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1. D1 TRACTION INTERLOCK SWITCH Normally Open L H HANDLE R H HANDLE 85 Z 86 bopel x po OPERATION PLUNGER DEPRESSED CLOSED IN NEUTRAL HIGH amp REVERSE GEAR POSITIONS AND SWITCH AND SWITCH e 1Zz 9 CIRCUIT 2 D3 PLUNGER NOT DEPRESSED OPEN WHEN GOING BETWEEN GEAR POSITIONS Normally Open Normally Open 87A BOARD D2 He e Bj L D A GREY GREY GREY GREY DC B A Hl RELAY al COMMON OPEN CLOSED CORING HEAD OPERATION a DIAGRAM DIODE Y n DIAGRAM PLUNGER OUT B C CORING HEAD LOWERED RUN PLUNGER OUT oa A a zZ OPEN S als x lt u PLUNGER IN C D TO START ENGINE WITH CORING HEAD LOWERED BROWN DEPRESS PLUNGER p c GREY ale CORING HEAD RASIED RUN OR T
2. FUSE BODY INLINE F H R FUSE mm Sce ENGINE REGULATOR RECTIFIER 11 FUEL SOLENOID Q P10 i ENGINE e STARTER P1 ES SOLENOID AN 15 RIGHT HAND J8 INTERLOCK SWITCH HANDLE 22 Pg CORING HEAD SWITCH 1 1 j P2 S LEFT HAND x AK INTERLOCK SWITCH rz 1 i HANDLE z 7 15 i ih i i nu 3 S SP1 SP2 3 2 0 0 i 0 I zl s 8 HI OPEN OPEN FAI HA Fx 2 L 2 OPEN m kaz 8E FER L B A Ale M P4 Ps ED E C O IGNITION SWITCH DIODE HOUSING 2 DIODE HOUSING 2 4 OPEN P6 J3 J4 CLUTCH FUSE HOLDER GROUND P3 SOLENOID RELAY Greens Aerator Model 09120 Wire Harness Drawing Page 9 5 PII PIO ENGINE FUEL REGULATOR STARTER STARTER STARTER ENGINE SOLENOID RECTIFIER cg_enero SOLENOID SOLENEID SHIFT INTERLO K J5 J6 j7 J
3. Figure 1 3 Blower housing 1 Cylinder head 2 Rotating screen Engine Fuel System NOTRO N Fueltank Lock nut 3 used Flat washer 4 used Spacer 6 used Flat washer 3 used Cap screw 3 used Rear bracket Engine Figure 2 Cap screw 2 used Lock washer 2 used Flat washer 2 used Muffler mount Socket head screw Lock washer Flat washer Page3 6 Muffler guard Bushing Fuel hose Hose clamp Fuel stand pipe Fuel cap Front bracket Greens Aerator Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel in a clean safety approved container and keep cap in place Use gasoline for the engine only not for any other purpose Check Fuel Lines and Connections Check fuel lines and connections periodically for deteri oration damage or leaking connections Replace hoses clamps and connections as necessary Drain and Clean Fuel Tank Drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an ex tended period To clean fuel tank remove tank from machine and flush tank out with clean solvent Make sure
4. 1 2 Jacking Instructions 1 4 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Engine Introduction 3 1 Specifications 3 2 Service and Repairs 3 5 BRIGGS amp STRATTON REPAIR MANUAL FOR 4 V TWIN CYLINDER OHV HEAD ENGI NES KOHLER MAGNUM SERVICE MANUAL Chapter 4 Hydraulic System Specifications 4 2 General Information 4 3 Hydraulic Schematic 4 6 Hydraulic System Operation 4 7 Special Tools 4 8 Troubleshooting 4 9 E 4 11 Service and Repairs 4 14 Greens Aerator Chapter 5 Electrical System Electrical Diagrams Special Tools Troubleshooting Electrical System Quick Checks Component Testing Service and Repairs Chapter 6 Chassis Specifications Service and Repairs Chapter 7 Drive Train Specifications Adjustments Servi
5. 8 Electrical Diagrams The electrical schematic and wire harness drawings for the Greens Aerator are located in Chapter 9 Electrical Diagrams Greens Aerator Page 5 1 Electrical System To o Special Tools Multimeter The multimeter can test electrical components and cir cuits for current amps resistance ohms or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Battery Terminal Protector Battery Terminal Protector Toro Part No 107 0392 is an aerosol spray that should be used on battery termi nals to reduce corrosion problems Apply terminal pro tector after battery cable has been secured to battery terminal Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Electrical System Page 5 2 Figure 1 Figure 2 Figure 3 Greens Aerator Troubleshooting A CAUTION Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect the battery cables unless the test requires battery voltage Starting Problems Starter
6. 3amps 3amps 3amps 3 amps 81 to 125 5 3 hrs 10 5 hrs 15 8 hrs 21 hrs 4amps 4amps 4amps 4 amps 16 5 hrs 22 hrs 5 amps 5 amps Battery Charge Level Percent of Fully Charged 126 to 5 5 hrs 11 hrs 170 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3hrs 23 hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps Greens Aerator Page 5 19 Do charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the c
7. 4 Traction Drive Belt 4 Drive Chain 6 Transaxle esne keret eee true e RE 3 UR os eee gen 8 Transaxle Service 10 Transaxle Disassembly 11 Shift Lever Service 13 Shifter Assembly Service 13 Differential Assembly Service 14 Transaxle Assembly 15 6 A o 2 e Greens Aerator Page 7 1 Drive Train Specifications Item Description Transaxle Peerless Model 2361 Manual shift 2 forward speeds and reverse Transaxle Fluid Capacity 2 quarts 1 9 liters Transaxle Fluid SAE E P 90 Wt Oil Drive Train Page 7 2 Greens Aerator Adjustments Adjust Shift Tower If the shift tower on the front of the aerator frame is not positioned correctly the shift lever will not properly en gage the transaxle gears Perform the following proce dure to position the shift tower is transaxle shifting is difficult 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Position shift lever into the neutral slot in shift tower 4 Loosen four 4 cap screws flat washers and lock nuts that secure shift tower to machine Fig 1 5 While rotating drive p
8. 5 Reconnect electrical connections to solenoid Figure 17 Torque nuts on coil posts from 15 to 20 in lb 1 7 to 2 3 1 Screw 2 used 5 Terminal boot and nuts on main contact posts from 50 to 60 in Ib 2 Starter solenoid 6 Hex nut 2 used 5 7 to 6 8 3 Lock washer 2 used 7 Lock washer 2 used 4 Hex nut 2 used 6 Reconnect battery Electrical System Figure 18 1 Coil post 2 Main contact post Greens Aerator Page 5 13 Electrical System Fuses The greens aerator uses two 2 fuses for circuit protec tion The fuses are held in individual fuse holders and have the following functions 20 Amp Fuse Protects main power circuit to ignition Switch terminal B The 20 Amp fuse is located behind the engine Fig 19 5 Amp Fuse Protects circuit to clutch solenoid The 5 Amp fuse is located under the console cover Fig 20 Figure 19 Testing 1 20Amp fuse Remove fuses from the fuse holder for testing Fuse should have continuity between fuse terminals Figure 20 1 5 Amp fuse Electrical System Page 5 14 Greens Aerator Diode Circuit Boards The Greens Aerator uses two 2 diode circuit boards that are located under the console cover Fig 21 One of these circuit boards has three 3 diodes while the oth er board has four 4 diodes The three diode circuit board Fig 22 provides logic for the interlock system Diode D3 on this board is not used The fou
9. 1 Remove oil from the lift cylinder into a drain pan by slowly pumping the cylinder rod Plug port and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot only Do not close vise enough to distort barrel 2 Mount lift cylinder in a vise so that the shaft end tilts up slightly 3 Remove retaining ring item 3 that retains head in barrel 4 Extract rod head and piston by carefully twisting and pulling on the rod clevis Hydraulic System Page 4 24 IMPORTANT Do not clamp vise jaws against rod surface Protect rod surface before mounting in vise 5 Mount rod securely in a vise by clamping vise on the flats of the rod clevis Remove lock nut item 15 from rod and carefully slide piston and head from the rod 6 Remove and discard o rings items 12 and 13 and back up rings item 11 from the piston 7 Remove and discard o rings items 7 and 9 back up rings items 6 and 8 and dust seal item 4 from the head 8 If necessary loosen jam nut item 2 and remove cle vis item1 from rod Greens Aerator Inspection A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect internal surface of barrel for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect rod piston and head for excessive pitting
10. 5 Inspect roll pin item 26 that is installed in housing to align shift lever keeper in housing Replace roll pin if damaged 6 Lightly oil new quad seal Install quad seal into hous ing 7 Slide shift lever up through housing 8 Install shift lever keeper into housing making sure to align keeper with roll pin Install snap ring to secure shift lever assembly in housing Greens Aerator Page 7 13 Shifter Assembly Service Figs 9 and 16 1 Slide shifter stop item 29 from shift rods 2 Carefully slide shifter forks from shift rods Locate and retrieve spring item 9 and detent ball item 10 from hole in fork 3 Check shift rods shifter forks and shifter stop for wear or damage Replace all worn or damaged compo nents 4 Lightly oil parts before assembly 5 Slide shifter fork onto shift rod until the rod end aligns with the shifter fork hole Install spring and detent ball through shifter fork hole and into cavity in opposite side of fork Use a small flat blade screwdriver to press det ent ball into cavity and move the fork completely onto the rod Repeat for other shift rod 6 Move shifter forks to the neutral position which is the second groove from the snap ring 7 Install shifter stop onto shift rods 8 When the shifter forks are properly assembled to the shifter rods and positioned in neutral the ends of the notches in the forks should be aligned Fig 16 Figure 15 1 Shiftlev
11. GROUND H A STARTER SOLENOID INTERLOCK CLUTCH CIRCUIT MODULE SOLENOID BREAKER Fg 9 IGNITION SWITCH 11 Vn OPEN Greens Aerator Model 09110 Wire Harness Drawing Page9 7 LEFT HAND RIGHT HAND INTERLOCK SWITCH INTERLOCK SWITCH OO l I GI 28 BROWN ORANGE 27 E CORING YELLOW D MEAD BROWN SWITCH WHITE e BLUE U o ks 1 STARTER BATTERY SOLENOID ENGINE ORANGE ORANGE QU 3 PURPLE min 00 OB SWITCH To IGNITION SWITCH INTERLOCK CLUTCH CIRCUIT MODULE SOLENOID BREAKER S 4 E 3 ae GROUND Greens Aerator Model 09110 Wire Harness Diagram Page 9 8
12. 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Ya
13. Tine arm Rivet LH wear plate Kickout deflector Lock washer Cap screw Cap screw LH wear plate bracket RH wear plate bracket 10 RH wear plate 11 Hex nut 12 Lock washer m gt N Coring Head Figure 7 Aerating tine Tine holder Stud Bushing Pyramidal washer Lock nut Rubber bushing Connecting rod Lock nut Flat washer Retaining ring Bearing Page 8 6 M 150 to 170 ft Ib amp 203 to 230 N m 150 to 170 ft lb 203 to 230 N m 25 Socket head screw 26 Socket head screw 27 Bearing cap short crank 28 Retaining clip 29 Lower crank arm assembly 30 Shoulder bolt 31 O ring 32 Connecting link 33 Roller chain 34 Upper crank arm assembly 35 Bearing cap long crank Greens Aerator Removal Fig 7 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Unlatch and remove coring head cover 4 Remove coring head chain see Coring Head Chain Removal in this section 5 Remove lock nut item 21 and flat washer item 22 that secure tine arm to upper crank arm item 34 6 Remove lock nut item 21 and flat washer item 22 that secure connecting rod to lower crank arm item 29 7 Slide tine arm from upper crank arm and connecting rod
14. taches lift valve handle to lift control 8 Remove four 4 hex nuts item 10 lock washers item 9 and cap screws item 2 that secure control valve to control panel 9 Remove control valve from the machine 10 If necessary remove hydraulic fittings from control valve Discard o rings Greens Aerator Page 4 27 Installation Fig 22 1 If fittings were removed from control valve lightly lu bricate new o rings with clean 10W30 engine oil and install fittings to control valve 2 Position control valve 1 to machine and secure with four 4 cap screws item 2 lock washers item 9 and hex nuts item 10 3 Attach lift valve handle to lift control with connecting link assembly item 8 4 Lightly lubricate new o rings with clean 10W30 engi ne oil and correctly connect hydraulic hoses to fittings on lift control valve 5 Check oil level in hydraulic reservoir and fill if neces sary Check hydraulic components for leaks and tighten any loose connections 6 Install control cover Fig 23 7 Raise coring head and raise lock up brackets on each side of machine Figure 23 1 Control cover Hydraulic System 9 G gt Lift Control Valve Service Disassembly Fig 24 1 Wash control valve in solvent and dry it thoroughly 2 Mount control valve into a vise so the mounting pads are against the jaws of the vice and snap ring faces up NOTE Remove check
15. Lift cylinder is binding Coring head is binding Control valve in hydraulic pump is stuck open Lift cylinder is leaking internally Hydraulic pump is worn or damaged Coring head raises but will not stay up Greens Aerator Page4 9 Lift cylinder is leaking internally Neutral position check valves in lift valve leak Hydraulic System This page is intentionally blank Hydraulic System Page 4 10 Greens Aerator Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks see Special Tools section in this Chapter Failure to use gauges with recommended pres sure PSI Bar rating as listed in test procedures could result in damage to gauge and possible personal injury from leaking hot oil Before Performing Hydraulic Tests All obvious areas such as oil supply binding linkage loose fasteners improper adjustments or improper op eration must be checked before assuming that a hy draulic component is the source of the problem being experienced Precautions For Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydrau lic System Pressure in the General Information section of this chapter Keep body and hands away from pin hole leaks or nozzles that eject hydrau
16. bearing retainers front wheel and thrust washer from axle 7 Inspect thrust washer bearing retainers and wheel bearings for wear or damage Replace components as needed Front Wheel Installation Fig 1 1 Position thrust washer on front axle 2 Make sure that bearing retainer is positioned on both sides of wheel Slide front wheel onto axle with valve stem and grease fitting outward 3 Secure front wheel to axle with washer slotted hex nut and cotter pin 4 Install hub cap Lubricate wheel bearings at grease fitting in wheel 5 Lower machine to ground Lower coring head lock up brackets before machine use Chassis Rear Wheel Hub 65 to 90 ft lb 88 to 122 See text for tightening 10 procedure Figure 2 1 Frame 12 Nut retainer 23 Idler cover 2 Lock nut 13 Tab washer 24 Retaining ring 3 Sprocket guard RH shown 14 Cotter pin 25 Ball bearing 4 screw 15 Half link 26 Idler sprocket 5 Shaft seal 16 Wheel stud 4 used per hub 27 Bushing 6 Bearing 17 Master link 28 RH chassis guard 7 Shaft 18 Drive chain 29 Special nut 8 Grease fitting 19 Spacer 30 LH chassis guard 9 Hub 20 Lock washer 31 Lug nut 4 used per hub 10 Jam nut 21 Cap screw 32 Rear wheel 11 Dust cap 22 Flat washer Removal Fig 2 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition switch 2 Raise lock up brackets on each side of ma
17. it is fully charged before storing the battery machine see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong battery post could result in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables with positive cable first Coat battery posts and cable connectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell electrolyte level with distilled or demin eralized water Do not fill cells above the fill line Greens Aerator Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Battery Specifications BCI Group Size U1 300 CCA at 0 F 189 C Reserve Capacity of 28 minutes at 80 F 27 C Dimensions including terminal posts and handle Length 7 7 inch
18. scoring or wear Replace any worn or damaged parts Assembly Fig 20 1 Coat new o rings items 7 9 12 and 13 back up rings item 6 8 and 11 and dust seal item 4 with clean 10W30 engine oil Carefully install sealing components to the head and piston 2 If removed thread jam nut item 2 and clevis item1 onto rod IMPORTANT Do not clamp vise jaws against rod surface Protect rod surface before mounting in vise 3 Mount rod securely in a vise by clamping vise on the flats of the rod clevis Carefully slide piston and head as semblies onto the rod Secure piston to shaft with lock nut Greens Aerator Page 4 25 4 Remove rod assembly from vise IMPORTANT Prevent damage when clamping the barrel into a vise clamp on the pivot end only Do not close vise enough to distort tube 5 Mount barrel in a vise so that the rod end tilts up slightly 6 Coat all internal lift cylinder parts with a light coating of clean 10W30 engine oil Slide rod piston and head assembly into barrel being careful not to damage the seals 7 Secure head in barrel by installing retaining ring item 3 8 Check that length of cylinder when fully extended is from 19 to 19 5 in 48 3 to 49 5 cm Fig 21 If needed loosen jam nut and adjust clevis position on rod to allow proper cylinder length 9 Make sure that jam nut is fully tightened after assem bly of lift cylinder 19t019 5in CC lt 48 3 49 5 c
19. 12 20UNF 80 10 ft lb 108 14 N m 5 6 18 UNC 215 35 inb 145 20 in Ib Grade 5 Ib 14 b 3 8 16 UNC 35 10 ft lb 18 3 ft lb M12 X 1 25 Class 8 8 50 10 ft ib M12 X 1 5 80 10 fil 108 14 N m E qe For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Threads per Inch Baseline Torque Thread Size Baseline Torque Type A Type B No 6 32 UNC 20 5 inIb 1 20 5 in Ib No 8 32 UNC 30 5 in lIb 1 1 No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in lb values All torque values are based on non lubricated 2 16 71 fasteners Conversion Factors in lb X 11 2985 X 0 08851 in Ib ft lb X 1 3558 N m N m X 0 7376 Product Records and Maintenance Page 2 6 Greens Aerator TORO Table of Contents INTRODUCTION 1 SPECIFICATIONS 2 Models 09120 2 Model 09100 and 09110 3 SERVICE AND REPAIRS 5 Cooling System 5 Fuel System 6 Exhaust Sy
20. 192 225 25 2542 282 325 3 3672 373 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 65 10 5 16 18 UNC 115 15 105 15 5 16 24 UNF 138 17 128 17 A ES m A N I N N N N o A o N Co N o a I I I I I I I I I N N 9 N a sim mens mere 16 2 3 8 24 UNF 7 16 20 UNF 29 3 77 8 104 11 NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above for by 25 for lubricated fasteners Lubricated fasteners Grade 5 and 8 fasteners are based on 75 of the mini are defined as threads coated with a lubricant such as mum proof load specified in SAE J429 The tolerance is engine oil or thread sealant such as Loctite approximately 10 of the nominal torque value Thin height nuts include jam nuts NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page 2 4 Greens Aerator Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size M5 X 0 8 Regular Height Nuts 57 6 in Ib 96 10 in lb
21. Remove drive chain from both transaxle sprockets Switch see Drive Chain Disassembly in this section 2 Raise lock up brackets on each side of machine and 6 Pull knob from shift lever lower coring head until it rests on brackets 7 Support transaxle to prevent it from falling 3 Remove brake caliper from machine see Brake Cal iper Removal in Service and Repairs section of Chapter 6 Chassis Drive Train 7 8 Greens Aerator 8 Remove fasteners that secure transaxle to frame A Cap screw item 17 and pyramidal washer item 19 B Four 4 cap screws item 5 and pyramidal wash ers item 4 C Four 4 cap screws item 30 lock washers item 8 and nuts item 31 NOTE One of these cap Screws is used to secure belt guide Fig 8 9 Carefully lower transaxle and remove from machine 10 If necessary brake disc item 29 can be removed from transaxle brake shaft by loosening two 2 set screws item 27 and sliding disc from shaft Locate and retrieve woodruff key item 16 11 If needed remove pulley from transaxle input shaft A Remove three 3 cap screws item 15 and lock washers item 14 that secure taper lock bushing to pulley IMPORTANT When removing taper lock bushing tighten cap screws progressively and evenly Ex cessive or unequal pressure on the screws can break the taper lock bushing flange B Insert cap screws into threaded removal holes of the bushing Tighten screws prog
22. bearing cap Bearing caps must be installed in the same position they were removed from 6 Remove socket head screws and lock washers that secure bearing cap to coring head frame Remove bear ing cap from coring head frame 7 Pull crank arm assembly from coring head frame 8 If necessary remove retaining clip s from bearing cap and or coring head frame Installation Fig 9 1 Make sure that bores of coring head frame and bear ing caps are free of nicks burrs or corrosion If neces sary use 320 grit emery cloth to remove imperfections in bores Clean bores thoroughly before installation of crank arms 2 If any retaining clips were removed secure retaining clips with lock washer and socket head screw Make sure that clips are perpendicular to bearing bore prior to tightening screw 3 Position crank arm assembly to coring head frame Make sure that bearing with retaining ring is placed at re taining clips on the outer coring head frame plate Fig 10 IMPORTANT Bearing caps must be installed in the same position they were removed from 4 Install bearing cap noting matchmark made during removal to ensure that bearing cap is properly posi tioned Secure bearing cap to coring head frame with lock washers and socket head screws Torque screws from 20 to 35 ft lb 27 to 47 5 Install both tine arms to crank arm assembly that was removed see Tine Arm Installation in this section Greens Aerator Pag
23. frame IMPORTANT Bearing caps must be installed in the same position they were removed from 5 Install bearing caps noting matchmarks made during removal to ensure that bearing caps are properly posi tioned Secure bearing caps to coring head frame with lock washers item 11 and socket head screws item 28 Torque screws from 20 to 35 ft Ib 27 to 47 6 Position coring head drive belt to the right side of the pulley The left pulley groove should be unused Fig 12 7 Position idler pulley item 44 to idler brackets Place spacer item 41 on each side of pulley Secure idler pulley to idler brackets with cap screws items 10 and 12 and lock washers 8 Place coring head drive belt onto engine pulley 9 Slide spacer items 23 and 37 sprocket item 24 and flat washer item 25 onto each end of power shaft Sprocket and shaft splines have marks that should be aligned during assembly Install lock nuts item 26 on shaft and torque from 150 to 170 ft lb 203 to 230 10 Check that coring head drive belt alignment is still correct If needed readjust location of power shaft pulley and or idler bracket to align drive belt 11 Check that 1 8 3 2 mm clearance exists between bottom of belt guide item 2 and installed belt Reposi tion guide if needed Figure 12 3 Unused pulley groove 1 Pulley 2 Drive belt Coring Head 6 gt 12 Install traction drive be
24. gear Greens Aerator Chapter 8 TORO Coring Head Table of Contents GENERAL INFORMATION 2 Coring Head Operation 2 Coring Head Lock up Brackets 2 Coring Head Adjustments 2 Coring Head Bearing Caps 3 SERVICE AND REPAIRS 4 Coring Head Chain 4 TIBI 6 Crank ATIS oa eie e Et ede ERA enn 8 Coring Head Drive Belt 10 Coring Head Drive 14 6 Greens Aerator Page 8 1 Coring Head General Information Coring Head Operation The coring head of the Greens Aerator consists of a piv oting coring frame two coring crank sets tine arms with connecting rods to provide vertical tine motion turf guards tine holders and aerating tines Drive for the coring head comes from the engine mounted pulley through a 3V section drive belt that is tensioned by a spring loaded idler pulley The drive belt rotates the power shaft located on the coring head which in turn drives the coring crank sets with roller chains The two coring crank sets are composed of welded sprocket and crankarm assemblies that are supported by bearings and bearing caps For assembly purposes proper crank position is identified by alignment holes that exist in crank gears and the coring frame Crank sets are ti
25. m 11 28 33 34 35 36 37 38 Pulley guard 40 Spacer 42 43 Idler pulley 45 46 47 41 22 23 26 24 150 to 170 ft lb 203 to 230 N m Set screw Pulley Bearing cap Bearing Spacer 560 long RH idler bracket LH idler bracket Idler shaft Bearing 2 used Retaining ring Spacer 1 060 long Idler pulley Greens Aerator Removal Fig 11 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Unlatch and remove coring head cover 4 Remove exhaust muffler guard see Exhaust Sys tem Removal in Service and Repair section of Chapter 3 Engine 5 Remove traction drive belt from engine pulley see Traction Drive Belt Removal in Service and Repairs sec tion of Chapter 7 Drive Train 6 Remove both coring head chains see Coring Head Chain Removal in this section 7 Remove lock nuts item 26 that secure sprockets item 24 to power shaft Pull flat washer item 25 sprocket and spacer items 23 and 37 from both ends of shaft Note that length of spacers is different 8 Remove cap screws items 10 and 12 and lock washers that secure idler pulley item 44 to idler brack ets Pull idler pulley from brackets Locate and retrieve two 2 spacers item 41 from sides of pulley I
26. or missing filler cap overcharging loose terminal post or overfilling Also check battery case for dirt and oil Clean the bat tery with a solution of baking soda and water then rinse it with clean water 4 Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking 5 Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maximum fill lines Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte Electrical System SE 89 ov 9 5 Testing 1 To properly test a battery perform a high discharge test using an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial battery load tester is required to perform this test Ad caution Follow the manufacturer s instructions when us ing a battery load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D Measure the temperature of the center cell E Connect a battery load tester to
27. solenoid clicks but starter will not crank If starter solenoid clicks problem is not in safety interlock system Nothing happens when start attempt is made gear shift lever must be in neutral position and traction drive must be in neutral for successful start Greens Aerator Page 5 3 For effective troubleshooting and repairs you must have a good understanding of the electrical circuits see Chapter 9 Electrical Diagrams and components used on this machine If the machine has any interlock switches by passed they must be reconnected for proper troubleshooting and safety Possible Causes Battery charge is low Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty Battery cables are loose or corroded Battery ground to frame is loose or corroded Battery is discharged or faulty Coring head is not raised 20 amp fuse is faulty Coring head switch es is are faulty Wiring to start circuit components is loose corroded or damaged see Chapter 9 Electrical Diagrams Ignition switch is faulty Starter solenoid is faulty Electrical System Electrical System Starting Problems continued Engine cranks but does not start Circuit wiring to engine magneto is grounded see Chapter 9 Electrical
28. tachometer 12 Shut engine off before checking or adding oil to the engine crankcase 13 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive bat tery cable last If battery voltage is required for trouble shooting or test procedures temporarily connect the battery Reconnect positive battery cable first and nega tive battery cable last 14 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 15 Battery gases can explode Keep cigarettes sparks and flames away from the battery 16 When changing tires or performing other service use correct blocks hoists and jacks Make sure ma chine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised ma chine If the machine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions 17 At the time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made b
29. tank is free of contaminates and debris Greens Aerator Page 3 7 Fuel Tank Removal Fig 2 NOTE On Models 09100 and 09110 equipped with a Kohler M16 engine the fuel tank is an engine compo nent On these models refer to the Kohler Magnum Ser vice Manual at the end of this chapter for additional fuel system information 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Loosen hose clamp that secures fuel hose to fuel stand pipe in fuel tank Remove fuel hose from stand pipe 4 Remove fuel tank using Figure 2 as a guide 5 Empty fuel tank into a suitable container Fuel Tank Installation Fig 2 1 Install fuel tank to frame using Figure 2 as a guide 2 Connect fuel hose to the fuel stand pipe Secure fuel hose with hose clamp 3 Fill fuel tank see Operator s Manual 4 Return coring head lock up brackets to stored posi tion Engine Exhaust System Figure 3 1 Muffler 7 Lock washer 2 used 13 Exhaust tube 2 Socket head screw 8 screw 2 used 14 Engine 3 Lock washer 9 Self tapping screw 4 used 15 Exhaust tube 4 Flat washer 10 Exhaust outlet 16 Lock washer 4 used 5 Muffler guard 11 Spark arrester optional 17 Cap screw 4 used 6 Flat washer 2 used 12 Self tapping screw 4 used
30. the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Voltage Tem a re an ec 10 09C 4 49C 1 19C 6 79C 12 29C If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Electrical System Page 5 18 2 If a battery load tester is not available the battery can be tested by conducting a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 79C add 0 004 to the specific gravity reading For each 109F 5 59C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 1009F Cell Gravity 1 245 1009F minus 809F equals 209F 37 79C minus 26 79
31. the engaged position for continued traction drive operation as long as the solenoid is ener gized Testing 1 Make sure engine is off Disconnect battery Unplug solenoid from machine wire harness 2 Apply 12 VDC directly across the clutch solenoid connector terminals The solenoid should click and the solenoid shaft should retract The shaft should stay re tracted as long as the voltage is applied to the terminals 3 Remove voltage from solenoid coil posts The sole noid shaft should extend 4 Replace clutch solenoid if necessary 5 Reconnect electrical connections to solenoid 6 Reconnect battery Figure 15 1 Clutch solenoid 3 Traction drive lever 2 Latch Figure 16 1 Clutch solenoid 4 Latch 2 Adjusting rod 5 Traction drive lever 3 Ball joint Electrical System Page 5 12 Greens Aerator Engine Starter Solenoid The engine starter solenoid is attached to a bracket on the starter motor Fig 17 Testing 1 Make sure engine is off Disconnect battery Discon nect solenoid electrical connections 2 Apply 12 VDC directly across the solenoid coil posts The solenoid should click Make sure resistance across the main contact posts is less than 1 ohm continuity 3 Remove voltage from solenoid coil posts The sole noid should click Make sure resistance across the main contact posts is infinite ohms no continuity 4 Replace starter solenoid if necessary
32. tilt case so that the shifter rods will clear the edge of the case Rotate case so the boss hidden inside will clear the gears Lift case from transaxle Fig 10 NOTE Refer to Figure 11 for transaxle gear and shaft identification during disassembly Three gear cluster Shifter rod 3rd amp Ath gt Reverse idler gear Low gear 8 Remove thrust washer item 16 and three gear clus 3 Pinion shaft 7 Differential assembly ter item 36 from the brake shaft 4 Shifter Low 8 Output gear Greens Aerator Page 7 11 Drive Train 9 Remove the reverse idler gear item 66 spacer item 65 and reverse idler shaft item 64 from the boss in the cover Note that spacer goes between the gear and cover and the gear bevels go down 10 Squeeze top end of shifter rods and lift shifter assem bly from cover Fig 12 Shifter assembly includes pin ion shaft item 25 shifting gears items 32 and 33 and shift rod assemblies items 8 and 13 See Shifter As sembly Service in this section for information regarding shifter service 11 Remove low gear shaft and pinion item 62 and spur gear item 67 Separate the gear and shaft Locate and retrieve thrust washer item 61 12 Remove spacer item 37 and two gear cluster item 27 from brake shaft Fig 13 13 Lift differential assembly from the cover See Differ ential Assembly Service in this section for information regarding differential service 14 Remove output
33. 00 18 1 to 22 6 N m in three equal steps and in a circular pattern 5 Install bearings on power shaft Make sure that right side bearing has retaining ring toward the middle of the shaft 6 Position power shaft assembly into coring head frame 7 Install coring head drive belt see Coring Head Drive Belt Installation in this section During assembly make sure to check belt alignment If necessary loosen set screw on taper lock bushing and adjust location of pulley on power shaft Re tighten set screw when alignment is correct Belt Tensioner Disassembly Fig 13 Be careful when removing extension springs on idler assembly The springs are under heavy load and may cause personal injury 1 Disassemble belt tensioner components as required using Figure 13 as a guide Belt Tensioner Assembly Fig 13 1 Assemble belt tensioner components as required using Figure 13 as a guide noting the following A When installing the idler pulley item 47 position short spacer item 18 on the hub side of the pulley B Liberally apply antisieze lubricant to the shaft of cap screw item 9 before installation of the cap screw into the idler brackets and idler pulley C Make sure that idler brackets items 38 and 40 pivot freely after tightening the lock nut item 14 that secures idler pulley item 47 D If bearings were removed from idler pulley item 44 install one retaining ring press bearings into pulle
34. 18 Muffler mount NOTE On Models 09100 and 09110 equipped with a Kohler M16 engine exhaust system service is similar to the following procedure Engine 3 8 Greens Aerator Removal Fig 3 The muffler guard and exhaust system may be hot To avoid possible burns allow the engine and exhaust components to cool before working on the exhaust system 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Remove fasteners that secure muffler guard to ma chine Remove muffler guard from machine 4 Remove four 4 self tapping screws item 12 that secure muffler to muffler mount 5 Slide muffler from muffler tubes and from machine 6 If exhaust tubes items 13 and 15 require removal remove four 4 cap screws item 17 and lock washers item 16 from the engine Separate the exhaust tubes from the engine 7 Remove exhaust gaskets not shown Greens Aerator Page 3 9 Installation Fig 3 IMPORTANT Finger tighten all exhaust system fasteners before securing so there is no preload on exhaust components NOTE If exhaust tubes were removed make sure ex haust tube flanges and engine sealing surfaces are free of debris or damage that may prevent a tight leak free seal 1 If exhaust tubes were removed position exhaust
35. 2 Spacer 6 Cam pin 13 Spool snap ring 7 Control valve body 14 Snap ring 4 If check valve seat was damaged and removed press fit replacement into the valve body 5 Lubricate and install cam pin ball and spring Place new o ring on plug and install into the valve body Tight en plug 6 Repeat steps 4 and 5 for the second plug assembly Greens Aerator Chapter 5 TORO Electrical System Table of Contents ELECTRICAL DIAGRAMS 1 Interlock Lever Switches 9 SPECIAL TOOLS 2 Traction Interlock Switch 10 TROUBLESHOOTING 3 Coring Head Switch Assembly 11 Starting Problems 3 Clutch Solenoid 12 General Run Problems 4 Engine Starter Solenoid 13 ELECTRICAL SYSTEM QUICK CHECKS 5 FUSES mL n 14 Battery Test Open Circuit Test 5 Diode Circuit Boards 15 Charging System Test 5 SERVICE AND REPAIRS 16 Check Operation of Safety Interlock System 6 Battery Storage 16 COMPONENT TESTING 7 Battery 16 Ignition Switch 7 Battery Service 17 Engine Stop Relay
36. 8 SWITCH a a JI J2 E I 3 z 3 i I P12 6 8 d E E 4 I I INLINE 5 3 gt z z FUSE 5 n n T T RED SP UN WHITE RED ORANGE z 5 ORANGE YELLOW 2 P9 CORING HEAD SWITCH PI 2 L BROWN BLACK 2 RIGHT HAND INTERLOGK SWITCH HANDLE GRAY PURPLE P BLACK LEFT HAND INTERLOCK SWITCH 5 HANDLE ORANGE SP2 BLACK z g 3 i E P E x x x T 5 m 2 gt x m ct 5 S cr 9 z 5 5 z 5 3 5 5 5 9 a 8 a 9 T 3 5 t a m a m W27 m a m B BLACK BLACK RED WHITE OPEN OPEN OPEN OPEN OPEN J3 Ju 2 3 4 5 B 6 L 5 D c B A 2 A B H c F E p c B A GROUND P3 Pu PS P6 P7 P8 RELAY IGNITION SWITCH DIODE HOUSING CLUTCH FUSE DIODE HOUSING SOLENOID HOLDER Greens Aerator Model 09120 Wire Harness Diagram Page 9 6 ENGINE m 2 t t EFT HAND RIGHT HAND NTERLOCK SWITCH INTERLOCK SWITCH ANDLE HANDLE F T 274 5 INTERLOCK SWITCH OPEN S el el CORING HEAD SWITCH e a E iu LU el BATTERY 4 INLINE FUSE HOLDER x
37. C equals 11 09C 209F multiply by 0 004 10 F equals 0 008 119C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 809F 26 79C 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery Greens Aerator Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Level Voltage 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Specific Gravity 1 265 1 225 1 190 1 155 1 120 Battery Reserve Capacity Minutes 80 or less 3 8 hrs 7 5 hrs 11 3 hrs 15
38. Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 644 68 N cm 78 8 in Ib 881 90 N cm 1085 113 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 133 14 in lb 1503 158 N cm M6 X 1 0 M8 X 1 25 19 2 ft lb M10 X 1 5 M12 X 1 75 M16 X 2 0 M20 X 2 5 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Greens Aerator 26 3 N m 38 4 ft lb 52 5N m 54 6 ftb 73 8 N m 66 7 ft lb 90 10 N m 93 10 ft lb 126 14 N m 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 325 33 ft lb 440 45 450 46 ft lb 610 62 N m Page 2 5 28 3 ft lb 38 4 N m NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Grade 5 Ib E
39. Diagrams Circuit wiring to carburetor solenoid is loose corroded or damaged see Chapter 9 Electrical Diagrams Engine stop relay is faulty Ignition switch is faulty Engine or fuel system is malfunctioning see Chapter 3 Engine Engine may be too cold General Run Problems Battery does not charge Wiring to the charging circuit components is loose corroded or damaged see Chapter 9 Electrical Diagrams Ignition switch is faulty Battery is faulty Engine alternator is faulty see Chapter 3 Engine Engine kills during operation Interlock switch on handle is not depressed Ignition switch is faulty Engine stop relay is faulty Interlock switch es on handle is are faulty Coring head switch es is are faulty Circuit wiring to engine magneto is damaged see Chapter 9 Electrical Diagrams Circuit wiring to carburetor solenoid is loose corroded or damaged see Chapter 9 Electrical Diagrams Engine or fuel system is malfunctioning see Chapter 3 Engine Electrical System 5 4 Greens Aerator Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level 12 68 v or higher Fully charged 10096 Set the multimeter to the DC volts setting The battery 12 45 v 7596 charged 12 24 v 5096 charged battery terminals should be at a temperature of 60 to 100 F 16
40. Fig 11 When the gear shift lever is in a gear the switch plunger is depressed and the switch should be closed continu ity When shifting gears the switch plunger extends and the switch should open no continuity The interlock switch can be adjusted by loosening the mounting screws and repositioning the switch Figure 10 1 Traction interlock switch 2 Mounting screw Figure 11 1 Plunger 3 Normally open 2 Common ground 4 Normally closed Electrical System Page 5 10 Greens Aerator Coring Head Switch Assembly The coring head switch assembly monitors the position of the coring head raised or lowered for correct aerator operation This switch includes two 2 normally open ball switches one 1 normally closed ball switch a spring loaded plunger and a housing Fig 13 The plunger in the switch assembly is extended when the coring head is lowered In this position the switches are in their normal states two are open and one is closed The plunger in the switch assembly is pushed in when the coring head is raised In this position the switches are not in their normal states two are closed and one is open The adjustment procedure for the coring head switch assembly is included in Operator s Manual Figure 12 Testing 1 Coring Head Switch 7 Switch actuator 2 Self tapping screw 8 Lock washer 2 used TM i 3 Adjustment screw 9 Screw 2
41. GINE ENGINE 09120 cate SPARES CLUTCH Electrical Schematic DIODE SOLENOID D3 DIAGRAM All ground wires are black D4 D2 Page 9 3 LH HANDLE RH HANDLE INTERLOCK TRACTION INTERLOCK AND SWITCH AND SWITCH MODULE SWITCH Normally Open Normally Open Normally Open COMMON CLOSED VIOLET 2 8 2 E SIE GRAY GRAY GRAY GRAY OPEN T GND GND 1 1 1 I I I 1 I n a n D 0 YELLOW SWITCH N C SWITCH N O 0 1 01 CORING HEAD SWITCH ASSEMBLY RUN LIGHTS SWITCH MODE 12 34 3 4 IGNITION MODULE WHITE WHITE FUSE 20 AMP BLACK BLACK _ RED L BLACK 4 ENGINE ENGINE STARTER ENGINE STARTER ALTERNATOR CLUTCH MOTOR SOLENOID BATTERY SOLENOID Normally Open ORANGE PURPLE Greens Aerator Model 09110 Electrical Schematic All ground wires are black Page 9 4 SOLENOID J6 SHIFT INTERLOCK SWITCH 6 J1 J2 U
42. MPORTANT Matchmark bearing cap and coring head frame bore before removing bearing cap Bearing caps must be installed in the same position they were removed from 9 Remove socket head screws item 28 and lock washers item 11 that secure bearing caps to coring head frame Slide bearing caps from frame 10 Carefully reposition power shaft in coring head frame to allow coring head drive belt to be removed from pulley and shaft After belt has been removed support power shaft to prevent it from falling 11 Remove coring head drive belt from idler bracket engine pulley and machine Installation Fig 11 1 Make sure that bores of coring head frame and bear ing caps are free of nicks burrs or corrosion If neces sary use 320 grit emery cloth to remove imperfections in bores Clean bores thoroughly before installation of power shaft into coring head frame 2 If any retaining clips were removed secure retaining clips with lock washer and socket head screw Make sure that clips are perpendicular to bearing bore prior to tightening screw Greens Aerator Page 8 11 3 Carefully position power shaft in coring head frame to allow coring head drive belt to be placed around pow er shaft and pulley Install belt and support power shaft to prevent it from falling 4 Position power shaft to coring head frame Make sure that shaft bearing with retaining ring is placed at re taining clips on the right side of the coring head
43. ONTROL VALVE HYDRAULIC PUMP INTERNAL 1300 PSI RELIEF VALVE PUMP RESERVOIR Greens Aerator Hydraulic Schematic Hydraulic System Page 4 6 Greens Aerator Hydraulic System Operation Coring Head Raise Lower The hydraulic pump supplies hydraulic pressure for rais ing and lowering the coring head The pump is belt driv en The hydraulic pump takes its suction from the hydraulic reservoir which is part of the pump assembly During conditions of not lifting or lowering the coring head flow from the hydraulic pump goes to the lift con trol valve and is by passed directly back to the pump reservoir Maximum raise lower circuit pressure 1300 PSI is lim ited by the control valve located in the hydraulic pump assembly Raise Coring Head When the coring head is to be raised the control valve spool is positioned down and flow is directed out the top of the control valve to the lower portion of the lift cylinder Hydraulic pressure against the cylinder piston extends the cylinder to raise the coring head At the same time the piston pushes the hydraulic fluid in the upper portion of the lift cylinder out and through the control valve to the pump return When the control valve lever is released spring action returns the spool to the center position and by passes flow back to the pump reservoir Lift cylinder movement is stopped
44. Oil Capacity 5 25 Pints 2 5 Liters Starter 12 VDC Greens Aerator 3 3 Engine This page is intentionally blank Engine Page3 4 Greens Aerator Service and Repairs Cooling System To ensure proper engine cooling make sure the rotating screen cooling fins and other external surfaces of the engine are kept clean at all times IMPORTANT The engine that powers the Greens Aerator is air cooled Operating the engine with dirty or plugged cooling fins a blocked rotating Screen or a plugged or dirty blower housing will re sult in engine overheating and engine damage 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 3 Clean cooling fins on both cylinder heads 4 Clean rotating screen and blower housing of dirt and debris Fig 1 IMPORTANT Never operate engine without the blower housing installed Overheating and engine damage will result 5 Make sure rotating screen and blower housing are reinstalled to the engine if removed NOTE For additional information regarding the engine cooling system refer to the engine service manual at the end of this chapter Greens Aerator Page 3 5
45. Parts Catalog for your Greens Aerator at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Greens Aerator are covered in the Opera tor s Manual Refer to that publication when performing regular equipment maintenance Refer to the Engine Operator s Manual for additional engine specific main tenance procedures Greens Aerator Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 6 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32
46. RANSPORT Z PLUNGER DEPRESSED ORANGE BROWN ORANGE 6 ORANGE ORANGE BURELE m gch ormally YELLOW 2 SWITCH _ L gt Open Normally PURPLE N PURPLE e Closed HANDLE SWITCH OPERATION d OFF G M A CASE q AIB D d H o 8 lt RUN B L A l p cl BLACK i rs m BLACK HAND SWITCH MUST BE CLOSED TO OPERATE IN CORING MODE TRANSPORT OR REVERSE START B L S L 3 SWITCH IGNITION BLACK Lj SWITCH RED WHITE RED WHITE YELLOW Normally Open TRANSPORT MODE RELEASING HANDLE DE OPEN ran CLUTCHES TRACTION DRIVE amp APPLIES BRAKE YELLOW Ed YELLOW CORING MODE RELEASING HANDLE STOPS ENGINE a RED BUT KEEPS TRACTION CLUTCH ENGAGED M 7 GREEN S WHITE RED WHITE Cel 4 s WHITE RED RED WHITE CARBURETOR x x x FUEL 9 SOLENOID d d i BLACK L RETRACTED WHEN ENERGIZED BLACK E rn x a z 85 8 zz X lt x GREEN m 2 z PURPL 20 AMP 5 AMP H G F E D C B A z FUSE O FUSE alala n zi i l 8 g RECTIFIER ac AC PURPLE REGULATOR et ait a A H g 0 dh E 0 c ella D4 BLACK RED D3 DIODE 11 CIRCUIT ENGINE D2 BOARD SOLENOID n ENGINE IGNITION Normally Open e BATTERY PLUNGER Di MODULES RETRACTED WHEN V x x ENERGIZED ENGINE s s STARTER cL d gl MOTOR e e H G F E BG B M L Lo 9 d A Greens Aerator ENGINE EN
47. Stratton 4 V Twin Cylinder OHV Air Cooled Gasoline Engine Model 303447 Number of Cylinders Bore x Stroke 2 68 x 2 60 68 mm x 66 mm Total Displacement 29 3 Cubic Inches 480 cc Dry Weight approximate 72 Pounds 32 4 Kilograms Fuel Unleaded Regular Gasoline Minimum 85 Octane Fuel Pump Pulsating Crankcase Vacuum Fuel Tank Capacity 4 5 U S Gallons 17 Liters Governor Mechanical Idle Speed no load 1400 100 RPM High Idle no load NOTE High Idle when shift lever is in reverse position 3600 100 RPM 1400 to 1800 RPM Engine Oil See Operator s Manual Oil Pump Gear Driven Geroter Type Crankcase Oil Capacity 1 75 Quarts 1 66 Liters with New Filter Starter 12 VDC Engine Page 3 2 Greens Aerator Models 09100 and 09110 Item Description Make Designation Kohler 4 Air Cooled Gasoline Engine Model M16S Number of Cylinders Bore x Stroke 3 75 x 3 25 95 3 mm x 82 6 mm Total Displacement 35 9 Cubic Inches 588 cc Dry Weight approximate 129 Pounds 58 6 Kilograms Fuel Unleaded Regular Gasoline Fuel Pump Mechanical Fuel Tank Capacity 1 5 U S Gallons 5 7 Liters Governor Mechanical Idle Speed no load 1300 RPM High Idle no load 3600 RPM Engine Oil See Operator s Manual Crankcase
48. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Greens Aerator REFER TO THE OPERATOR S MANUALS FOR OP ERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Cata logs for your machine Replacement Operator s Manu als are available on the internet at www toro com or by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice Part No 04133SL Service Manual Greens Aerator This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2004 This page is intentionally blank Greens Aerator Table Of Contents Chapter 1 Safety Safety Instructions
49. The cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinder Lower Coring Head Circuit operation for lowering the lift cylinder is similar to raising it However the control valve spool is shifted up and flow is reversed to and from the lift cylinder thus re tracting the cylinder to lower the coring head 2 E S gt Greens Aerator Page 4 7 Hydraulic System Special Tools Order these special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Hydraulic Pressure Test Kit Part Number TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Hydraulic Test Fitting Kit Part Number TOR4079 This kit includes a variety of O ring Face Seal fittings to enable connection of test gauges to the Greens Aerator hydraulic system The kit includes tee s unions reducers plugs caps and male test fittings Hydraulic System Page 4 8 Figure 9 TORO TEST FITTING KIT NO TOR4079 Union 1 ea Toro No Figure 10 Greens Aerator Troubleshooting The cause of an improperly functioning hydraulic sy
50. Tine arm Rivet LH wear plate Kickout deflector Lock washer Cap screw Cap screw LH wear plate bracket RH wear plate bracket 10 RH wear plate 11 Hex nut 12 Lock washer m gt N Coring Head 26 20 to 35 ft lb 35 27 to 47 N m 33 VA lt ic ZU P x Page 8 8 150 to 170 ft lb amp 203 to 230 N m 26 Nec 20 to 35 ft lb 27 to 47 N m 150 to 170 ft lb 203 to 230 N m Figure 9 Aerating tine 25 Socket head screw Tine holder 26 Socket head screw Stud 27 Bearing cap short crank Bushing 28 Retaining clip Pyramidal washer 29 Lower crank arm assembly Lock nut 30 Shoulder bolt Rubber bushing 31 O ring Connecting rod 32 Connecting link Lock nut 33 Roller chain Flat washer 34 Upper crank arm assembly Retaining ring 35 Bearing cap long crank Bearing Greens Aerator Removal Fig 9 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Unlatch and remove coring head cover 4 Remove coring head chain see Coring Head Chain Removal in this section 5 Remove both tine arms from crank arm assembly that is to be removed see Tine Arm Removal in this sec tion IMPORTANT Matchmark bearing cap and coring head frame bore before removing
51. VIT 68 227 51 156 in Ib 17 6 N m Figure 9 Drive Train Page 7 10 Greens Aerator Figure 9 Continued 1 Socket head screw 3 used 28 Bushing 54 Needle bearing 2 Snapring 29 Shifter stop 55 Needle bearing 3 Quadring 30 Gasket 56 Ball bearing 4 Roll pin 31 Shift lever housing gasket 57 Needle bearing 5 Shift lever housing 32 Shifting gear 58 Sealed ball bearing 6 Shift lever keeper 33 Shifting gear 59 Needle bearing 7 Shiftlever 34 Bevel gear 60 Oil seal 8 Shiftrod assembly 35 Idler gear 61 Thrust washer 1 16 thick 3 4 ID a 36 Three gear cluster 62 Low gear shaft and pinion os 37 Spacer 63 Needle bearing Hs Bub 3rd amp 4th 3 38 Snap ring 64 Reverse idler shaft 1 3 SUR de E 8 grooves 39 Input shaft 65 Reverse idler spacer ADI 40 Input shaft spur gear 66 Reverse idler gear 12 41 Thrust washer 1 16 thick 1516710 67 Spur gear 22 teeth 16 Thrust washer 1 32 thick 7 8 ID 42 Oil seal retainer 68 Thrust bearing 43 Output gear 69 Differential carrier 17 Cap screw 8 used n 18 Lock washer 8 used 44 Output shaft 70 Differential carrier 19 Ring gear 45 Oil seal 71 Bushing 20 Drive pin 46 Axle housing 72 O ring 21 Drive block 47 Transaxle cover 73 Thrust washer 1 32 thick 1 ID 22 Bevel pinion gear 48 Transaxle case 74 Thrust washer 1 32 thick 3 4 ID 23 Brake shaft amp gear 49 Flange head scr
52. a circular pattern to secure pulley and taper lock bushing 3 If sprocket item 11 was removed from transaxle shaft apply antiseize lubricant to transaxle shaft before installing sprocket Also apply Loctite 242 or equiva lent to set screws item 6 before installation 4 Position transaxle to the frame Attach transaxle to the frame with fasteners removed during disassembly A Four 4 cap screws item 30 lock washers item 8 and nuts item 31 NOTE Leave front cap screw on input shaft side of transaxle loose until belt guide is installed Fig 8 B Four 4 cap screws item 5 and pyramidal wash ers item 4 C Cap screw item 17 and pyramidal washer item 19 5 Install knob to shift lever 6 Install drive belt to transaxle and engine pulleys see Traction Drive Belt Installation in this section 7 Install brake caliper to machine see Brake Caliper Installation in Service and Repairs section of Chapter 6 Chassis 8 Install drive chain to both transaxle sprockets see Drive Chain Assembly in this section 9 Check and adjust transaxle oil level see Operator s Manual Figure 8 Drive Train 6 A o 2 Transaxle Service SHIFTER 120 10 16 13 6 coo 13 6 N m 39 3 lt 32 e 64 33 S e 3 7 jg ac 84 in Ib 16 ae a 9 5 N m 17 X a 9 54 3 41 218 d gt ae a X E I Se
53. aise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Remove rear wheel see Rear Wheel Removal in Service and Repairs section of Chapter 6 Chassis 4 While holding idler sprocket remove cap screw item 5 lock washer item 6 flat washer item 16 and spe cial nut item 18 to allow idler cover item 15 to be re moved Reinstall cap screw washers and special nut to retain idler sprocket 5 Remove sprocket guard item 2 and chassis guard item 17 from machine 6 Remove components as needed using Figure 5 as a guide Assembly Fig 5 1 Install removed components using Figure 5 as a guide A If idler sprocket was removed attach idler to frame as shown but don t install idler cover item 15 and leave cap screw item 5 finger tight B If sprocket item 24 was removed from transaxle shaft apply antiseize lubricant to transaxle shaft be fore installing sprocket Install and tighten cap screw item 20 lock washer item 21 and thrust washer item 22 Slide sprocket out to installed thrust wash er Apply Loctite 242 or equivalent to set screws item 19 and install set screws to secure sprocket 2 Position drive chain to sprockets Fig 6 Install mas ter link to chain Lubricate chain Greens Aerator Page 7 7 3 Install chassis guard item 17 and sprocket guard item 2 to machine 4 While holding idler sprocket remove cap screw item 5 lo
54. al Fig 13 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Remove control cover from machine Fig 14 4 Loosen two 2 self tapping screws item 16 that se cure pump support bracket to frame Loosen jam nut item 17 and then loosen square head screw item 18 Figure 14 to relax pump drive belt 1 Control cover 5 Remove drive belt from hydraulic pump and engine pulleys Drive Belt Installation Fig 13 1 Install pump drive belt to hydraulic pump and engine pulleys 2 Adjust pump drive belt tension see Operator s Manual 2 5 i gt 3 Install control cover to machine Fig 14 Greens Aerator Page 4 17 Hydraulic System Hydraulic Pump Figure 15 1 Engine 9 Flat washer 16 O ring 2 Key 10 Spacer 17 Cap screw 2 used 3 Set screw 2 used 11 Hydraulic pump 18 Spacer 2 used 4 Pulley 12 Pump drive belt 19 Pump support bracket 5 Shield 13 Pulley 20 Self tapping screw 2 used 6 Hydraulic pressure hose 14 Hose clamp 21 Jam nut 7 Hexnut 15 Return hydraulic hose 22 Square head screw 8 Lock washer 3 used Removal Fig 15 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets o
55. al components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Electrical System p SWITCH LOCK WASHER Figure 6 Electrical System Engine Stop Relay The Greens Aerator uses a relay for grounding the en gine magneto and thus stopping the engine This relay is located under the console Fig 7 Testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting Resistance should be from 70 to 95 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Di
56. at end of control valve faces out ward 14 Place new o ring item 4 on hydraulic fitting item 3 Thread fitting into pump and torque fitting from 37 to 55 ft lb 50 to 75 15 Torque mounting studs item 1 from 26 to 59 ft lb 35 to 80 16 Install pulley onto pump shaft Hydraulic System 9 FE Ow 0 ro Lift Cylinder Figure 18 Coring head frame 90 hydraulic fitting O ring 2 used O ring 2 used REN Removal Fig 18 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets Operate hydraulic lift control to relieve system pressure and avoid injury from pressurized hy draulic oil 3 Move lift lever to both raise and lower to make sure that hydraulic system pressure is relieved 4 Remove control cover from machine Fig 19 Hydraulic System 5 Hydraulic hose 6 Clevis pin 2 used 7 Hydraulic hose Page 4 22 8 Cotter pin 2 used 9 Lift cylinder 10 Main frame 5 Disconnect hydraulic hoses from hydraulic fittings on lift cylinder Locate and discard o rings from between hoses and fittings Allow hoses to drain into a suitable container 6 Plug disconnected hoses and fittings to prevent con tamination 7 Support lift cylinder to prevent it from falling Remove cotter p
57. be 5 Reinstall engine to machine A Connect a hoist or chain fall to lift tabs located on each of the cylinder heads One person should operate lift or hoist while another person guides the engine to the ma chine IMPORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while installing the engine B Reinstall engine with engine mount plate at tached to the machine Make sure fastener holes of the mount plate are aligned with the threaded holes in the machine frame C Secure engine mount plate to the frame with four 4 cap screws item 42 and lock washers Greens Aerator 6 Reconnect electrical connections to engine A Install harness wires double green and yellow to starter motor solenoid side posts B Connect harness alternator wire white fuel so lenoid wire white red and magneto ground wire black to engine leads Fig 6 C Install positive battery cable and fused harness wire red to the starter motor solenoid stud Fig 6 7 After engine installation verify pulley alignment across engine and hydraulic pump pulley faces with a straight edge If necessary loosen two 2 set screws on engine flywheel pulley and adjust location of pulley Re tighten pulley set screws after alignment Make sure that shield item 48 behind flywheel pulley is free to ro tate after pulley alignment 8 Install hydraulic pump drive belt see Pump Drive Belt i
58. c system is designed to op erate on SAE 10W 30 engine oil or as a substitute SAE 10W 40 engine oil Check level of hydraulic fluid dai ly See Operator s Manual for fluid level checking proce dure Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy draulic system all pressure in the hydraulic system must be relieved With the coring head fully raised turn key switch to OFF and allow engine to stop Raise coring head lock up brackets on each side of machine and lower coring head until coring head depth adjustment screws rest on brackets Fig 2 Move lift lever to both raise and lower to make sure that hydraulic system pres sure is relieved Greens Aerator Page 4 3 Figure 1 1 Hydraulic pump amp reservoir 2 Hydraulic reservoir cap amp dipstick 2 5 gt Figure 2 Lock up bracket 2 Depth adjustment screw Hydraulic System Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and mainte nance These conditions can cause damage or premature deterioration Some hoses are more suscep tible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted befor
59. ce and Repairs Chapter 8 Coring Head General Information Service and Repairs Chapter 9 Electrical Diagrams Electrical Schematics Wire Harness Drawings Hydraulic Product Records and Maintenance Electrical Coring Head Drive Train Electrical 2 gt Diagrams This page is intentionally blank Greens Aerator Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 5 Greens Aerator Page 1 1 Safety Safety Instructions The Greens Aerator is designed and tested to offer safe service when operated and maintained properly Al though hazard control and accident prevention partially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance of the machine can result in injury or death To re duce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the mach
60. chine and lower coring head until it rests on brackets 3 Remove rear wheel see Rear Wheel Removal in this section Chassis Page 6 6 4 While holding idler sprocket remove cap screw item 21 lock washer item 20 flat washer item 22 and special nut item 29 to allow idler cover item 23 to be removed Reinstall cap screw washers and special nut to retain idler sprocket 5 Remove sprocket guard item 3 and chassis guard item 28 or 30 from machine 6 Position idler sprocket to allow slack in drive chain Greens Aerator 7 Remove master link from drive chain Remove chain from sprocket on rear hub 8 Carefully pry dust cap item 11 from hub 9 Remove cotter pin item 14 from shaft 10 Remove nut retainer item 12 jam nut item 10 and tab washer item 13 that secure hub to shaft Slide hub with bearings from shaft 11 Disassemble wheel hub A Pull shaft seal item 5 from hub B Remove bearings item 6 from both ends of hub C Inspect bearing cups and cones for wear or dam age 12 If required remove lock nut item 2 that secures shaft to frame and remove shaft from machine Installation Fig 2 1 Clean all parts thoroughly before reassembly 2 If shaft was removed from frame clean taper shaft and frame Position shaft to frame and secure with lock nut item 2 3 Assemble wheel hub A If bearing cups were removed from the wheel hub press inner and outer cups into th
61. ck washer item 6 flat washer item 16 and spe cial nut item 18 and then install idler cover item 15 Reinstall cap screw washers and special nut Make sure that special nut is correctly positioned in slot in frame 5 Adjust drive chain tension see Operator s Manual 6 Install rear wheel assembly with valve stem facing out Secure wheel to machine with four 4 lug nuts Torque lug nuts from 65 to 90 ft lb 88 to 122 7 Lower machine to ground 8 Lower lock up brackets from coring head before ma chine use Figure 6 3 Wheel hub sprocket 1 Transaxle sprocket 2 Idler sprocket Drive Train 6 A o 2 Transaxle Figure 7 1 Transaxle 12 Taper lock bushing 22 Spring 2 Elbow 13 Pulley 23 Socket head screw 3 used 3 Oiltube 14 Lock washer 3 used 24 Shift guide plate 4 Pyramidal washer 4 used 15 Cap screw 3 used 25 Gasket 2 used 5 Cap screw 4 used 16 Woodruff key 26 Roll pin 6 Setscrew 2 used per sprocket 17 Cap screw 27 Set screw 2 used 7 Capscrew 18 Oil plug 28 Brake caliper 8 Lock washer 19 Pyramidal washer 29 Brake disc 9 Thrust washer 20 Shift lever assembly 30 Cap screws 4 used 10 Key 21 Knob 31 Nut 4 used 11 Sprocket Removal Fig 7 4 Remove drive belt from machine see Traction Drive Belt Removal in this section 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition 5
62. d B Check keyways splines threads and grooves for wear C Replace worn or damaged components 4 Inspect case and cover for cracks stripped threads metal chips flat sealing surfaces and rust Replace damaged components as necessary 5 Check thrust washers and spacers for shiny sur faces which indicate wear Try to determine the cause of thrust washer wear e g lack of end play due to reuse of old gasket or incorrect placement of thrust washer Replace any worn components 6 Examine bearings and bushings for scuffing wear pitting and any abnormal conditions Bearings should not exhibit any roughness when rotated Replace any worn or damaged bearings and bushings 7 Examine the external bearing surface of the differen tial assembly If wear or pitting are identified disas semble differential and repair or replace components as needed Shift Lever Service Figs 9 and 15 1 Place shift lever in a vise so the shift lever housing is at lease one inch 25 4 mm from the top of the vise jaws 2 Remove snap ring item 2 that retains shift lever keeper item 6 in housing Remove shift lever assembly from vise 3 Remove shift lever item 7 and quad ring item 3 from housing Discard quad ring 4 Inspect roll pin item 4 that is installed in shift lever ball If roll pin is damaged remove roll pin and replace Roll pin should be centered in shift lever ball with equal lengths protruding from sides of ball
63. de toward pulley end of shaft Install rotor item 11 onto shaft and secure with new retaining ring item 21 5 Apply coating of 10W30 engine oil to shaft bearing in pump housing 6 Install drive shaft assembly into pump housing taking care to not damage shaft seal Make sure that dowel pins positioned in housing extend through holes in thrust plate 7 Install rotor vanes item 12 into rotor making sure that rounded edges face the pump ring location 8 Install pump ring item 10 over vanes and rotor us ing identification mark made during disassembly to cor rectly position pump ring to thrust plate Make sure that dowel pins are located in small holes of pump ring and thrust plate recesses are aligned with large holes of pump ring 9 Install pressure plate item 9 using identification mark made during disassembly to correctly position plate to pump ring 10 Install pressure plate spring item 8 and end plate item 7 Compress end plate into pump housing to allow retaining ring item 6 to be installed Install retaining ring to secure pump assembly 11 Install new o ring item 15 and seals item 17 IMPORTANT Take care to not distort pump reser voir when installing reservoir to pump housing 12 Carefully install pump reservoir onto pump housing Install mounting studs item 1 finger tight to retain reser voir to pump housing 13 Install control spring item 19 and control valve item 18 Make sure that fl
64. draulic hose from lower fitting on lift cylinder Fig 12 Install T fitting with pressure gauge between disconnected hose and lower fitting on lift cylin der 7 Make sure that gear shift lever is in neutral and trac tion lever is disengaged 8 Start engine and operate engine at full speed 3600 100 RPM 9 Move lift lever to the raise position and while holding the lift lever in the raised position watch the pressure gauge Record pressure when the relief valve opens 10 Return lift lever to neutral position Shut off engine 11 Relief valve should open at approximately 1300 PSI 89 6 Bar 12 If specification is not met inspect pressure control valve located in hydraulic pump 13 Disconnect pressure gauge and T fitting from hy draulic hose and lift cylinder Connect hydraulic hose to lift cylinder Greens Aerator Page 4 13 Hydraulic System Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Raise coring head lock up brackets on each side of machine and lower coring head until coring head depth adjustment screws rest on brackets 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sur
65. draulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the hydraulic system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Hydraulic 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 6 Before disconnecting any hydraulic component or performing any work on the hydraulic system all pres sure in system must be relieved To relieve hydraulic System pressure stop engine raise coring head lock up brackets and lower coring head onto lock up brack ets 7 f major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 Use care when checking or servicing the coring head wear gloves and use caution 9 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt 10 If engine must be running to perform maintenance or make an adjustment keep hands feet clothing and oth er parts of the body away from all moving machine parts Keep bystanders away Greens Aerator Page 1 3 11 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed with a
66. ds toward the center of the transaxle 7 Install the two gear cluster item 27 and spacer item 37 onto brake shaft Fig 21 Drive Train 8 Install thrust washer item 61 low gear shaft and pinion item 62 and spur gear item 67 into cover Make sure that the small gear meshes with the larger gear of the two gear cluster 9 Slide shifting gears onto pinion shaft Position shifter assembly to sifting gears and pinion shaft making sure that shift forks engage gear slots Figure 20 1 Output shaft 3 Brake shaft 2 Output gear Greens Aerator Page 7 15 Drive Train 10 Center thrust washer item 16 on the pinion shaft bearing While squeezing shifter rods to hold shifter as sembly together install pinion shaft and shifter assem bly into cover Fig 22 11 Install reverse idler shaft item 64 spacer item 65 and reverse idler gear item 66 into cover Note that spacer goes between the gear and cover and the bev eled side of idler gear should be down into the cover 12 Install three gear cluster item 36 onto brake shaft Place thrust washer item 16 on brake shaft 13 Place gasket item 30 on cover sealing surface and then install case over differential shaft Make sure the case boss goes under the gears and the case edge goes over the shaft rods by tilting and rotating the case in the opposite manner in which it was removed 14 If necessary to close the case to the cover A Turn input shaft to
67. e hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Before working on ANY hydraulic component operate hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 3 Put caps or plugs on any hydraulic lines hydraulic fit tings or hydraulic components left open or exposed to prevent hydraulic system contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and fittings Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Hydraulic System Page 4 14 After Repair or Replacement of Components 1 Check oil level in the hydraulic pump reservoir and add correct oil if necessary D
68. e 8 9 IMPORTANT When installing coring head chain make sure that alignment pins are used to properly time the crank arm assemblies 6 Install coring head chain see Coring Head Chain Installation in this section 7 After assembly rotate coring crankshaft by hand to make sure that no binding occurs 8 Install coring head cover 9 Lower coring head lock up brackets before machine use Figure 10 1 Crankarm 2 Outer frame plate 3 Retaining clip Coring Head 6 Coring Head Drive Belt 90 og iom 41 44 1 8 Belt Guide clearance should be checked in this area Coring head frame Belt guide Flat washer Cap screw 2 used Lock nut 2 used Idler pulley pivot bracket Pyramidal washer 2 used Cap screw 2 used Cap screw Cap screw 2 used Lock washer Cap screw Handle Lock nut Square head screw 2 used Jam nut 2 used Coring Head 42 10 40 39 11 150 to 170 ft lb 203 to 230 N m Y Figure 11 Extension spring 2 used Spacer 500 long Coring head drive belt Lock washer 3 used Cap screw 3 used Bearing Spacer 740 long Sprocket Flat washer Lock nut Socket head screw 3 used Socket head screw Retaining clip 3 used Power shaft Key Taper lock bushing Page 8 10 38 26 252437 36 35 20 to 35 ft lb prd 27 to 47 N
69. e Operator s Manual 7 Lower lock up brackets from coring head before ma chine use Figure 6 1 Brake caliper 4 Brake rod 2 Brake bracket 5 Brake cable 3 Brake arm 44 5 mm Figure 7 Greens Aerator Page 6 11 Chassis Brake Caliper Service 24 ft lb 44 925 Anti seize Lubricant Anti seize Lubricant Figure 8 1 Adjustment pin 5 Live side housing 9 Anvil housing 2 Jamnut 6 Backing plate 10 Brake lining 3 Groove pin 7 Floating bracket 11 Actuator pin 4 Cap screw 2 used 8 Lock nut 2 used 12 Cam lever Disassembly Fig 8 Assembly Fig 8 1 Disassemble brake caliper using Figure 8 as a guide 1 Assemble brake caliper using Figure 8 as a guide noting the following items NOTE Brake lining on anvil housing side may have adhesive to secure it to housing A Apply anti seize lubricant to actuator and ad justment pin before assembly 2 Clean and inspect all caliper parts after disassembly Replace components that are worn or damaged B Secure the caliper assembly by torquing the cap screws 24 ft lb 32 5 N m C Make sure that caliper assembly moves freely on the floating bracket Chassis Page 6 12 Greens Aerator Chapter 7 TORO Drive Train Table of Contents SPECIFICATIONS 2 ADJUSTMENTS 3 Adjust Shift 3 SERVICE AND REPAIRS
70. e hub until they seat against the hub shoulder B Pack both bearing cones with grease Install greased inner bearing into the cup on inboard side of the wheel hub IMPORTANT The lip of the seal must face the bearing The seal must be pressed in so it is flush with the end of the hub C Lubricate the inside of the new lip seal and press it into the wheel hub 4 Install the wheel hub onto the shaft taking care to not damage seal 5 Install greased outer bearing cone tab washer item 13 and jam nut item 10 onto shaft Greens Aerator Page 6 7 6 Rotate the wheel hub by hand and torque the jam nut from 75 to 180 in Ib 8 5 to 20 3 to seat bearings Loosen nut until it is away from tab washer and hub has end play Finally tighten jam nut from 15 to 20 in lbs 1 7 to 2 3 N m while rotating hub 7 Install nut retainer and cotter pin to secure hub as sembly 8 Fill dust cup approximately 50 full of grease and install dust cap to hub 9 Grease hub bearings at grease fitting on hub until grease purges from seal Clean excess grease from seal area 10 Position drive chain to hub sprocket Fig 3 Install master link to chain Lubricate chain 11 Install chassis guard item 28 or 30 and sprocket guard item 3 to machine 12 While holding idler sprocket remove cap screw item 21 lock washer item 20 flat washer item 22 and special nut item 29 and then install idler cover item 23 Reinsta
71. e machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will discharge more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug battery charger from electrical outlet be fore connecting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove battery filler caps while cleaning battery 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tion of baking soda and water Rinse with clear water B Spray battery terminals with Battery Terminal Protector Toro Part No 107 0392 to prevent cable and terminal corrosion Petroleum jelly can be used as well Electrical System Page 5 16 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing make sure
72. e tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect Flats From Finger Tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nominal hose or tubing 0 75 0 25 6 3 8 in 0 75 0 25 8 1 2 in 0 75 0 25 10 5 8 in 1 00 0 25 12 3 4 in 0 75 0 25 16 1 in 0 75 0 25 Hydraulic System Page 4 4 Before disconnecting or performing any work on hydraulic system relieve all pressure in system by moving lift lever to both raise and lower AFTER the engine has been stopped Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use pap
73. ead frame dg Figure 3 1 Upper crank arm bearing cap 2 Power shaft bearing cap 3 Lower crank arm bearing cap 6 Greens Aerator Page 8 3 Coring Head Service and Repairs Coring Head Chain Figure 4 1 screw 11 Bushing 2 Lower crank arm assembly 12 Retaining ring 3 Socket head screw 13 Bearing 4 Lock washer 14 Idler sprocket 5 Bearing cap short crank 15 Drive sprocket 6 Lock nut 16 Flat washer 7 Eye bolt 17 Lock nut 8 Idler sprocket shaft 18 Bearing cap power shaft 9 Keeper bar 19 Power shaft 10 Flat washer 20 Connecting link Coring Head Page 8 4 Connecting link o ring Roller chain Upper crank arm assembly Bearing cap long crank Tine arm Coring frame Tap screw Chain guard Lock nut Greens Aerator Removal Fig 4 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Unlatch and remove coring head cover 4 Loosen two 2 lock nuts item 6 to allow chain slack 5 Rotate coring assembly by hand to locate drive chain connecting link Remove connecting link from drive chain 6 Remove drive chain from coring head Installation Fig 4 1 Route end of drive chain down between upper crank arm assembly sprocket and chai
74. em Fluid 3 Hydraulic System Components 14 Relieving Hydraulic System Pressure 3 Check Hydraulic Lines and Hoses 14 Hydraulic Hoses 4 Hydraulic System Start up 15 Hydraulic Fitting Installation 4 Hydraulic Pump Drive Belt 16 HYDRAULIC SCHEMATIC 6 Hydraulic 18 HYDRAULIC SYSTEM OPERATION 7 Hydraulic Pump Service 20 Coring Head Raise Lower 7 Lift Cylinder S 22 SPECIAL TOOLS er RR Meer Rx 8 Lift Cylinder Service 24 Hydraulic Pressure Test Kit 8 Lift Control 26 Hydraulic Test Fitting Kit 8 Lift Control Valve Service 28 TROUBLESHOOTING 9 TESTING ioc e xoa Tp a 11 TEST NO 1 System Relief Pressure 12 Greens Aerator Page 4 1 Hydraulic System 9 Ow gt ESA Specifications Item Description Hydraulic Pump Vane Pump Belt Driven System Relief Pressure 1300 PSI 89 6 Bar Hydraulic Oil 10W30 Engine Oil Hydraulic Reservoir Capacity 2 7 Pints 1 3 Liters Hydraulic System Page 4 2 Greens Aerator General Information Hydraulic System Fluid The Greens Aerator hydrauli
75. er 4 Roll pin 2 Snapring 5 Quadring 3 Shiftlever keeper Figure 16 1 Shifter rod Low 3 Shifter stop 2 Shifter rod 3rd amp 4th 4 Aligned notches Drive Train A o 2 Differential Assembly Service Figs 9 and 17 1 Place differential assembly in a large vise with soft jaws with the cap screw heads up Do not clamp the vise on the bearing race of the differential carrier or the seal area of the axle 2 Remove cap screws item 17 and lock washers item 18 that secure the differential carriers together Lift upper axle and carrier from the assembly If neces sary tap lightly on the ring gear with a soft faced ham mer to loosen it from carrier 3 Remove the drive blocks item 21 bevel pinion gears item 22 and drive pin item 20 from the ring gear 4 Lift ring gear item 19 from lower axle and differential E Bushing Reject carrier If necessary tap lightly on the ring gear with a 878 22 3 mm soft faced hammer to loosen it from carrier 5 Remove snap ring item 38 from end of axles Slide i 1 Axle 5 Thrust washer differential components from axle using Figure 9 as a 2 Needle bearing 6 Bushing guide 3 Drive block 7 Thrust bearing 4 Drive pin 8 Snapring 6 Inspect differential components A Replace bushings in differential carriers if the bushings are worn in excess of 878 22 3 mm B Check internal splines of bevel gears and axles f
76. er or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Sleeve Figure 3 Final Position Mark Nut and Body Initial Extend Line Position Finger Tight After Proper Tightening Figure 4 Greens Aerator SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct Flats From Finger TT Tight F F F T Fitting Size Installation Torque 4 9 10 ft Ib 12 13 N m 6 20 21 ft lb 27 28 N m 4 1 4 in nominal hose or tubing 1 00 0 25 eX 22 6 3 8 in 1505025 8 1 2 in 1 50 0 25 60 66 ft lb 81 89 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 81 87 ft lb 110 117 LN D 121 131 ft lb 164 177 NOTE Installation torque values for non adjustable fit Figure 6 tings are listed in Fi
77. es 19 6 cm Width 5 2 inches 13 2 cm Height 7 2 inches 18 3 cm Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 79C Discharged less than 1 240 Removal and Installation Fig 24 1 Loosen and remove negative cable from battery After negative cable is removed loosen and remove positive cable 2 Remove wing nuts and washers that secure battery hold down rod Slide hold down rod away from battery 3 Carefully remove battery from machine 4 Install battery in reverse order making sure to con nect positive cable to battery before connecting neg ative cable NOTE Before connecting the negative ground cable connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested and repaired Greens Aerator Page 5 17 Figure 24 1 Positive battery cable 2 Negative battery cable Inspection and Maintenance 1 Check for cracks in battery case Replace battery if cracked or leaking 2 Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly 3 Check for signs of wetness or leakage on the top of the battery which might indicate a loose
78. ew 11 used 75 Pipe plug 24 Snap ring 50 Dowel pin 2 used 76 Thrust race 25 Pinion shaft amp bearing 51 Cap screw 8 used 77 Washer 26 Roll pin 52 Drain plug 78 Bracket 27 Two gear cluster 53 Lock washer 8 used 79 Shift guide plate Transaxle Disassembly Fig 9 1 Drain lubricant from transaxle and clean outside of transaxle before disassembly 2 Place the transaxle in neutral Remove three 3 Socket head screws item 1 that secure shift lever as sembly to transaxle Lift shift lever assembly gaskets and shift guide plate from transaxle See Shift Lever Ser vice in this section for shift lever assembly service 3 For assembly purposes mark axle housings and transaxle to identify orientation of axle housings Re move cap screws item 51 and lock washers item 53 that secure axle housings to the transaxle Pull axle housings from the transaxle case and cover 4 Use exposed axles as a ram to separate seal retain ers from transaxle case and cover Remove and discard seals item 45 and o rings item 72 from retainers 5 Support transaxle so it is resting on the cover with no weight on the brake shaft Make sure that transaxle is well supported to prevent it from shifting or falling during disassembly procedure 6 A o 2 6 two 2 dowel pins item 50 into the cover and then remove eleven 11 flange head screws item 49 7 Liftthe case 1 1 2 to 2 inches 38 to 50 8 mm and
79. ews Figure 1 Greens Aerator Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records 2 52 G Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 147 23 282 56 339 56 599 79 100 10 1130 113 140 15 1582 169 734 113 115 12 1299 136 160 17 1808 192 1186 169 200 25 2260 282 300 30 3390 339 1446
80. f compo nent failure was severe or if system is contaminated 2 After the hydraulic system components have been properly installed make sure hydraulic reservoir is full Add correct oil if necessary see Operator s Manual 3 Make sure all hydraulic connections and lines are se cured tightly 4 Disconnect and ground both spark plug wires to pre vent engine from starting Greens Aerator Page 4 15 5 Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pump Repeat this step again 6 Reattach both spark plug wires 7 Start engine and run at low idle The hydraulic pump should pick up oil and fill the hydraulic system If there is no indication of fill in 30 seconds stop the engine and determine the cause 8 Raise and lower the coring head numerous times 9 Stop the machine Check hydraulic reservoir level and fill if necessary Check hydraulic components for leaks and tighten any loose connections Hydraulic System 9 G gt Hydraulic Pump Drive Belt Figure 13 1 Engine 7 Lock washer 3 used 13 Cap screw 2 used 2 Key 8 Flat washer 14 Spacer 2 used 3 Set screw 2 used 9 Spacer 15 Pump support bracket 4 Engine pulley 10 Hydraulic pump 16 Self tapping screw 2 used 5 Shield 11 Pump drive belt 17 Jam nut 6 Hexnut 12 Hydraulic pump pulley 18 Square head screw Hydraulic System Page 4 16 Greens Aerator Drive Belt Remov
81. f the ground 5 Position jack stands or hardwood blocks under the frame to support the machine Safety Page 1 4 Figure 1 1 Lock up bracket raised position Figure 2 1 Front wheel 2 Frame jacking point Figure 3 2 Frame jacking point 1 Rear wheel Greens Aerator Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Greens Aerator If any decal becomes illegible or damaged install a new decal Part numbers for replace ment decals are listed in your Parts Catalog Order re placement decals from your Authorized Toro Distributor Greens Aerator Page 1 5 Safety This page is intentionally blank Safety Page 1 6 Greens Aerator Chapter 2 TORO Product Records and Maintenance Table of Contents 28 8 PRODUCT RECORDS 1 Standard Torque for Dry Zinc Plated and MAINTENANCE 1 Steel Fasteners Inch Series 4 JEE 5 EQUIVALENTS AND CONVERSIONS 2 Standard Torque for Dry Zinc Plated and 8 Decimal and Millimeter Equivalents 2 Steel Fasteners Metric Fasteners 5 EX U S to Metric Conversions 2 Other Torque Specifications 6 TORQUE SPECIFICATIONS 3 Conversion Factors 6 Fastener Identification 3 Product Records Insert Operator s Manual and
82. from lower crank arm Lower tine arm assembly out bottom of coring frame 8 Dissasemble tine arm using Figure 7 as a guide Installation Fig 7 1 Assemble tine arm using Figures 7 and 8 as guides A If stud item 14 was removed from tine arm ap ply Loctite 271 red or equivalent to threads of stud before installing stud into tine arm B If connecting rod item 20 was removed install rod with the straight side down C When installing shoulder bolt item 30 align the bolt head to the center of coring head 2 Raise tine arm assembly up from bottom of coring frame Position tine arm to upper crank arm and con necting rod to lower crank arm 3 Install flat washer item 22 and lock nut item 21 to crank arms to retain tine arm and connecting rod Torque lock nuts from 150 to 170 ft lb 203 to 230 IMPORTANT When installing coring head chain make sure that alignment pins are used to properly time the crank arm assemblies 4 Install coring head chain see Coring Head Chain Installation in this section 5 After assembly rotate coring crankshaft by hand to make sure that no binding occurs 6 Install coring head cover 7 Lower coring head lock up brackets before machine use Greens Aerator Page 8 7 STRAIGHT BOLT HEAD TO SIDE DOWN CORING HEAD CENTER LOCTITE 271 Figure 8 6 Coring Head Crank Arms 150 to 170 ft lb 203 to 230 N m
83. gaskets between the engine and the exhaust tube flanges Make sure that gaskets are positioned correct ly Install four 4 cap screws with lock washers finger tight to keep exhaust tubes and gaskets in position 2 Slide muffler onto muffler tubes 3 Install four 4 self tapping screws item 12 finger tight to position muffler to muffler mount 4 Tighten cap screws to secure exhaust tubes to en gine Then tighten self tapping screws to secure muffler to muffler mount 5 Position muffler guard to machine and secure with fasteners removed during disassembly 6 Return coring head lock up brackets to stored posi tion Engine Engine i mh mh mh k k k k Loctite 242 Engine Lock washer 2 used Screw 2 used Throttle adjuster bracket Hex nut Cap screw Hex nut 2 used Exhaust tube Lock washer 4 used Cap screw 4 used Exhaust tube Pipe cap Pipe nipple Elbow Muffler mount Clevis pin Throttle control rod Loctite 242 Figure 4 Spring Muffler Spark arrester optional Self tapping screw 4 used Exhaust outlet Cap screw Lock washer Belt guide Grease fitting Cotter pin Support bracket Cap screw Self tapping screw 4 used Cap screw Lock washer Flat washer Flat washer NOTE On Models 09100 and 09110 equipped with a Kohler M16 engine engine removal and installation is
84. gure 6 These torque values should only be used when a fitting can be accessed with a Socket Use of an offset wrench e g crowfoot wrench will affect torque wrench accuracy and should not be used Figure 5 Size F F F T 9 G gt SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil Lock Nut 4 Turn back the jam nut as far as possible Make sure Back up Washer the back up washer is not loose and is pushed up as far as possible Step 1 O Ring 5 Install the fitting into the port and tighten finger tight Figure 7 until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct Flats From Finger Tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Figure 8 Greens Aerator Page 4 5 Hydraulic System Hydraulic Schematic LIFT CYLINDER LIFT C
85. harging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical System This page is intentionally blank Electrical System Page 5 20 Greens Aerator Chapter 6 TORO Chassis Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 4 Wheels 4 52723 nnt eI bmi es 4 Rear Wheel Hub 6 Steering Assembly 8 Brake Caliper 10 Brake Caliper Service 12 Greens Aerator Page 6 1 Chassis Specifications Item Description Front and Rear Tire Pressure 10 PSI 68 Bar Rear Wheel Lug Nut Torque 65 to 90 ft lb 88 to 122 Chassis Page 6 2 Greens Aerator This page is intentionally blank Greens Aerator Page 6 3 Chassis Service and Repairs Wheels Front axle assembly Thrust washer Front tire and wheel assembly Bearing 2 used per wheel Grease fitting PON Chassis 2 Figure 1 Slotted hex nut Hub cap Cotter pin Washer Bearing retainer 2 used per wheel Page 6 4 65 to 90 ft lb 88 to 122 11 Rear wheel stud 4 used per wheel 12 Rear tire a
86. hreads of set Screw item 2 Install set screw into handle 7 Connect brake cable to brake lever and cable brack et on handle Connect interlock switch wires to machine harness 8 Retain brake cable and wire harness to handle with cable ties 9 Install front wheels see Front Wheel Installation in this section 10 Lower machine to ground 11 Make sure that steering components do not contact brake cable or wire harness 12 Lubricate steering bearings by applying grease to grease fitting at front of frame 13 Lower lock up brackets from coring head before ma chine use Chassis Brake Caliper Figure 5 1 Brake caliper assembly 10 Cap screw 2 used 19 Brake clevis 2 Locknut 11 Brake cable clevis 20 Hex nut 3 Brake disc 12 Brake cable 21 Jam nut 4 Woodruff key 13 Cotter pin 22 Cap screw 2 used 5 Transaxle 14 Clevis pin 23 Brake arm 6 Setscrew 2 used 15 Clevis pin 24 Brake rod 7 Cap screw 2 used 16 Clutch cross shaft 25 Spring 8 Brake bracket 17 Flat washer 26 Brake spring retainer 9 Lock washer 18 Cotter pin Chassis Page 6 10 Greens Aerator Removal Figs 5 and 7 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Disconnect brake arm item 23 from brake caliper lever by removing two 2 cap screws i
87. ine Be come familiar with the controls and know how to stop the machine and engine quickly A replacement Operator s Manual is available on the Internet at www Toro com or by sending the complete model and serial number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington Minnesota 55420 1196 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 3 Assure interlock switches are adjusted correctly so engine cannot be started unless gear shift lever is in NEUTRAL and traction drive is DISENGAGED While Operating 1 Operator should be standing at the side console when starting the engine and at the handle when operat ing the machine Stay away from the coring head when it is engaged 2 Before starting the engine A Make sure gear shift lever is in neutral B Disengage the traction drive 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns Safety Page 1 2 To reduce the potential for injury or death comply with the following safety instructi
88. ins and clevis pins that secure lift cylinder to cor ing head and machine frame 8 Remove lift cylinder from the machine 9 If needed remove hydraulic fittings and o rings from the lift cylinder Discard o rings Greens Aerator Installation Fig 18 1 If removed install hydraulic fittings and new o rings into lift cylinder 2 Position lift cylinder to the machine mounting points Make sure the ports of the lift cylinder face the left side of the machine 3 Align lift cylinder mounting holes with frame and cor ing head mounts Install clevis pins and secure with cot ter pins 4 Remove plugs from disconnected hoses and fittings Figure 19 1 Control cover 5 Connect hydraulic hoses with new o ring to hydrau lic fittings on lift cylinder Tighten hose connections 6 Install control cover to machine Fig 19 7 Check hydraulic oil level in pump reservoir and fill with proper if necessary see Operator s Manual 8 Follow Hydraulic System Start up procedures 9 Raise coring head and raise lock up brackets on each side of machine 2 E S gt 10 Check hydraulic components for leaks Greens Aerator Page 4 23 Hydraulic System Lift Cylinder Service Figure 20 1 Rodclevis 7 O ring 12 O ring 2 Jamnut 8 Back up ring 13 O ring 3 Retaining ring 9 O ring 14 Piston 4 Dust seal 10 Rod 15 Lock nut 5 Head 11 Back up ring 16 Barrel 6 Back up ring Disassembly Fig 20
89. ley item 34 from taper lock bushing item 32 A Remove three 3 cap screws item 21 and lock washers item 20 that secure pulley to taper lock bushing IMPORTANT Excessive or unequal pressure on the cap screws can break the taper lock bushing flange When removing taper lock bushing tighten screws progressively and evenly B Insert cap screws into threaded removal holes of the bushing Tighten screws progressively and even ly until the pulley is loose on the bushing 9 Loosen set screw item 33 that secures taper lock bushing to power shaft Remove bushing and pulley from the shaft Locate and retrieve key item 31 that lo cate bushing on shaft Power Shaft Assembly Fig 13 NOTE Power shaft is not symmetrical Keyway in shaft is closer to right side of machine 1 Install key item 31 into keyway in power shaft 2 Using measurement made during disassembly lo cate taper lock bushing on shaft and secure in place with set screw item 33 3 Position pulley to bushing making sure that tapered surfaces of pulley and bushing align Align threaded holes of pulley with non threaded holes of bushing IMPORTANT When securing pulley to taper lock bushing tighten cap screws progressively and evenly to prevent bushing flange damage Greens Aerator Page 8 15 4 Secure pulley to taper lock bushing with three 3 cap screws item 21 and lock washers item 20 Tighten cap screws to a torque from 160 to 2
90. lic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and cause serious injury If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Greens Aerator Page 4 11 1 Thoroughly clean the machine before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hydraulic equipment Hydraulic system contamination will cause excessive wear of hydraulic components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition Use a tachometer when making a hydraulic test Engine speed will affect the accuracy of hydraulic test results 4 Because the hydraulic pump is belt driven check for proper pump belt adjustment before performing any hy draulic test 5 Install hydraulic fittings finger tight far enough to in sure that they are not cross threaded before tightening fitting with a wrench 6 To prevent hose or tester damage position the tester hoses so that moving machine parts will not make con tact with them 7 Check and adjust the oil level in the reservoir after connecting hydraulic test equipment 8 Check the control linkage f
91. ll cap screw washers and special nut Make sure that special nut is correctly positioned in slot in frame 13 Adjust drive chain tension see Operator s Manual 14 Install rear wheel assembly with valve stem facing out Secure wheel to machine with four 4 lug nuts Torque lug nuts from 65 to 90 ft lb 88 to 122 15 Lower machine to ground 16 Lower lock up brackets from coring head before ma chine use Figure 3 Chassis Steering Assembly Figure 4 1 Handle 6 Bearing cup 11 Brake cable 2 Set screw 7 Bearing cone 12 Brake cable bracket 3 Roll pin 8 Front axle 13 Brake lever 4 Key 9 Bearing cone 14 Interlock switch handle 2 used 5 Grease fitting 10 Lock nut Chassis Page 6 8 Greens Aerator Disassembly Fig 4 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Block rear wheels Jack front of machine from ground and support machine with blocking or jack stands see Jacking Instructions in Chapter 1 Safety 4 Remove front wheels see Front Wheel Removal in this section 5 Disconnect brake cable from brake lever and cable bracket on handle 6 Disconnect interlock switch wires from machine har ness 7 Remove cable ties that retain brake cable and wire harness to handle Position cable and wire harnes
92. low the thrust surface B If installing needle bearing into pinion shaft item Figure 18 25 press bearing into shaft until it is recessed 010 1 Differential bearing 4 Pinion shaft bearing 254 mm 2 Output shaft bearing 5 Brake shaft bearing 3 Shifter rod socket 6 Low gear shaft bearing C Remaining needle bearings should be pressed into housing 015 to 020 381 to 508 mm below the thrust surface TRANSAXLE CASE 3 Slide spur gear item 40 flat side of gear toward center of transaxle and thrust washer item 74 on input shaft item 39 Install input shaft into case Use a press or soft faced hammer to fully seat the shaft into the case If input shaft is not fully seated transaxle binding will occur 4 Center thrust washer item 73 on the cover brake shaft needle bearing Slide idler gear item 35 onto brake shaft item 23 with the chamfer side of the gear away from the cover Install brake shaft assembly into cover Fig 20 5 Center thrust washer item 41 on the output shaft Figure 19 bearing Slide output gear item 43 onto output pinion 1 Differential bearing 4 Input shaft and gear item 44 Install output shaft assembly into cover Place 2e Row geat shaft bearing 95 Shiferrod socket item y 3 Brake shaft bearing 6 Output shaft bearing thrust washer item 41 on output pinion 6 Insert differential assembly into the cover making sure to orientate the differential bolt hea
93. lt to engine pulley see Trac tion Drive Belt Installation in Service and Repairs sec tion of Chapter 7 Drive Train 13 Install exhaust muffler guard see Exhaust System Installation in Service and Repair section of Chapter 3 Engine IMPORTANT When installing coring head chain make sure that alignment pins are used to properly time the crank arm assemblies 14 Install coring head chain see Coring Head Chain Installation in this section 15 After assembly rotate coring crankshaft by hand to make sure that no binding occurs 16 Install coring head cover 17 Lower coring head lock up brackets before machine use 18 Check and adjust coring head drive belt tension see Operator s Manual Coring Head Page 8 12 Greens Aerator This page is intentionally blank 6 Greens Aerator Page 8 13 Coring Head Coring Head Drive 41 44 Antisieze Lubricant Coring head frame Belt guide Flat washer Cap screw 2 used Lock nut 2 used Idler pulley pivot bracket Pyramidal washer 2 used Cap screw 2 used Cap screw 10 Cap screw 2 used 11 Lock washer 12 Cap screw 13 Handle 14 Lock nut 15 Square head screw 2 used 16 Jam nut 2 used 0 CIO SON Coring Head 40 39 11 150 to 170 ft lb 203 to 230 N m Y Antisieze gt S Figure 13 Extension spring 2 used Spacer 500 long Coring head drive bel
94. m Figure 21 Hydraulic System 9 Ow Lift Control Valve Figure 22 1 Shaft 8 Connecting link 15 Hydraulic return hose 2 Cap screw 4 used 9 Lock washer 4 used 16 Hose clamp 3 Control panel 10 Hex nut 4 used 17 O ring 4 Lift valve handle 11 Lift control valve 18 90 hydraulic fitting 5 Knob 12 O ring 2 used 19 O ring 6 Flat washer 13 Straight fitting 2 used 20 O ring 7 Locknut 14 O ring 2 used 21 Hydraulic hose Hydraulic System Page 4 26 Greens Aerator Removal Fig 22 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets Operate hydraulic lift control to relieve system pressure and avoid injury from pressurized hy draulic oil 3 Move lift lever to both raise and lower to make sure that hydraulic system pressure is relieved 4 Remove control cover from machine Fig 23 5 Disconnect hydraulic hoses items 15 and 21 from 90 hydraulic fittings item 18 on lift control valve Allow hoses to drain into a suitable container Discard o rings 6 Tag hydraulic hoses attached to straight fittings in lift control valve ports A and B Disconnect hoses and allow them to drain into a suitable container Discard o rings 7 Remove connecting link assembly item 8 that at
95. make sure all gears mesh properly B Using needle nose pliers agitate shifter rod ends into their machined recesses in the case 15 Align the case and cover with two 2 dowel pins Install eleven 11 flange head screws Torque screws to 10 ft Ib 13 6 N m NOTE Use seal protectors during seal installation to prevent damage to oil seals 16 Lubricate new oil seals Install input shaft seal item 60 into case and brake shaft seal item 45 into cover 17 Lubricate and install new oil seals item 45 and o rings item 72 to oil seal retainers item 42 Install seal retainers to transaxle case and cover 18 Position axle housings to transaxle noting marks made during disassembly for correct housing orienta tion Secure axle housings with lock washers item 53 and cap screws item 51 Torque cap screws to 156 Ib 17 6 N m 19 Coat both sides of new shift lever housing gaskets item 31 with Permatex 2 or equivalent Install gas kets shift guide plate item 79 bracket item 78 and shift lever to transaxle Secure assembly to transaxle with three 3 socket head screws item 1 Torque screws to 120 in Ib 13 6 Drive Train Page 7 16 1 2 PONT Two gear cluster Spacer Three gear cluster Reverse idler gear Input pinion shafts Shifter rod Low Figure 21 3 Figure 23 5 6 7 8 Brake shaft Shifter rod 3rd amp 4th Low gear Differential assembly Output
96. med to ensure minimal machine vibration A variety of aerating tines and tine holders are available for use on the Greens Aerator Refer to the Operator s Manual for available options Coring Head Lock Up Brackets Whenever service is to be performed on coring head components fully raise coring head and raise lock up brackets on each side of machine Once lock up brack ets are raised lower coring head until it rests on brack ets Fig 2 After service is completed raise coring head and lower lock up brackets Coring Head Adjustments See Operator s Manual for adjustment procedures for the coring head on the Greens Aerator Figure 1 Figure 2 1 Lock up bracket raised position Never work on the coring head with the engine running Always fully raise coring head stop en gine remove key from the ignition switch and install the coring head lock up brackets before performing any service to coring head compo nents Coring Head Page 8 2 Greens Aerator Coring Head Bearing Caps The Greens Aerator coring head frame includes several bearing caps used to position the power shaft and crank arms Line boring of the coring head frame during manufacture determines location of the bearing caps If any of the bearing caps are removed during repairs they need to be reinstalled in the exact position that they were removed from Matchmark bearing cap and frame location before removing a bearing cap from the coring h
97. n each side of machine and lower coring head until it rests on brackets Operate hydraulic lift control to relieve system pressure and avoid injury from pressurized hy draulic oil Hydraulic System Page 4 18 3 Move lift lever to both raise and lower to make sure that hydraulic system pressure is relieved 4 Remove control cover from machine Fig 16 5 Position a drain pan under machine below hydraulic pump Loosen hose clamp item 14 from return hydrau lic hose item 15 and remove hose from pump fitting to allow pump to drain 6 Loosen and remove hydraulic pressure hose item 6 from pump Locate and discard o ring item 16 7 Loosen two 2 self tapping screws item 20 that se cure pump support bracket to frame Loosen jam nut item 21 and then loosen square head screw item 22 to relax pump drive belt Remove drive belt from the hy draulic pump pulley Greens Aerator 8 Plug or cap openings of pump and hoses to prevent contamination Support hydraulic pump when removing it from the pump support bracket to prevent the pump from falling and causing personal injury or pump damage 9 Remove fasteners that secure hydraulic pump to support bracket Locate and retrieve spacers items 10 and 18 1 Control cover Figure 16 10 Lift pump assembly from the machine 11 Remove hydraulic fitting and o ring from the pump if required Installation Fig 15 1 If removed install hydraulic fit
98. n guard 2 Insert alignment pins through holes in coring head plates and crank arm sprockets see Fig 5 and Opera tor s Manual 3 Place lower end of chain onto approximate center of lower crank arm assembly sprocket Pull chain slack up ward and position chain onto upper crank arm assembly sprocket 4 Route upper free end of chain downward in front of idler sprocket behind drive sprocket on power shaft and then around front of lower crank arm assembly sprocket to opposite end of chain Fig 6 5 Install connecting link to attach chain ends A Lubricate connecting link pins chain bushings and connecting link o rings B Place o ring on both connecting link pins and in sert connecting link to chain ends C Place o ring on both connecting link pins and install connecting link side plate D Secure connecting link with spring lock making sure that spring lock fits into grooves of connecting link 6 Adjust coring head chain tension see Operator s Manual Lubricate chain 7 Install coring head cover 8 Lower coring head lock up brackets before machine use Greens Aerator 8 5 Figure 5 1 Upper crank arm alignment hole 2 Lower crank arm alignment hole Figure 6 Upper crank sprocket 3 Idler sprocket 2 Lower crank sprocket 4 Drive sprocket 6 lt Coring Head Tine Arms 150 to 170 ft lb 203 to 230 N m
99. n the Service and Repairs section of Chapter 4 Hydraulic System 9 Adjust hydraulic pump drive belt tension see Opera tor s Manual 10 Install coring head drive belt to the engine PTO pulley see Coring Head Drive Belt in the Service and Repairs section of Chapter 8 Coring Head Greens Aerator Page 3 13 11 Install transaxle drive belt to the engine PTO pulley see Transaxle Drive Belt in the Service and Repairs section of Chapter 7 Drive Train 12 Remove plug installed in fuel hose during disassem bly Connect fuel hose to the fuel filter and secure with hose clamp 13 Connect spring item 18 to clevis pin in shift plate Fig 8 14 Install exhaust system see Exhaust System Instal lation in this section 15 Check engine oil level see Operator s Manual 16 Check all wires control cables and hoses to make sure that they are not contacted by rotating or moving parts 17 Connect positive and then negative battery cables at the battery 18 Install control cover to machine Fig 5 19 Return coring head lock up brackets to stored posi tion Engine This page is intentionally blank Engine Page 3 14 Greens Aerator Chapter 4 TORO Hydraulic System Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 14 GENERAL INFORMATION 3 General Precautions for Removing and Installing Hydraulic Syst
100. nd wheel assembly 13 Lug nut 4 used per wheel 14 Rear wheel hub Greens Aerator Rear Wheel Removal Fig 1 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets Chock front wheels 3 Jack rear of machine from ground and support ma chine with blocking or jack stands see Jacking Instruc tions in Chapter 1 Safety 4 Loosen and remove four 4 lug nuts that secure rear wheel to be removed 5 Remove rear wheel from machine Rear Wheel Installation Fig 1 1 Position rear wheel to wheel hub 2 Secure wheel to machine with four 4 lug nuts Torque lug nuts from 65 to 90 ft Ib 88 to 122 3 Lower machine to ground Lower coring head lock up brackets before machine use Greens Aerator 6 5 Front Wheel Removal Fig 1 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets Chock rear wheels 3 Jack front of machine from ground and support ma chine with blocking or jack stands see Jacking Instruc tions in Chapter 1 Safety 4 Remove hub cap from front wheel to be removed 5 Remove cotter pin and then remove slotted hex nut from front axle 6 Slide washer
101. ons 4 Since gasoline is highly flammable handle it careful A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill the fuel tank E Wipe up any spilled fuel 5 Before leaving the operator s position A Ensure that gear shift lever is in neutral B Raise coring head and wait for coring head to stop C Set parking brake Stop engine and remove key from ignition switch 6 Anytime the machine is parked short or long term raise coring head lock up brackets to secure the coring head in the raised position This eliminates the risk of the coring head accidentally lowering to the ground 7 Do not park on slopes unless wheels are chocked or blocked Greens Aerator Maintenance and Service 1 Before servicing or making adjustments position machine on level surface raise coring head stop en gine and remove key from the ignition switch Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hy
102. or improper adjustment binding or broken parts Make sure control linkage is functioning properly before conducting hydraulic tests 9 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Hydraulic System FE Ow TEST NO 1 System Relief Pressure Using Pressure Gauge LIFT CYLINDER gt PRESSURE GAUGE LIFT CONTROL VALVE HYDRAULIC PUMP INTERNAL 1300 PSI RELIEF VALVE Working Pressure Return or Suction PUMP gt Flow Direction RESERVOIR Figure 11 Hydraulic System Page 4 12 Greens Aerator Procedure for System Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 3 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 4 Read Precautions For Hydraulic Testing in this sec tion Figure 12 1 Hydraulic lift cylinder 2 Lift cylinder lower fitting Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 5 With engine off move lift control lever to raise and lower to relieve system pressure 2 5 gt 5 gt 6 Disconnect hy
103. or wear or damage C Inspect drive blocks and drive pin for wear or damage D Replace differential components that are worn or damaged 7 Assemble the differential in the reverse order of dis assembly using Figure 9 as a guide Lightly oil compo nents before installation into differential Make sure that thrust washers item 16 and thrust races item 76 are placed on the correct sides of thrust bearings item 68 8 Secure the differential assembly with lock washers and cap screws Torque cap screws 84 9 5 N m 9 After assembly test differential action by holding the upper axle vertically and spinning the differential Next place the assembly on the bench and rotate both axles in opposite directions In both tests the assembly should rotate freely without binding If any binding is noted check cap screw torque gear meshing and bear ings Little or no play should be evident between the axles and carriers Drive Train Page 7 14 Greens Aerator Transaxle Assembly Fig 9 TRANSAXLE COVER 1 During assembly of transaxle lightly oil components before installation into transaxle 2 Use a press and appropriate installation tool to press all removed bearings into transaxle cover and case Figs 18 and 19 IMPORTANT When installing needle bearings press only on stamped side of bearing A If installing needle bearings for low gear shaft item 62 press bearings into housing 010 254 mm be
104. orientation 10 Lightly tap on end of drive shaft with soft face ham mer until pressure plate item 9 and pump ring item 10 are free of pump housing Remove pressure plate 11 Remove pump ring item 10 and rotor vanes item 12 from rotor 12 Remove retaining ring item 21 from pump drive shaft 13 Complete pump disassembly by removing rotor item 11 thrust plate item 13 dowel pins item 16 rings item 14 and shaft seal item 22 Inspection 1 Inspect rotating group components A Inspect rotor vanes for scoring or wear Also check the fit of the vanes into the rotor for sticking or excessive play B Check rotor slots for burrs or excessive wear at thrust faces C Inspect inner surface of pump ring for scoring or excessive wear 2 Inspect thrust plate and pressure plate for wear or scoring on thrust surfaces 3 Inspect drive shaft for scoring or wear 4 Inspect control valve to make sure it moves freely in valve bore 5 Replace any components found to be damaged Assembly Fig 17 NOTE During the assembly process lightly oil all pump components with 10W30 engine oil before instal ling them 1 Install two 2 new o rings item 14 into pump hous ing grooves 2 Install new shaft seal item 22 into pump housing Greens Aerator Page 4 21 3 Install two 2 dowels pins item 16 into pump hous ing 4 Install thrust plate item 13 onto drive shaft with countersunk si
105. pin 2 used Disassembly Fig 17 1 Empty any oil remaining in reservoir into a drain pan Thoroughly clean the outside of the pump assembly 2 Using suitable puller remove pulley from pump shaft Clean pump shaft with crocus cloth if any corro sion on shaft exists 3 Remove the pump mounting studs item 1 4 Remove the hydraulic fitting item 3 and o ring item 4 Discard o ring 5 Turn the pump so the shaft faces up Remove the control valve item 18 and control valve spring item 19 Hydraulic System Page 4 20 IMPORTANT Prevent damage when clamping the pump in a vise Do not close vise enough to distort pump housing 6 Mount pump assembly in a vise clamping on the housing around the shaft seal 7 Using a soft face hammer tap on pump reservoir item 5 to remove it from pump housing Take care not to damage reservoir during removal 8 Remove c ring item 15 and seals item 17 Retain seals item 17 to help identify correct replacement seals from seal kit as different thicknesses of seals have been used Greens Aerator 9 Rotate retaining ring item 6 so end of ring is at hole in pump housing Insert a punch into hole and remove retaining ring from housing Remove end plate item 7 and pressure plate spring item 8 from pump housing IMPORTANT When removing pressure plate item 9 pump ring item 10 and thrust plate item 13 mark components so that they can be assembled in the same
106. r diode circuit board Fig 23 is used for circuit protection from voltage spikes that occur when circuit solenoids are de energized Diode D1 on this board is not used Testing The diodes can be individually tested using a digital multimeter diode test position or ohms setting and the diode diagrams to the right Figures 22 and 23 The diodes should have continuity in one direction and no continuity in the other direction If any diode is faulty re place the diode board Greens Aerator Page 5 15 Figure 21 1 Diode board 4 diode 2 Diode board 3 diode DIODE DIAGRAM BIC D DIODE CIRCUIT BOARD Figure 22 a D2E gt a D3 lI p Ben E DIODE CIRCUIT BOARD DIODE DIAGRAM Figure 23 Electrical System SE ov 92 Service and Repairs NOTE See the engine Repair Manuals located after chapter 3 for engine component repair information Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected if the battery is stored on th
107. rain and refill entire hy draulic system if component failure was severe or if hy draulic system is contaminated 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in the General Information section of this chapter 5 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system see Hydraulic System Start Up in this sec tion 6 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic pump reservoir and add correct oil if necessary Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and or chemical deterioration Make all necessary repairs before operating machine Greens Aerator Hydraulic System Start up NOTE When initially starting the hydraulic system with new or rebuilt components pump lift cylinder or lift con trol valve it is important that this start up procedure be used This procedure reduces the chance of damaging the hydraulic system or its components from not purging the system of air 1 Drain flush and refill hydraulic reservoir i
108. rds Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Greens Aerator Torque Specifications 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 spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Scr
109. remaining harness wires double green and yellow from starter motor solenoid side posts 8 Remove coring head and transaxle drive belts from the engine PTO pulley see Coring Head Drive Belt in the Service and Repairs section of Chapter 8 Coring Head and Transaxle Drive Belt in the Service and Re pairs section of Chapter 7 Drive Train 9 Remove hydraulic pump drive belt from the engine flywheel pulley see Pump Drive Belt in the Service and Repairs section of Chapter 4 Hydraulic System 10 Disconnect spring item 18 from clevis pin in shift plate Fig 8 Figure 5 1 Control cover Figure 6 1 Starter motor solenoid 2 Positive battery cable 3 Fused harness wire 4 Alternator wire 5 Fuel solenoid wire 6 Magneto ground wire Figure 7 3 Set screw 2 used 1 Engine flywheel pulley 2 Hydraulic pump drive belt Greens Aerator Page 3 11 Engine 1 Remove engine from machine A Connect a hoist or chain fall to lift tabs located on each of the cylinder heads B Remove four 4 cap screws item 42 and lock washers that secure the engine mount plate to the machine frame One person should operate lift or hoist while another person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while removing the engine C Carefully lift engine with engine mount plate at tached f
110. ressively and even ly until the pulley is loose on the bushing C Remove pulley and bushing from transaxle shaft D Locate and retrieve woodruff key item 16 that lo cates bushing on transaxle shaft Installation Fig 7 1 If brake disc was removed A Position woodruff key in transaxle brake shaft slot and slide brake disc hub first onto shaft so disc hub is 060 1 5 mm from transaxle housing B Apply Loctite 4242 or equivalent to threads of two 2 sets screws item 27 Secure brake disc on shaft with set screws 2 If pulley was removed from transaxle input shaft A Make sure that tapered surfaces of pulley and ta per lock bushing are thoroughly clean no oil grease dirt rust etc B Place woodruff key item 16 in input shaft slot Slide pulley item 13 and then taper lock bushing item 12 onto transaxle shaft making sure that ta pered surfaces of pulley and bushing align Greens Aerator Page 7 9 C Align threaded holes of pulley with non threaded holes of bushing Loosely install three 3 cap screws with lock washers into pulley threads IMPORTANT When tightening cap screws tighten in three equal steps and in a circular pattern to pre vent bushing flange damage D Align the outside of bushing with the inside of the groove on the input shaft approx 1 8 from end of shaft Tighten three 3 cap screws to a torque from 90 to 120 in Ib 10 2 to 13 6 in three equal steps and in
111. rom the machine 12 If needed remove engine from engine mount plate by removing four 4 cap screws item 44 lock nuts and lock washers 13 If needed remove drive pulleys from engine Installation Fig 4 1 Locate machine on a level surface with key removed from the ignition switch Chock wheels to keep the ma chine from moving 2 Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled to the engine 3 If pulleys were removed from engine A Apply anti seize lubricant to pulley bores Posi tion keys in shaft slots B Install engine flywheel pulley with the pulley hub toward engine Apply Loctite 242 or equivalent to two 2 set screws Tighten set screws to retain pulley C Slide engine PTO pulley onto crankshaft Apply Loctite 242 or equivalent to cap screw and secure pulley to crankshaft with cap screw lock washer and two 2 flat washers 4 If engine was removed from engine mount plate position engine on mount plate so the letter F on the mount plate is up amp on the oil drain tube side of the en gine Fig 9 Secure engine to mount plate with four 4 cap screws item 44 and lock nuts NOTE Cap screw closest to flywheel on the starter motor side of the en gine uses two 2 lock washers item 45 Engine Page 3 12 Figure 8 1 Throttle control rod 3 Shift plate 2 Spring 4 Clevis pin Figure 9 1 Mounting plate F mark 2 Oildrain tu
112. s tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat or noise has a potential for failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive hydraulic component damage Problem Possible Cause The chart below contains information to assist in trou bleshooting There may possibly be more than one cause for a machine malfunction Refer to the Testing section of this Chapter for precau tions and specific test procedures Hydraulic oil leaks Foaming hydraulic fluid Hydraulic system operates hot Coring head will not lift or lifts slowly Oil level in reservoir is low Hydraulic system has wrong kind of oil Pump suction return line has an air leak Oil level in reservoir is low Hydraulic fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged 2 5 x gt r Excessive dirt and or debris on hydraulic components Oil is contaminated or too light Air trapped in hydraulic system Hydraulic pump is worn or damaged Engine speed is too low Reservoir oil level is low Pump drive belt is loose or worn
113. s away from handle 8 Support handle Loosen set screw item 2 Remove roll pin item 3 that secures handle to front axle Slide control handle from machine taking care to not damage brake cable or wiring harness that will stay attached to machine Locate and retrieve key item 4 9 Support front axle Remove lock nut that secures front axle in frame Lower front axle from frame 10 Remove upper bearing cone from frame and lower bearing cone from front axle 11 If necessary remove bearing cups from machine frame 12 Inspect bearing cups and cones for wear or damage Replace worn or damaged components Greens Aerator Page 6 9 Assembly Fig 4 1 If bearing cups were removed from frame install new cups to frame Make sure that cones are fully seated 2 Pack bearing cones with grease Install lower bear ing cone on front axle 3 Slide front axle shaft up through frame Position rub ber seal on lower bearing on inside of frame tube Place upper bearing cone onto axle shaft 4 Install lock nut onto front axle Tighten nut completely and then back nut off slightly Retighten nut until drag is felt while rotating front axle Make sure that front axle ro tates freely after lock nut has been tightened 5 Position key item 4 in front axle Slide handle onto front axle and align roll pin holes in handle and front axle Install roll pin so that it is flush with handle 6 Apply Loctite 4242 or equivalent to t
114. s is not gripped the engine should stop running 3 With the transaxle in gear and the coring head raised and disengaged transport if one of the handle inter lock levers is not gripped the traction clutch should dis engage and the brake should apply at the same time The engine should continue to run Electrical System Page 5 6 Greens Aerator Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check NOTE Electrical troubleshooting of any 12 Volt power connection can be performed through voltage drop tests without disconnecting the component Ignition Switch The ignition key switch has three positions OFF RUN and START Fig 4 The terminals are marked as shown in Figure 5 Testing The circuitry of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Unplug wire harness connectors from switch and verify continuity between switch terminals Reconnect the har ness connectors to the switch after testing Greens Aerator Page 5 7 NOTE See the appropriate engine Repair Manual lo cated after Chapter 3 for engine component testing in formation When testing electric
115. sconnect voltage and multimeter leads from the relay terminals Electrical System Page 5 8 Figure 7 1 Engine stop relay Figure 8 Greens Aerator Interlock Lever Switches The two interlock lever switches are located on the han dle Fig 9 The lever switches are normally open and close when the lever is raised to the handle The inter lock lever switches are used to permit engine operation when the coring head is lowered and also allows the traction drive lever to be retained in the engaged posi tion Testing 1 Unplug the switch connector from the machine har ness 2 With the use of a multimeter ohms setting deter mine whether continuity exists between the switch con nector terminals for each switch position Figure 9 A With the lever extended away from the handle there should be continuity open between the switch terminals B When the lever is raised to the handle there should be continuity closed between the switch ter minals 3 Replace the interlock lever switch if necessary 4 After testing plug the switch connector into the ma chine harness m Wu Greens Aerator Page 5 9 Electrical System Traction Interlock Switch The traction interlock switch is attached to the shift plate at the front of the aerator Fig 10 The greens aerator uses the normally open center and common ground terminals of the switch
116. shaft item 44 and output gear item 43 from cover Fig 14 Locate and retrieve thrust washer item 41 from both ends of shaft 15 Remove brake shaft item 23 and idler gear item 35 from cover Locate and retrieve thrust washer item 73 16 Remove input shaft item 39 and spur gear item 40 from case by tapping end of shaft with soft faced ham mer Locate and retrieve thrust washer item 74 17 Remove and discard seals from transaxle cover and case Transaxle Inspection 1 Thoroughly clean all transaxle components 2 Inspect all transaxle gears A Check gear bevels for wear chipping or breaks Wear or chipping on transaxle gear bevels indicates improper transaxle shifting B Check face of teeth for wear Large shiny areas indicate excessive tooth contact and possible exces sive wear C Check that shifting gears items 32 and 33 slide freely on pinion shaft Also check that splines of shifting gears are not worn Worn shifting gear splines allow the gears to cock on the shaft causing difficult shifting D Replace gears that are damaged or show exces sive wear Drive Train Page 7 12 Figure 13 1 Two gear cluster 3 Brake shaft 2 Spacer Figure 14 Output shaft 3 Brake shaft Output gear Na Greens Aerator 3 Inspect shafts and axles A Carefully check shaft and axle surfaces for rust pitting scratches or wear Use crocus cloth to repair rust burrs or sharp edges if neede
117. similar to the following procedure Engine Page 3 10 Washer Key Cap screw Lock washer Flat washer Flat washer Pulley Cap screw 4 used Engine mount plate Cap screw 4 used Lock washer Lock washer Lock nut Shield Pulley Set screw 2 used Key Greens Aerator Removal Fig 4 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch Chock wheels to keep the machine from moving 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Disconnect negative and then positive battery cables at the battery 4 Remove control cover from machine Fig 5 5 Remove exhaust system see Exhaust System Re moval in this section 6 Loosen hose clamp and disconnect fuel hose from the fuel filter on the rear side of the engine Plug fuel hose to prevent leakage and contamination Position fuel line away from engine 7 Disconnect electrical connections from engine Position disconnected wires away from the engine NOTE Label all electrical connections for reassembly purposes A Remove positive battery cable and fused har ness wire red from the starter motor solenoid stud Fig 6 B Disconnect harness alternator wire white fuel solenoid wire white red and magneto ground wire black from engine Fig 6 C Remove
118. st 3 minutes Record the battery voltage After allowing the engine to run for at least three 3 min utes battery voltage should be at least 0 5 volts higher than initial battery voltage see example in table to the right NOTE While engine is running if battery voltage ex ceeds 15 volts the regulator in the charging system should be inspected see the engine Repair Manuals lo cated after Chapter 3 After allowing the engine to run for at least three 3 min utes if battery voltage does not increase at least 0 5 volts additional testing of the battery and or charging system should be performed Greens Aerator Page 5 5 Electrical System Check Operation of Safety Interlock System Do not disconnect interlock switches They are for the operator s protection Check operation of the switches daily to make sure the interlock system is operating correctly If a switch is not operating properly adjust or replace it before operating the machine Interlock switch operation is described in the Greens Aerator Operator s Manual Testing of individual inter lock switches is included in the Component Testing sec tion of this Chapter The Safety Interlock System of the Greens Aerator en sures the following operations 1 The engine should crank only when the traction drive lever is disengaged and the coring head is raised 2 With the transaxle in gear and the coring head oper ating if one of the handle interlock lever
119. stem 8 Englne iore ensue 10 BRIGGS amp STRATTON REPAIR MANUAL FOR 4 CYCLE V TWIN CYLINDER OHV HEAD ENGI NES KOHLER MAGNUM SERVICE MANUAL Introduction This Chapter gives information about specifications and repair of the Briggs amp Stratton engine used in the Greens Aerator Model 09120 NOTE Greens Aerators Models 09100 and 09110 are powered by a Kohler M16 engine Service for these ma chines is similar to the procedures identified in this Chapter General engine maintenance procedures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the engine Repair Manual that is included at the end of this chapter Greens Aerator Page 3 1 Chapter 3 Engine Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the engine Repair Manual The use of some specialized test equipment is explained However the cost of the test equipment and the special ized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for the engine used in the Greens Aerator are supplied through your local engine dealer or distributor Briggs amp Stratton or Kohler Engine Engine Specifications Model 09120 Item Description Make Designation Briggs and
120. t Lock washer 3 used Cap screw 3 used Bearing Spacer 740 long Sprocket Flat washer Lock nut Socket head screw 3 used Socket head screw Retaining clip 3 used Power shaft Key Taper lock bushing Page 8 14 38 26 252437 36 35 19 20 to 35 ft lb Pr d 27 to 47 N m un 22 23 0 See text for tightening procedure 150 to 170 ft lb 203 to 230 N m FRONT RIGHT N 33 Set screw 34 Pulley 35 Bearing cap 36 Bearing 37 Spacer 560 long 38 RH idler bracket 39 Pulley guard 40 LH idler bracket 41 Spacer 42 Idler shaft 43 Bearing 2 used 44 Idler pulley 45 Retaining ring 46 Spacer 1 060 long 47 Idler pulley Greens Aerator Power Shaft Disassembly Fig 13 1 Park the machine on a level surface fully raise the coring head and stop the engine Remove the key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Unlatch and remove coring head cover 4 Remove coring head drive belt see Coring Head Drive Belt Removal in this section 5 Remove power shaft assembly from machine 6 Press bearings from power shaft Note that right side bearing has retaining ring used to locate bearing in cor ing frame 7 Measure and record distance from shaft end to loca tion of taper lock bushing to ease reassembly 8 Loosen pul
121. tem 22 and lock nuts item 2 4 Remove two 2 cap screws item 10 and lock wash ers that secure brake bracket to frame 5 Slide brake caliper and brake bracket assembly from brake disc 6 Brake disc can be removed from transaxle shaft by loosening two 2 set screws item 6 and sliding disc from shaft Locate and retrieve woodruff key item 4 Installation Figs 5 and 7 1 If brake disc was removed A Position woodruff key in transaxle shaft and slide brake disc hub first onto shaft so disc hub is 060 1 5 mm from transaxle housing B Apply Loctite 4242 or equivalent to threads of two 2 sets screws item 6 Secure brake disc on shaft with set screws 2 Slide brake caliper and brake bracket assembly onto brake disc 3 Secure brake bracket to frame with two 2 cap screws item 10 and lock washers 4 Connect brake arm item 23 to brake caliper lever with two 2 cap screws item 22 and lock nuts item 2 5 Check and adjust location of nuts on brake rod Fig 7 A Make sure that traction drive lever is disengaged B Spring length from bottom of brake arm to bottom of spring retainer should be 1 75 44 5 mm C There should be approximately 125 3 2 mm between top of brake arm and hex nut directly above arm D If adjustment is necessary loosen appropriate jam nut change position of hex nut and tighten jam nut to secure adjustment 6 Check and adjust brake as needed se
122. ting with new o ring to the hydraulic pump 2 5 i gt Support hydraulic pump when removing it from the pump support bracket to prevent the pump from falling and causing personal injury or pump damage 2 Position hydraulic pump assembly to the support bracket Secure pump to the pump support with re moved fasteners Make sure that spacers items 10 and 18 are positioned between bracket and pump 3 Remove any caps or plugs that were placed in pump openings and hydraulic hoses during the pump removal procedure Connect hydraulic hoses to hydraulic pump 4 Install pump drive belt to the pump pulley Adjust belt tension see Operator s Manual 5 Fill pump reservoir with proper oil see Operator s Manual 6 Install control cover to machine Fig 16 7 Follow Hydraulic System Start up procedures 8 Check for any hydraulic leaks 9 Raise coring head and return coring head lock up brackets to stored position Greens Aerator Page 4 19 Hydraulic System Hydraulic Pump Service 35 ft lb 47 N m Figure 17 1 Mounting stud 2 used 9 Pressure plate 17 Seal 2 used 2 Reservoir cap dipstick 10 Pump ring 18 Control valve 3 Hydraulic fitting 11 Rotor 19 Control valve spring 4 O ring 12 Rotor vane 10 used 20 Pump housing 5 Pumpreservoir 13 Thrust plate 21 Retaining ring 6 Retaining ring 14 O ring 22 Seal 7 End plate 15 O ring 23 Drive shaft 8 Pressure plate spring 16 Dowel
123. to 38 C The ignition key should be in the OFF position and all accessories turned off Connect the positive me 25 charged ter lead to the positive battery post and the negative 096 charged meter lead to the negative battery post Use the table to the right to determine charge level of the battery NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if the charging system is functioning It will tell you if the charging sys tem has an output but not its capacity Initial Battery Voltage 12 25 v Acceptable voltage increase Use a multimeter set to the DC volts position Connect Battery Voltage after 3 Minute Charge the positive meter lead to the positive battery post Difference 0 55 v and the negative meter lead to the negative battery post Leave the multimeter test leads connected to the battery and record the battery voltage Wu NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Start the engine and run at 3600 RPM high idle Allow the battery to charge for at lea
124. ulley on transaxle adjust posi tion of shift lever and shift tower until sprockets on trans axle output shafts do not move 6 Secure shift tower in position with four 4 cap screws flat washers and lock nuts Figure 1 1 Shifttower 3 Flat washer 4 used 2 Cap screw 4 used 4 Locknut 4 used 6 A o 2 Greens Aerator Page 7 3 Drive Train Service and Repairs Traction Drive Belt Figure 2 1 Transaxle 12 Set screw 22 Bracket 2 Transaxle pulley 13 Cap screw 23 Lock nut 3 Belt guide 14 Spring 24 Belt guide 4 Flat washer 15 Idler pulley 25 Cap screw 5 Capscrew 16 Transaxle drive belt 26 Lock washer 6 Flat washer 17 Engine pulley 27 Cross shaft arm traction drive 7 Spring 18 Engine 28 Spring bracket 8 Clutch arm 19 Spacer 29 Lock washer 9 Roll pin 20 Lock nut 30 Cap screw 10 Cross shaft 21 Bushing 2 used 31 Cross shaft arm brake 11 Jam nut Drive Train Page 7 4 Greens Aerator Removal Fig 2 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition switch 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets 3 Remove exhaust muffler guard see Exhaust Sys tem Removal in Service and Repair section of Chapter 3 Engine 4 Loosen fasteners that secure belt guide item 3 to machine 5 Remove drive belt from engine pulley and transaxle pulley Pull dri
125. used The switch can be tested for continuity at the wire har 4 Jam nut 10 Screw 2 used ness connector as shown in Figure 14 5 Seal 11 Flange nut 2 used 6 Switch harness When the switch plunger is extended continuity should exist across harness connector terminals B and C Con tinuity should not exist between any other connector ter minals When the switch plunger is pushed in continuity should exist across harness connector terminals A and B and also between terminals C and D Continuity should not exist between any other connector terminals m If necessary switch testing can be done at the switch terminals Figure 13 1 Switch housing 3 Switch normally closed 2 Switch normally open 4 Switch plunger HARNESS E CONNECTOR ORANGE exe an eS SWITCH ee NORMALLY sd PURPLE 45 SWITCH qt OPEN NORMALLY PURPLE CLOSED A gl PM e C p cl 1 t BLACK BLACK 3 SWITCH BEA NORMALLY J OPEN YELLOW Figure 14 Greens Aerator Page 5 11 Electrical System Clutch Solenoid The clutch solenoid is used in conjunction with the trac tion interlock switch the coring head switch assembly and the interlock lever switches in the Greens Aerator in terlock system When the clutch solenoid is energized the solenoid plunger rotates a latch which retains the traction drive lever in
126. valve seat only if it needs re placement it is pressed into the valve body 3 Remove plugs and o rings from the valve body Re move springs balls and cam pins from the valve body 4 Remove snap ring from the bottom of the valve body Remove spool snap ring spring retainer spacer and spring 5 Push and twist spool carefully out of the valve body Set spool aside 6 Remove o rings from valve body using a soft hooked scribe or a thin screwdriver taking care not to scratch the valve bore finish Inspection Fig 24 A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect spool for bending and flatness Signs of wear on one side of the spool may indicate damage Replace a worn or damaged spool if necessary 3 Inspect other components for wear or damage and replace damaged items as necessary Assembly Fig 24 1 Coat all new o rings with 10W30 engine oil Install new o rings into the bore of the valve body 2 Coat spool lightly with 10W30 engine oil Push and twist spool carefully into the valve body Avoid damaging o rings 3 Install spring retainer spring spacer second spring retainer and spool snap ring onto the spool Install snap ring into the valve body Hydraulic System Page 4 28 1 Plug 8 Spool 2 O ring 9 O ring 3 Spring 10 Spring retainer 4 Ball 11 Spring 5 Check valve seat 1
127. ve belt from machine Installation Fig 2 1 Position drive belt to transaxle and engine pulleys noting correct belt routing Fig 3 2 Secure belt guide item 3 to machine with fasteners loosened during belt removal After guide is secured there should be 030 to 090 8 to 2 3 mm clearance between the guide and the drive belt Fig 4 3 Check and adjust drive belt tension see Operator s Manual 4 Install exhaust muffler guard see Exhaust System Installation in Service and Repair section of Chapter 3 Engine 5 Lower lock up brackets from coring head before ma chine use Greens Aerator 7 5 Figure 3 030 to 090 8 to 2 3 mm 030 to 090 8 to 2 3 mm lt 4 Figure 4 6 A o 2 Drive Train Drive Chain Figure 5 1 Frame 10 Half link 2 Sprocket guard RH shown 11 Bushing 3 Capscrew 12 Retaining ring 4 Wheel hub 13 Idler sprocket 5 Capscrew 14 Bearing 6 Lock washer 15 Idler cover 7 Spacer 16 Flat washer 8 Drive chain 17 Chassis guard RH shown 9 Master link Drive Train Page7 6 Lubricant Loctite 242 Special nut Set screw 2 used per sprocket Thrust washer Lock washer Cap screw Key Sprocket Transaxle Greens Aerator Disassembly Fig 5 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition Switch 2 R
128. y and then install second retaining ring E Coat idler shaft item 42 with antisieze lubricant before installation 2 After assembly of belt tensioner components make sure to check belt alignment If necessary loosen fas teners that secure idler pivot pulley bracket item 6 and adjust location of bracket on coring head frame Coring Head s 6 This page is intentionally blank Coring Head Page 8 16 Greens Aerator Chapter 9 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS Electrical Schematic Model 09120 3 Electrical Schematic Model 09110 4 WIRE HARNESS DRAWINGS Wire Harness Drawing Model 09120 5 Wire Harness Diagram Model 09120 6 Wire Harness Drawing Model 09110 7 Wire Harness Diagram Model 09110 8 lt 6 oD ua Greens Aerator Page 9 1 Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 9 2 Greens Aerator
129. y other manufacturers may result in non conformance with the safety standards and the warranty may be voided Safety Jacking Instructions When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and prop er raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury Jacking the Front End 1 Chock rear tires to prevent the machine from mov ing 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets Fig 1 3 Position jack securely under the front of the frame on side of machine Fig 2 4 Jack front of machine off the ground 5 Position jack stands or hardwood blocks under the front of the frame to support the machine 6 Repeat jacking and support on other side of frame Jacking the Rear End 1 Chock front tire to prevent the machine from moving 2 Raise lock up brackets on each side of machine and lower coring head until it rests on brackets Fig 1 3 Place jack securely under the main frame just inside of the rear wheel Fig 3 4 Jack rear of machine of

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