hydraulic oil spills with towels and dispose of them properly. Plug the hydraulic hoses to keep them free of dirt and debris. Drain the oil from the cylinder into an approved container. 4. Put the yoke of the piston assembly in a vise. Remove the retaining nut (Fig. 147). 2. Put the cylinder in a vise. Insert the tabs of a spanner wrench into the holes on the top cover of the cylinder.
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HYDRAULICS & ENGINE MOUNTING 6. With a pick, remove and replace the inner shaft O-ring (Fig. 149). Fig. 149 o-ring_a 7. Remove and replace the yellow outer band and the black inner band (Fig. 150). Fig. 150 Toro 30” Aerator Service Manual 8. Remove and replace the large O-ring and flat O-ring (Fig. 151). Fig. 151 large o-ring_a 4 9. Remove and replace the inner wiper (Fig. 152). Fig.
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HYDRAULICS & ENGINE MOUNTING 10. Remove and replace the top seal (Fig. 153). Fig. 153 4 12. Install the piston assembly into the cylinder. Align the retaining ring catch hole with the retaining ring slot on the side of the cylinder and push down on piston cover until flush with the top of the cylinder slot (Fig. 155). top seal_a 11. Install the piston stack onto the piston shaft. Install the nut and torque the nut to 50 ft-lbs (69 Nm) (Fig. 154). Fig. 155 slot_a 13.
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HYDRAULICS & ENGINE MOUNTING 14. Using the spanner wrench, turn the the top cover of the cylinder until the retaining ring is fully seated into the slot (Fig. 157). Fig. 157 spanner 1_a 4 15. Install cylinder into chassis. Connect the hoses and fill the hydraulic reservoir with oil. Start the unit and purge the system of any air. Check for leaks.
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HYDRAULICS & ENGINE MOUNTING Engine Engine Mounting (Fig. 158) A 1 4 B 3 4 C Fig. 158 A. Engine oil drain hose assembly with plug B. Screw - engine mount C. Screw - pulley 4-34 engine mounting 1 Torque 26 + 3 in-lbs. (3 Nm) 2 Adjust high idle 3600 + 50 3 Torque to 17 - 23 ft-lbs. (23 - 31 Nm) 4 Torque to 55 + 6 ft-lbs.
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HYDRAULICS & ENGINE MOUNTING Engine Pulley (Fig. 159) A B 4 C D D E Fig. 159 A. Pulley B. Key C. Washer, clutch Toro 30” Aerator Service Manual engine pulley D. Washer, spring (2) E.
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HYDRAULICS & ENGINE MOUNTING Engine Replacement 3. Disconnect the fuel line and the emissions line from the engine (Fig. 162). Engine Removal 1. Remove positive (+) and negative (-) cables from battery (Fig. 160). Fig. 162 4 Fig. 160 pos cable lines 4. Disconnect the positive (+) wires from the starter solenoid and secure out of the way (Fig. 163). 2. Turn off fuel valve (Fig. 161). Fig. 163 Fig.
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HYDRAULICS & ENGINE MOUNTING 5. Disconnect the engine wiring harness from the main wiring harness (Fig. 164). Fig. 164 7. Remove the throttle and choke cables from the engine. Mark the wires with tape or a marker to ensure they get reinstalled correctly (Fig. 166). harness Fig. 166 cables 6. Disconnect the ground wires from the engine block (Fig. 165). Fig.
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HYDRAULICS & ENGINE MOUNTING 8. Remove the transaxle as outlined in the “Trans mission Removal” section of this chapter. 9. Remove the hydraulic pump belt as outlined in the “Hydraulic Pump Belt Removal & Installation” section of this chapter. Engine Installation 1. Line up mounting bolt holes on the engine to the holes on the deck. Install mounting bolts. Torque bolts to 17-23 ft-lbs. (23-31 Nm) (Fig. 169). 10. Remove the bolt securing the PTO pulley and remove pulley. Make sure to secure the key (Fig.
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HYDRAULICS & ENGINE MOUNTING 3. Install the hydraulic pump belt as outlined in the “Hydraulic Pump Belt Removal & Installation” section of this chapter. 7. Connect the engine wiring harness to the main wiring harness (Fig. 173). 4. Install the transaxle as outlined in the “Transmission Installation” section of this chapter. 5. Install the throttle and choke cables (Fig. 171). Fig. 173 harness 4 8. Connect the fuel line and emissions line to the engine (Fig. 174). Fig. 171 cables 6.
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HYDRAULICS & ENGINE MOUNTING 9. Turn on fuel valve. 10. Connect positive (+) wires to the starter solenoid (Fig. 175). 4 Fig. 175 battery cable 11. Connect positive and negative wires to the battery (Fig. 176). Fig.
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GROUND DRIVE & TINE SYSTEMS Ground Drive Subsystem Ground Drive (Fig. 177) D G F J H K 5 I C B A C G Fig. 177 A. When tightening the slotted nut on the wheel motor tapered shaft: torque the slotted nut to 235 + 35 ftlbs. (325 + 48 Nm). Note: Do not use anti-seize on wheel hub. B. Snug all nuts in alternating pattern on wheel then torque in alternating pattern to 77-95 ft-lbs. (105130 Nm). C. Chains should have 1/4”-1/2” deflection half-way between sprockets. D. Torque to 45-55 ft-lbs.
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GROUND DRIVE & TINE SYSTEMS Chains (Fig. 178) A 5 B Fig. 178 chains Transmission Chains Drive Chains A. Install the connecting link so the cover plate and spring clip are to the outside of the machine. Split end of chain clasp must be oriented away from the forward direction of chain travel. B. Install the connecting link so the cover plate and spring clip are to the inside of the machine. Split end of chain clasp must be oriented away from the forward direction of chain travel.
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GROUND DRIVE & TINE SYSTEMS Aerator Assembly (Fig. 179) D F E H B A/H C E B D 5 A G Fig. 179 A. Apply Loctite® 242 to setscrews (4) and screws (4) and tighten to 27 + 3 ft-lbs. (37 + 4 Nm). B. Adjust idler position to allow a maximum of 3/8” of chain movement. C. Zerk on tine shaft bearings must face rear of unit. D. Adjust tine shaft outward until the spyder contacts the outer tine shaft bearings. Slide locking collar up to the tine idler and slide tine idler up to center tine shaft bearing.
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GROUND DRIVE & TINE SYSTEMS Tinebar Chain Assembly Tine Shaft Replacement Install the connecting links so the cover plate and spring clip are to the OUTSIDE of the machine. Install spring clip so opening is away from forward direction of rotation (Fig. 180). Tine Shaft Removal 1. Rotate the wheels until the master links on the drive chains are in a position to be removed (Fig. 181). Fig. 181 Fig. 180 drive chains tine chain connector link 2.
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GROUND DRIVE & TINE SYSTEMS 3. Remove tine chains by rotating the tines until the master links are in a position to be removed (Fig. 183). 5. Loosen the lock collars (Fig. 185). Fig. 185 Fig. 183 lock collar drive chains 4. Loosen the tensioners and remove the spring clips, cover plates, master links and chains (Fig. 184). 6. Slide the inner tines and lock collar to the outside of the machine (Fig. 186). 5 Fig. 186 Fig.
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GROUND DRIVE & TINE SYSTEMS 7. Remove the bolts holding the outer flange bearings (Fig. 187). 9. Remove bolts holding the inner flange bearings while supporting the tine axles. 10. Carefully slide the tine axle assemblies out of the trailing arm (Fig. 189). Fig. 187 outer flange brgs 8. Loosen the bolts holding the inner flange bearings (Fig. 188). Fig. 189 tine asm Tine Wheel Assembly (left side shown) (Fig. 190) 5 Fig. 188 inner flange brgs Fig.
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GROUND DRIVE & TINE SYSTEMS Coring Tine Removal & Replacement Tine Shaft Installation 1. Remove the bolt holding the tine to the shaft (Fig. 191). 1. Slide the tine axle assemblies into the trailing arm (Fig. 192). Note: Chains on in picture for orientation purposes only. Fig. 192 trainling arm 2. Apply Loctite® 242 to the inner flange bearing bolts and install the bolts through the inner flange bear ings. Make sure the grease fittings on the bearings face the rear of the unit.
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GROUND DRIVE & TINE SYSTEMS 3. Slide the inner tines and lock collars to the inside of the machine. Adjust the tine shafts outward until the spyder contacts the outer tine shaft bearings. Slide lock collars up to the tine idler. Apply Loctite® 243 to the lock collar screws. Tighten the lock collars to 12-14 ft-lbs. (16-19 Nm). Make sure tine idler turns freely (Fig. 194). 5. Reinstall the tine chains. Ensure that the cover plate and spring clip are to the OUTSIDE of the machine.
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GROUND DRIVE & TINE SYSTEMS 7. Place the idler sprocket on the tine chain. Adjust idler position to allow a maximum of 3/8” of chain movement. Torque nut to 50 ft-lbs. (69 Nm) (Fig. 198). Jackshaft Replacement Jackshaft Removal 1. Remove the two bolts and nuts holding the chain guard (Fig. 200). Fig. 198 idler sprocket 8. Place the idler sprocket on the drive chain. Adjust idler position to allow a maximum of 3/8” of chain movement. Torque nut to 50 ft-lbs. (69 Nm) (Fig. 199). Fig. 200 chain guard 2.
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GROUND DRIVE & TINE SYSTEMS 4. Loosen the two transmission support plate bolts located at the front of the unit under the muffler (Fig. 202). 6. Remove the chain (Fig. 204). Fig. 204 Fig. 202 chain removal front mount bolts 7. Loosen the tine chain tensioner (Fig. 205). 5 5. Jack up the rear of the unit. Turn the rear wheel until the master link is accessible on the transmission chain. Remove the master link, cover plate, and spring clip (Fig. 203). Fig. 205 Fig.
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GROUND DRIVE & TINE SYSTEMS 8. Rotate the rear wheel until the master link is accessible. Remove the master link, cover plate, and spring clip. Remove the chain. 12. Remove the three nuts and bolts that secure the jack shaft plate (Fig. 208). 9. Loosen the tensioner for the drive wheel chain (Fig. 206). Fig. 208 Fig. 206 drive chn tensioner jackshaft plate 13. Slide the bearing and plate off the jack shaft (Fig. 209). 10. Rotate the rear wheel until the master link is acces sible.
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GROUND DRIVE & TINE SYSTEMS 14. Slide the jack shaft out of the remaining bearings (Fig. 210). Jackshaft Installation 1. Reinstall the shaft into the two bearings on the chassis. Be sure to include any spacers (A) that were included (Fig. 211). Fig. 210 jackshaft A Fig. 211 shaft install 2. Install the outer flange bearing and jack shaft plate. Re-install the bolts and tighten them to 30 ft-lbs (41 Nm) (Fig. 212). 5 Fig.
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GROUND DRIVE & TINE SYSTEMS 3. The end of the jackshaft should be flush with the end of the lock collar on the bearing. If not, tap the jack shaft one way or the other with a hammer to get the shaft flush with the end of the lock collar. Do NOT tighten the bearing collar set screws at this time (Fig. 213). 5. Place the idler sprocket on the drive wheel chain. Adjust idler position to allow a maximum of 3/8” of chain movement (A). Torque nut to 50 ft-lbs. (69 Nm) (Fig. 215). A Fig. 215 Fig.
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GROUND DRIVE & TINE SYSTEMS 7. Place the idler sprocket on the tine chain. Adjust idler position to allow a maximum of 3/8” of chain movement. Torque nut to 50 ft-lbs. (69 Nm) (Fig. 217). Fig. 217 9. Tighten the front mounting bolts and the transmis sion adjustment plate bolts on both sides of the unit tight, then loosen them one turn. 10. Turn the adjustment bolt to move the transmission adjustment plates and hydros (Fig. 219). idler sprocket Fig. 219 5 trans adj plate 8.
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GROUND DRIVE & TINE SYSTEMS 11. Tighten until the chain has between 1/4” and 1/2” deflection (Fig. 220). A B 12. When the correct deflection is achieved, tighten the front mounting bolts and transmission adjustment plate bolts on both sides to 35 ft-lbs. (48 Nm). 13. Check the deflection on the chains again. If they are too tight, loosen the mounting bolts one turn and loosen the chains using the adjustment bolt. Retorque the mounting bolts to 35 ft-lbs. (48 Nm) and check deflection again. C 14.
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GROUND DRIVE & TINE SYSTEMS 16. Install chain guard. Torque bolts to 20 ft-lbs. (27 Nm) (Fig. 222). Fig. 222 chain guard 17. Test drive unit and re-check chain tension. If too loose or too tight, readjust tension.
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ELECTRICAL How It Works CAUTION Before performing any tests with a continuity light or ohmmeter, disconnect the component from the wire harness. This ensures you are testing the component rather than another circuit. Detents inside the switch gives it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released (Fig. 224).
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ELECTRICAL Foot Switch How It Works Purpose Pressing the foot switch sends electrical current through it to the hydraulic valve. The valves inside open so that fluid flows to the hydraulic cylinder causing it to lower the tines. Releasing the switch causes fluid to run in reverse order pulling the tines from the turf and back into the transport position. The foot switch engages the hydraulic valve which allows fluid to flow to the hydraulic cylinder and lowers the aeration tines for use.
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ELECTRICAL Starter Solenoid How It Works Purpose The solenoid has two primary parts. One, a coil wire is wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a bar type switch. Because it has a large contact area with contact terminals, it can easily handle the high current loads required by the starter motor of the engine.
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ELECTRICAL Parking Brake Switch Location Purpose The parking brake switch (A) is located between the two hydro pumps mounted to the transmission guard. It is connected to a slide bracket, which is used to adjust the switch (Fig. 230). The parking brake switch is part of the safety circuit. The switch is used to ensure the parking brake is engaged allowing the machine to start (Fig. 229). A Fig. 229 IMG-0001a Fig. 230 neutral switch How It Works This is a “normally open (NO)” switch.
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ELECTRICAL Fuse Block & Fuses How It Works Purpose The fuse block houses the fuses that protect the electrical system from electrical surges. The fuse block houses the electrical system fuses. Location The fuse block is located on the right hand side of the unit, from the operator position, near the fuel tank (Fig. 231). Fig. 231 fuse block Testing The fuses used in this application can be visually inspected.
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ELECTRICAL Hour Meter Relay Purpose Purpose The hour meter keeps track of the actual running hours of the engine. There are two relays on this machine. Location The hour meter is located on the control panel (Fig. 233). 1. Start Relay: Functions as an electronic switch. Once the safety connections are met, the relay will activate completing the circuit to the starter solenoid. 2. Stop Relay: Functions as an electronic switch.
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ELECTRICAL How It Works Testing A relay is an electrically actuated switch. 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into an electromagnet. 2. Switch: Terminals 30, 87 and 87a are actually part of a single pole, double throw (SPDT) switch. Terminal 30 is the common lead. The switch is spring loaded so that 30 and 87a are connected when the coil is not energized.
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ELECTRICAL 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 237). Fig.
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ELECTRICAL Subsystem Electrical Diagram A G B C 6 D E F Fig. 238 subsystem electrical 1 A. Hour meter D. Relay, 12 VDC-40 Amp F. Switch, single pole normally B. Switch, ignition E. Fuses, 20 Amp open C. Wiring harness G.
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ELECTRICAL Wiring Harness Diagram A B C D 6 E F Fig. 239 wiring harness A. Hour meter C. Wiring harness E. Fuses, 20 Amp B. Switch, ignition D. Relay, 12 VDC-40 Amp F.
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ELECTRICAL Electrical Diagram 6 Fig.
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ELECTRICAL Electrical Schematic 6 Fig.
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30 inch Stand-On Aerator Service Manual Form Number 492-9332