Toro 23518, 29518, 33518, 39518 Service Manual

Residential and

LCE Products

30 inch

Stand-On Aerator

Service Manual

ABOUT THIS MANUAL

This service manual was written expressly for Toro and Lawn-Boy service technicians. The Toro Company has made every effort to make the information in this manual complete and correct.

Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.

For additional information on the electrical system, please refer to the Toro Electrical Demystication Guide (492-

4761) and subsequent. For service information on drive systems, please refer to the Hydro-Gear BDP service manual (492-4779). For information specic to the engine used on this unit, refer to the appropriate engine manufacturer’s service and repair instructions.

The Toro 30” Aerator, model year 2013, is covered in this manual. The manual may also be specied for use on later model products.

Due to the compact design, parts were removed for photographic purposes when necessary.

The hydraulic components are sophisticated pieces of machinery. Maintain strict cleanliness control during all stages of service and repair. Cover or cap all hose ends and ttings whenever they are exposed. Even a small amount of dirt or other contamination can severely damage the system.

We are hopeful that you will nd this manual a valuable addition to your service shop. If you have any questions or comments regarding this manual, please contact us at the following address:

The Toro Company Residential and Landscape Contractor Service Training Department 8111 Lyndale Avenue South Bloomington, MN 55420

The Toro Company reserves the right to change product specications or this manual without notice.

ABOUT THIS MANUAL

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TABLE OF CONTENTS

1 - Safety Information

General Information ..................................................................................................................................... 1-1

Think Safety First......................................................................................................................................... 1-1

2 - Specications & Maintenance

Torque Specications .................................................................................................................................. 2-1

Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) ....................................................... 2-2

Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) .......................................................... 2-3

30” Aerator Specications............................................................................................................................ 2-4

Recommended Maintenance Schedule....................................................................................................... 2-5

Premaintenance Procedures ....................................................................................................................... 2-6

Lubrication ................................................................................................................................................... 2-6

Lubricate Chains ................................................................................................................................... 2-6

Lubricate Grease Fittings ...................................................................................................................... 2-7

Lubricate Caster Wheel Hubs ............................................................................................................... 2-8

Engine Maintenance .................................................................................................................................... 2-9

Service Air Cleaner ............................................................................................................................... 2-9

Change Engine Oil ................................................................................................................................ 2-9

Check Spark Plugs ............................................................................................................................... 2-9

Check Spark Arrester (if equipped) ....................................................................................................... 2-9

Fuel System Maintenance ......................................................................................................................... 2-10

Change Fuel Filter .............................................................................................................................. 2-10

Electrical System Maintenance ................................................................................................................. 2-10

Check Battery Charge ......................................................................................................................... 2-10

Drive System Maintenance.........................................................................................................................2-11

Check Tire Pressures ...........................................................................................................................2-11

Check Wheel Hub Nuts Torque Specication ......................................................................................2-11

Check Wheel Lug Nuts Torque Specication .......................................................................................2-11

Check Condition Of Chains ..................................................................................................................2-11

Check Condition Of Sprockets .............................................................................................................2-11

Check Transmission Output Shaft Nut Torque Specication ...............................................................2-11

Jackshaft Drive Chain Tension Adjustment ......................................................................................... 2-12

Drive Wheel Chain Tension Adjustment .............................................................................................. 2-13

Caster Pivot Bearings Pre-Load Adjustment ....................................................................................... 2-13

Brake Maintenance.................................................................................................................................... 2-13

Adjusting the Parking Brake ................................................................................................................ 2-13

Adjusting the Brake Switch ................................................................................................................. 2-14

Belt Maintenance ....................................................................................................................................... 2-14

Check Condition & Tension Of Belts ................................................................................................... 2-14

Transmission Drive Belt Tension ......................................................................................................... 2-14

Auxiliary Pump Drive Belt Adjustment ................................................................................................. 2-14

Controls System Maintenance................................................................................................................... 2-15

Motion Control Linkage Adjustment .................................................................................................... 2-15

Hydraulic System Maintenance ................................................................................................................. 2-16

Check Auxiliary Hydraulic Oil Level .................................................................................................... 2-16

Check Hydraulic Transmission Oil Level ............................................................................................. 2-16

Change Auxiliary Hydraulic Reservoir Fluid and Filter ........................................................................ 2-16

Change Hydraulic Transmission Filters and Fluid ............................................................................... 2-17

Tine Maintenance ...................................................................................................................................... 2-18

Check Tines ........................................................................................................................................ 2-18

Tine Drive Chain Adjustment ............................................................................................................... 2-18

TOC-1Toro 30” Aerator Service Manual

TABLE OF CONTENTS

3 - Chassis

Chassis ............................................................................................................................................................3-1

Exploded View - Mainframe ......................................................................................................................3-1

Lubricate Caster Wheel Hubs..........................................................................................................................3-2

Caster Wheel Assembly Replacement ............................................................................................................3-3

Caster Wheel Assembly Removal .............................................................................................................3-3

Caster Wheel Assembly Installation ..........................................................................................................3-6

Exploded View – Tower .................................................................................................................................3-12

Adjusting the Parking Brake ..........................................................................................................................3-13

Adjusting the Brake Switch ............................................................................................................................3-13

Fuel System...................................................................................................................................................3-14

Engine Fuel Line Routing ..............................................................................................................................3-14

Motion Control System ..................................................................................................................................3-15

Motion Control Linkage Adjustment ...............................................................................................................3-16

Axle Bearing Assembly Replacement............................................................................................................3-17

Axle Bearing Assembly Removal ............................................................................................................3-17

Axle Bearing Assembly Installation .........................................................................................................3-18

4 - Hydraulics & Engine Mounting

Hydraulics ........................................................................................................................................................4-1

Hydraulic Subsystem ................................................................................................................................4-1

Valve Manifold ...........................................................................................................................................4-2

Auxiliary Hydraulic Subsystem ..................................................................................................................4-3

Checking the Transmission Expansion Tank Hydraulic Oil ..............................................................................4-4

Servicing the Auxiliary Hydraulic Oil ................................................................................................................4-4

Changing Auxiliary Hydraulic Reservoir Fluid and Filter..................................................................................4-6

Changing Hydraulic Transmission Filters and Fluid ........................................................................................ 4-7

Hydraulic Transmission Filter Removal .....................................................................................................4-7

Hydraulic Transmission Filter Installation ..................................................................................................4-7

Transmission Belt Replacement .....................................................................................................................4-8

Transmission Belt Removal ......................................................................................................................4-8

Transmission Belt Installation ................................................................................................................. 4-11

Transmission Replacement ...........................................................................................................................4-13

Transmission Removal ............................................................................................................................4-13

Transmission Installation .........................................................................................................................4-17

Transaxle Chain Tensioning ....................................................................................................................4-20

Hydraulic Pump Belt Removal & Installation .................................................................................................4-21

Idler Arm Removal & Installation ...................................................................................................................4-22

Return to Neutral Setting ........................................................................................................................4-23

Hydraulic Pump Rebuild ................................................................................................................................4-24

Hydraulic Pump Assembly .............................................................................................................................4-28

Hydraulic Cylinder Rebuild ............................................................................................................................4-29

Engine ...........................................................................................................................................................4-34

Engine Mounting .....................................................................................................................................4-34

Engine Pulley ..........................................................................................................................................4-35

Engine Replacement .....................................................................................................................................4-36

Engine Removal ......................................................................................................................................4-36

Engine Installation ...................................................................................................................................4-38

TOC-2 Toro 30” Aerator Service Manual

TABLE OF CONTENTS

5 - Ground Drive & Tine Systems

Ground Drive ...................................................................................................................................................5-1

Subsystem Ground Drive ..........................................................................................................................5-1

Chains .......................................................................................................................................................5-2

Aerator Assembly ............................................................................................................................................5-3

Tinebar Chain Assembly ..................................................................................................................................5-4

Tine Shaft Replacement ..................................................................................................................................5-4

Tine Shaft Removal ...................................................................................................................................5-4

Tine Wheel Assembly ................................................................................................................................5-6

Coring Tine Removal & Replacement .......................................................................................................5-7

Tine Shaft Installation ................................................................................................................................5-7

Jackshaft Replacement ...................................................................................................................................5-9

Jackshaft Removal ....................................................................................................................................5-9

Jackshaft Installation ...............................................................................................................................5-12

6 - Electrical

Ignition Switch .................................................................................................................................................6-1

Purpose .....................................................................................................................................................6-1

Location ....................................................................................................................................................6-1

How It Works .............................................................................................................................................6-1

Testing .......................................................................................................................................................6-1

Foot Switch ......................................................................................................................................................6-2

Purpose .....................................................................................................................................................6-2

Location ....................................................................................................................................................6-2

How It Works .............................................................................................................................................6-2

Testing .......................................................................................................................................................6-2

Starter Solenoid ...............................................................................................................................................6-3

Purpose .....................................................................................................................................................6-3

Location ....................................................................................................................................................6-3

How It Works .............................................................................................................................................6-3

Testing .......................................................................................................................................................6-3

Parking Brake Switch ......................................................................................................................................6-4

Purpose .....................................................................................................................................................6-4

Location ....................................................................................................................................................6-4

How It Works .............................................................................................................................................6-4

Testing .......................................................................................................................................................6-4

Fuse Block & Fuses.........................................................................................................................................6-5

Purpose .....................................................................................................................................................6-5

Location ....................................................................................................................................................6-5

How It Works .............................................................................................................................................6-5

Testing .......................................................................................................................................................6-5

Hour Meter.......................................................................................................................................................6-6

Purpose .....................................................................................................................................................6-6

Location ....................................................................................................................................................6-6

How It Works .............................................................................................................................................6-6

Testing .......................................................................................................................................................6-6

TOC-3Toro 30” Aerator Service Manual

TABLE OF CONTENTS

6 - Electrical cont.

Relay ...............................................................................................................................................................6-6

Purpose .....................................................................................................................................................6-6

Location ....................................................................................................................................................6-6

How It Works .............................................................................................................................................6-7

Testing .......................................................................................................................................................6-7

Subsystem Electrical Diagram.........................................................................................................................6-9

Wiring Harness Diagram ...............................................................................................................................6-10

Electrical Diagram .........................................................................................................................................6-11

Electrical Schematic ......................................................................................................................................6-12

TOC-4 Toro 30” Aerator Service Manual

General Information

SAFETY INFORMATION

This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because it has to do with your safety. Failure to comply with the

This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro 30” Aerator. The 30” Aerator operator’s manual contains

instruction may result in personal injury or even death.

Think Safety First

Avoid unexpected starting of engine...

Always turn off the engine and disconnect the spark plug wire(s) before cleaning, adjusting, or repair.

Avoid lacerations and amputations...

Stay clear of all moving parts whenever the engine is running. Treat all normally moving parts as if they were moving whenever the engine is running or has the potential to start.

safety information and operating tips for safe operating practices. Operator’s manuals are available through your Toro parts source or:

The Toro Company Publications Department 8111 Lyndale Avenue South Bloomington, MN 55420

Avoid injury from batteries...

Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Battery gases can explode. Keep cigarettes, sparks, and ames away from the battery.

Avoid injury due to inferior parts...

Use only original equipment parts to ensure that important safety criteria are met.

Avoid burns...

Do not touch the engine, mufer, or other components which may increase in temperature during operation, while the unit is running or shortly after it has been running.

Avoid res and explosions...

Avoid spilling fuel and never smoke while working with any type of fuel or lubricant. Wipe up any spilled fuel or oil immediately. Never remove the fuel cap or add fuel when the engine is running. Always use approved, labeled containers for storing or transporting fuel and lubricants.

Avoid asphyxiation...

Never operate an engine in a conned area without proper ventilation.

Avoid injury to bystanders...

Always clear the area of bystanders before starting or testing powered equipment.

Avoid injury due to projectiles...

Always clear the area of sticks, rocks, or any other debris that could be picked up and thrown by the powered equipment.

Avoid modications...

Never alter or modify any part unless it is a factory approved procedure.

Avoid unsafe operation...

Always test the safety interlock system after making adjustments or repairs on the machine. Refer to the Electrical section in this manual for more information.

Toro 30” Aerator Service Manual

1-1

SAFETY INFORMATION

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Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Torque Specications

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 identied and specied in the service manual.

These torque specications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specic requirement identied in the service manual. The following factors shall be consid ered 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 of the fastener’s head, or similar condition which affects the installation.

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 specic torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.

Fastener Identication

Inch Series bolts and Screws

(A) Grade 1 & 2 (B) Grade 5

The standard method of verifying torque shall be performed 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.

Metric Bolts and Screws

(A) Class 8.8 (B) Class 10.9

Toro 30” Aerator Service Manual

2-1

SPECIFICATIONS & MAINTENANCE

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series)

Grade 1, 5, &

Thread Size

# 6 - 32 UNC

# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20

# 8 - 32 UNC

# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3

# 10 - 24 UNC

#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70

1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170

1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170

5/16 - 18 UNC 115 ± 15 105 ± 15 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340

5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340

3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5

3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5

7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9

7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9

1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14

1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14

5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27

5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27

3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47

3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47

7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81

7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81

8 with Thin

Height Nuts

In-lb In-lb N-cm In-lb N-cm In-lb N-cm

10 ± 2 13 ± 2 147 ± 23

13 ± 2 25 ± 5 282 ± 30

18 ± 2 30 ± 5 339 ± 56

ft-lb ft-lb N-m ft-lb N-m ft-lb N-m

SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular

Height Nuts (SAE J995

Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs, & Sems with Regular

Height Nuts (SAE J995

Grade 2 or Stronger Nuts)

15 ± 2 169 ± 23 23 ± 2 260 ± 34

29 ± 3 330 ± 30 41 ± 4 460 ± 45

42 ± 4 475 ± 45 60 ± 6 674 ± 70

SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular

Height Nuts (SAE J995

Grade 2 or Stronger Nuts)

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 oil, graphite, 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.

2-2

Toro 30” Aerator Service Manual

Note: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

SPECIFICATIONS & MAINTENANCE

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)

Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws, and Studs with

Thread Size

M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm

M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm

M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 28 ± 3 ft-lb 38 ± 4 N-m

M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 54 ± 6 ft-lb 73 ± 8 N-m

M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 93 ± 10 ft-lb 126 ± 14 N-m

M16 X 2.0 166 ± 15 ft-lb 225 ± 23 N-m 229 ± 23 ft-lb 310 ± 31 N-m

M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 36 ft-lb 610 ± 62 N-m

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 oil, graphite, or thread sealant such as Loctite.

Regular Height Nuts

(Class 8 or Strong Nuts)

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. Thin height nuts include jam nuts.

Class 10.9 Bolts, Screws, and Studs with

Regular Height Nuts (

Class 10 or Strong Nuts)

Toro 30” Aerator Service Manual

2-3

SPECIFICATIONS & MAINTENANCE

30” Aerator Specications

30” Stand-On Aerator

Models: 23518 / 33518

Engines: 36.8 cu-in. (603cm³)

Make Kawasaki

Model FS481 V-Twin

Hi-Idle 3600 RPM

Low-Idle 1250-1550 RPM

Spark Plug BPR4ES (NKG)

Spark Plug Gap .030"/.76mm

Oil SAE 10W-30

Oil Capacity 1.8 Qt. (1.7 liters)

Starter Electric Only

Fuel Tank Volume 5.0 US gal (18.9 L)

Power System:

Transmission Hydro-Gear ZT3400

Hydraulic Fluid Toro Hydro Oil

Hydraulic Fluid Capacity

Ground Speed (fwd/rev)

Drive Tires (pneumatic)

Tire Pressure 12-14 psi (83-97 kPa)

70.3 oz.(2.0 L) w/lter

7.5 mph/NA

16 x 6.50 - 8

Dimensional:

Width (in/cm) 47.75/121.3

Length Operating (in/cm)

Length Handle Stored (in/cm)

Height Operating (in/cm)

Height Handle Stored (in/cm)

Weight (lb/kg) 1015.0/460.0

Max Operating Depth (in/cm)

Plugs per Sq-ft./ Sq-meter

2-4

64.0/162.6

52.0/132.1

4.0/10.2

4.6/49.5

N/A

Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Recommended Maintenance Schedule

Maintenance Service Interval Maintenance Procedure

After the rst 5 hours • Change the engine oil.

After the rst 100 hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 80 hours • Remove engine shrouds and clean cooling ns.

Every 100 hours • Change the engine oil. (May need more often under severe conditions.)

Every 160 hours • Check the spark plugs.

Every 250 hours

Every 500 hours

Monthly • Check the battery charge.

Yearly

Yearly or before storage • Touch up chipped paint

• Change the auxiliary hydraulic reservoir lter and uid.

• Change the hydraulic transmission lter and uid.

• Check the engine oil level.

• Check the safety interlock system.

• Check for loose hardware.

• Lubricate the chains.

• Check the condition and tension of the chains.

• Check the condition of the sprockets.

• Check the tines.

• Clean the engine and exhaust system area.

• Clean the grass and debris build-up from the machine.

• Grease the jackshaft bearings.

• Grease the wheel bearings.

• Grease the tine shaft bearings.

• Grease the tine assembly idlers.

• Grease the control pivots.

• Check spark arrester (if equipped).

• Check the tire pressures.

• Check the condition and tension of the belts.

• Check the auxiliary hydraulic oil level.

• Check the hydraulic transmission oil level.

• Replace the primary air cleaner element - check secondary air cleaner element; replace if dirty. (May need more often under severe conditions. See the Engine manual for additional information.)

• Change the auxiliary hydraulic reservoir lter and uid.

• Change the hydraulic transmission lter and uid.

• Replace the secondary air cleaner element. (May need more often under severe conditions. See the Engine manual for additional information.)

• Grease the front caster pivots.

• Grease the belt idler pivot.

• Lubricate the caster wheel hubs.

• Check the torque of the wheel hub nuts.

• Check the torque on the wheel lug nuts.

• Check the transmission output shaft nut torque specication.

Toro 30” Aerator Service Manual

2-5

SPECIFICATIONS & MAINTENANCE

Premaintenance Procedures

Note: Shut off engine, wait for all moving parts to

stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit.

Caution

Raising the unit for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury.

Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

Lubrication

Lubricate Chains

Service Interval: Before each use or daily

Important: Do not lubricate chains with penetrating

oil or solvents. Use oil or chain lubricant.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift the rear of the unit and support using jack stands or equivalent support.

Caution

Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

3. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake.

Warning

Engine must be running and drive wheels must be turning so adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep ngers, hands, and clothing clear of rotating components and hot surfaces.

4. With the engine running, slowly move the motion control levers forward and lubricate all six chains.

5. Check the condition and tension of the chains.

2-6

Toro 30” Aerator Service Manual

Lubricate Grease Fittings

SPECIFICATIONS & MAINTENANCE

Note: See chart for service intervals.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lubricate ttings with NGLI grade #2 multi-purpose gun grease.

Refer to the following chart for tting locations and lubrication schedule.

Lubrication Chart

Fitting Locations

A. Front Caster Pivots

B. Jackshaft Bearings

C. Wheel Bearings

D. Tine Shaft Bearings

E. Tine Assembly Idlers

F. Control Pivots

G. Belt Idler Pivot

H. Front Caster Hubs

Initial

Pumps

*0 2 Yearly

1 8 25 hours

1 2 25 hours

1 4 25 hours

1 2 25 hours

1 4 50 hours

1 1 Yearly

*0 2

Number

of Places

Service Interval

Yearly

A B

Fig. 001 g. 13a G020222

* Seestep3forspeciallubricationinstructionsonthefront

casterpivots.

3. Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease tting in hole and pump with grease until it oozes out around top bearing. Remove grease tting and thread plug back in. Place cap back on.

Toro 30” Aerator Service Manual

2-7

SPECIFICATIONS & MAINTENANCE

Lubricate Caster Wheel Hubs

Service Interval: Yearly

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove caster wheel from caster forks.

3. Remove seal guards from the wheel hub (Fig. 002).

4. Remove one of the spacer nuts from the axle assembly in the caster wheel (Fig. 002). Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

5. Pry out seals, and inspect bearings for wear or damage and replace if necessary.

6. Pack the bearings with a NGLI grade #1 multipurpose grease.

7. Insert one bearing, one new seal into the wheel.

Note: Replace the seals.

8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench ats facing outward. Do not thread spacer nut all of the way onto the end of the axle. Leave approximately 3mm (1/8”) from the outer surface of the spacer nut to the end of the axle inside the nut.

9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

10. With the open end of the wheel facing up, ll the area inside the wheel around the axle full of NGLI grade #1 multi-purpose grease.

Fig. 002 g. 14 G006115

A. Seal guard B. Spacer nut w/wrench ats

11. Insert the second bearing and new seal into the wheel.

12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench ats facing outward.

13. Torque the nut to 75-80 in-lbs. (8-9 Nm), loosen, then re-torque to 20-25 in-lbs. (2-3 Nm). Make sure axle does not extend beyond either nut.

14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully.

Important: To prevent seal and bearing damage,

check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust torque on spacer nut until there is a slight amount of drag. Reapply thread locking adhesive.

2-8

Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Engine Maintenance

Service Air Cleaner

Service Interval: Every 250 hours - Replace the primary

air cleaner element - check secondary air cleaner element; replace if dirty. (May need more often under severe conditions. See the Engine Owner’s Manual for additional information.)

Every 500 hours - Replace the secondary air cleaner

element. (May need more often under severe conditions. See the Engine Owner’s Manual for additional information.)

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. See the Engine Owner’s Manual for maintenance instructions.

Change Engine Oil

Service Interval: After the rst 5 hours

5. Clean around oil ll cap and remove cap. Fill to specied capacity and replace cap.

6. Add 1.8 qt. (1.7 L) of Toro Premium Oil. Do not overll. Start the engine and check for leaks. Stop engine and recheck oil level.

7. Wipe up any spilled oil from engine deck mounting surfaces.

Check Spark Plugs

Service Interval: Every 160 hours

Remove spark plugs, check condition and reset gaps, or replace with new plugs. See the Engine Owner’s Manual.

Check Spark Arrester (if equipped)

Service Interval: Every 50 hours

! !

Warning

Every 100 hours (May need more often under

severe conditions.)

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Drain oil while engine is warm from operation.

3. The oil drain hose assembly is located on the left side of the engine.

Place pan under machine to catch oil. Remove oil

drain plug. Allow oil to drain and replace oil drain plug. Torque plug to 20-24 ft-lbs. (27-33 Nm).

4. Replace the oil lter per the Engine Owner’s Manual. Clean around the oil lter and carefully remove the lter by unscrewing it. Make sure no oil drains onto the belt drives through the holes in the engine deck. Before the new lter is installed, apply a thin coating of Toro 4–Cycle Premium Engine Oil on the surface of the rubber seal. Turn lter clockwise until rubber seal contacts the lter adapter, then tighten lter an additional 2/3 to 3/4 turn.

Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. Hot particles exhausted during engine operation may ignite ammable materials. Fire may result in personal injury or property damage.

Do not refuel or run engine unless spark arrester is installed.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Wait for mufer to cool.

3. If any breaks in the screen or welds are observed, replace arrester.

4. If plugging of the screen is observed, remove arrester and shake loose particles out of the arrester and clean screen with a wire brush (soak in solvent if necessary). Reinstall arrester on exhaust outlet.

Toro 30” Aerator Service Manual

2-9

SPECIFICATIONS & MAINTENANCE

Fuel System Maintenance

Change Fuel Filter

A fuel lter is installed in the fuel line between the fuel tank and the engine. Replace when necessary.

Note: It is important to reinstall the fuel line

hoses and secure in place, the same way as originally installed at the factory, to keep the fuel line away from components.

Electrical System Maintenance

Check Battery Charge

Service Interval: Monthly

Warning

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and related

accessories contain lead and lead compounds,

chemicals known to the State of California to

cause cancer and reproductive harm.

Wash hands after handling.

Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery

should be fully charged before putting away for winter storage.

Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater.

Important: Make sure the negative battery cable

is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery.

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Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Drive System Maintenance

Check Tire Pressures

Service Interval: Every 50 hours

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Check tire pressure in drive tires.

3. Inate drive tires to 12-14 psi (83-97 kPa).

4. Semi-pneumatic caster tires do not need to be inated.

Check Wheel Hub Nuts Torque Specication

Service Interval: Yearly

Torque the wheel hub nuts to 210-260 ft-lbs. (285-350 Nm).

Note: Do not use anti-seize compound on the wheel

hub.

Check Wheel Lug Nuts Torque Specication

Check Condition Of Chains

Service Interval: Before each use or daily

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Check the chains on both sides of the unit for proper tension. The chains should be able to move up and down 1/4”-1/2” (6-12mm).

3. If chains pop or snap see “Jackshaft Drive Chain Tension Adjustment” on page 2-12, “Drive Wheel Chain Tension Adjustment” on page 2-13, or “Tine Drive Chain Adjustment” on page 2-18.

Check Condition Of Sprockets

Service Interval: Before each use or daily

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Inspect sprockets for wear and replace as required.

Check Transmission Output Shaft Nut Torque Specication

Service Interval: Yearly

Torque the wheel lug nuts to 90-95 ft-lbs. (122-129 Nm).

Service Interval: Yearly

Torque the nut on the transmission output tapered shaft to 210-260 ft-lbs. (285-353 Nm).

Toro 30” Aerator Service Manual

2-11

SPECIFICATIONS & MAINTENANCE

Jackshaft Drive Chain Tension Adjustment

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift the rear of the unit and support using jack stands or equivalent support.

3. Check the chains on both sides of the unit for proper tension. The chains should be able to move up and down 6-12mm (1/4”-1/2”).

4. Loosen the nuts on the three hydro mounting bolts and the two on the adjustment bolt as shown in Figure 003. The nuts on the hydro mounting bolts must be loosened on both sides of the unit (Fig.

003).

5. Turn the adjustment bolt to move transmission adjustment plates and hydros. Tighten the nuts on both sides of the adjustment bolts when the chains are properly tensioned.

6. Tighten hydro mounting bolts.

7. Adjust motion controls as stated in the “Motion Control Linkage Adjustment” section of this chapter.

Fig. 003 g. 16 G020261

A. Hydro mounting bolts D. 6-12mm (1/4-1/2”) & nuts E. Guard removed for B. Nuts clarity C. Adjustment bolt

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Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Drive Wheel Chain Tension Adjustment

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift the rear of the unit and support using jack stands or equivalent support.

3. Check the chains on both sides of the unit for proper tension. The chains should be able to move up and down 1/4”-1/2” (6-12mm).

4. Adjust the idler sprockets.

5. Recheck the chain tension and tighten the idler bolt.

Caster Pivot Bearings Pre-Load Adjustment

Remove dust cap from caster and tighten nyloc nut until washers are at and back off 1/4 of a turn to properly set the pre-load on the bearings. If disassembled, make sure the spring disc washers are reinstalled as shown in Figure 004.

Brake Maintenance

Adjusting the Parking Brake

If the parking brake does not hold securely, an adjustment is required.

1. Park the machine on a level surface.

2. Shut off engine and wait for all moving parts to stop.

3. Check the air pressure in the drive tires. If needed, adjust to the recommended ination.

4. Disengage the parking brake.

5. Loosen the adjustment nut on the brake cable under the console.

6. Engage the parking brake.

7. Adjust the nut position until 3-1/8” (7.9cm) from the bottom of the link to the bottom of the spring (Fig.

005).

Fig. 004 g. 17 G006131

A. Spring disc washers

Fig. 005 g. 18 G018143

A. 3-1/8” (7.9cm)

8. Tighten the cable adjustment nuts.

9. Check the parking brake; repeat steps 5 through 8 if necessary.

Toro 30” Aerator Service Manual

2-13

SPECIFICATIONS & MAINTENANCE

Adjusting the Brake Switch

1. Park the machine on a level surface.

2. Shut off the engine and wait for all moving parts to stop.

3. Prior the adjusting the brake switch ensure the parking brake is properly adjusted. See “Adjusting the Parking Brake” on page 3-13.

4. Engage the parking brake.

5. Check the distance from the parking brake switch bracket to the hydro brake arm. The distance should be 1/8” (3.2mm) (Fig. 006).

Belt Maintenance

Check Condition & Tension Of Belts

Service Interval: Every 50 hours

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift the front of the unit and support using jack stands or equivalent support.

3. Check the auxiliary pump drive belt condition and tension; belt should be snug. See Auxiliary Pump Drive Belt Adjustment in this section.

4. Check condition of the transmission drive belt.

Transmission Drive Belt Tension

Note: No adjustments are required for belt tension.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

Fig. 006 g. 19 G018137

A. Parking brake switch bracket B. 1/8” (3.2mm) gap

6. If adjustment is required, loosen the bolt holding the parking brake switch bracket and adjust the distance between the parking brake switch bracket and the hydro brake arm to be 1/8” (3.2mm).

2. Install the new belt.

3. Make sure the idler arm and pulley can move freely.

Auxiliary Pump Drive Belt Adjustment

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. To tighten belt, loosen the 3/8” nyloc nut on auxiliary pump belt idler pulley. Slide bolt inward in slot and retighten nyloc nut.

3. When properly adjusted, the belt should have 1/2” (1.3cm) of deection with 3 pounds of pressure on the belt midway between the auxiliary pump and engine pulley.

7. Tighten the bolt holding the parking brake bracket.

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Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Controls System Maintenance

Motion Control Linkage Adjustment

1. Park the machine on a level surface.

2. Shut off engine and wait for all moving parts to stop.

3. Push the control levers all the way forward to the front reference bar.

• If the control levers contact the reference bar,

allow the control levers to return to neutral. Remove the spring clevis pin on the turnbuckle of the motion control linkage. Rotate the turnbuckle counterclockwise (as viewed from the top of the machine). Reinstall the spring clevis pin and move the control lever forward (Fig. 007). Repeat this step until there is a gap between the control lever and the front reference bar. Once the gap is achieved, proceed with step 4.

• If the control levers do not contact the reference

bar, then proceed to step 4.

4. Allow the control levers to return to neutral. Remove the spring clevis pin on the turnbuckle of the motion control linkage. Rotate the turnbuckle clockwise (as viewed from the top of the machine). Reinstall the spring clevis pin and move the control lever forward. Repeat this step until there is minimal gap or contact between the control lever and the front reference bar.

5. Remove the spring clevis pin, rotate the turnbuckle clockwise one more full turn.

6. Reinstall the spring clevis pin. Rotate locknut against the turnbuckle.

7. Repeat steps 3 through 6 for other motion control linkage.

Fig. 007 g. 20 G020223

A. Spring clevis pin C. Turnbuckle B. Locknut

Toro 30” Aerator Service Manual

2-15

SPECIFICATIONS & MAINTENANCE

Hydraulic System Maintenance

Check Auxiliary Hydraulic Oil Level

Service Interval: Every 50 hours

1. Lower the tines to the ground.

2. Stop engine and wait for all moving parts to stop, and remove key. Engage parking brake.

3. Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the bafe inside the tank. If not, add oil. Use Toro Hydro Oil. Replace hydraulic reservoir cap and tighten until snug. Do not over-tighten.

Note: The bafe is labeled Hot and Cold. The oil

level varies with the temperature of the oil. The Hot level shows the level of oil when it is at 107°C (225°F). The Cold level shows the level of the oil when it is at 24°C (75°F). Fill to the appropriate level depending upon the temperature of the oil. For example: If the oil is about 65°C (150°F), ll to halfway between the Hot and Cold levels. If the oil is at room temperature (about 24°C (75°F)), ll only to the Cold level.

Check Hydraulic Transmission Oil Level

Change Auxiliary Hydraulic Reservoir Fluid and Filter

Service Interval: After the rst 100 hours Every 250 hours thereafter

1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake.

2. Carefully clean area around the front of the auxiliary pump and ll cap; also clean around the lter. It is important that no dirt or contamination enter hydraulic system.

3. Unscrew the suction hose from the pump tting, clean around the pump tting, and allow oil to drain.

4. Unscrew the lter to remove and allow oil to drain.

Important: Apply a thin coat of oil on the surface of

the rubber seal.

Turn lter clockwise until rubber seal contacts the

lter adapter, then tighten the lter an additional 2/3 to 3/4 turn.

5. Reinstall the hose and torque to 50 Nm (37 ft-lbs.).

6. Add Toro Hydro Oil until the level reaches the cold ll line located on the reservoir tank. Start engine and raise and lower the tines. Lower the tines to the ground and rell the reservoir to the cold ll line.

Service Interval: Every 50 hours

1. Stop engine and wait for all moving parts to stop, and remove key. Engage parking brake.

2. With the unit cold, check the expansion tank and if necessary add Toro Hydro Oil to the Full Cold line.

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Toro 30” Aerator Service Manual

SPECIFICATIONS & MAINTENANCE

Change Hydraulic Transmission Filters and Fluid

Service Interval: After the rst 100 hours Every 250 hours thereafter

1. Stop engine, wait for all moving parts to stop, and

remove key or spark plug wire(s). Engage parking brake.

2. Locate the two lters under the transmissions.

Remove lter guards.

3. Carefully clean area around lters. It is important

that no dirt or contamination enter hydraulic system.

4. Unscrew lters to remove and allow oil to drain from

drive system.

Important: Before reinstalling new lters, apply

a thin coat of Toro Premium Hydro Oil on the surface of the lters rubber seal.

Turn the lters clockwise until rubber seal contacts

the lter adapter then tighten the lter an additional 3/4 to 1 full turn.

5. Remove the vent plug on each transmission and ll

through expansion reservoir, when oil comes out of vent reinstall plug.

Toro Premium Hydro Oil is recommended. Refer to

the chart for an acceptable alternative:

Caution

Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

7. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake.

Warning

Engine must be running and drive wheels must be turning so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep ngers, hands, and clothing clear of rotating components and hot surfaces.

A. With the engine running, slowly move the

directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping the engine.

Hydro Oil Change Interval

Toro Premium Hydro Oil

(Preferred)

Mobil 1 15W50 250 Hours

Torque plugs to 20 Nm (180 in-lbs.). Continue to add

Toro Premium Hydro Oil until it reaches the full cold line on the expansion reservoir.

6. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

Toro 30” Aerator Service Manual

500 Hours

B. It may be necessary to repeat step A until all the

air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged.

Note: Do not change the hydraulic system oil

(except for what can be drained when changing lter), unless it is felt the oil has been contaminated or been extremely hot. Changing oil unnecessarily could damage hydraulic system by introducing contaminants into the system.

2-17

SPECIFICATIONS & MAINTENANCE

Tine Maintenance

Check Tines

Service Interval: Before each use or daily

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift the rear of the unit and support using jack stands or equivalent support.

Caution

Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

3. Remove and retain the two bolts from the rear cover panel.

4. Remove rocks and other debris from the tines.

5. Inspect the tines and replace as required.

Tine Drive Chain Adjustment

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift the rear of the unit and support using jack stands or equivalent support.

3. Check the chains on both sides of the unit for proper tension. The chains should be able to move up and down 1/4-1/2” (6-12mm).

4. Adjust the idler sprocket.

5. Recheck the chain tension and tighten the idler bolt.

2-18

Toro 30” Aerator Service Manual

Chassis

Exploded View - Mainframe

(Fig. 008)

CHASSIS

Fig. 008 subsystem mainframe_smr

A. Main frame assembly E. Mufer guard I. Plate, serial no. (1x2.88) B. Front caster assembly F. Guard - chain, RH J. Tube, manual C. Weight G. Guard - chain, LH K. Platform assembly D. Access cover H. Plate, serial no. (1x5)

1 Bolt installed from the bottom in this location only.

Toro 30” Aerator Service Manual

3-1

CHASSIS

Lubricate Caster Wheel Hubs

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove caster wheel from caster forks.

3. Remove seal guards from the wheel hub (Fig. 009).

Fig. 009 g. 14 G006115

A. Seal guard B. Spacer nut with wrench ats

4. Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

5. Pry out seals, and inspect bearings for wear or damage and replace if necessary.

9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

10. With the open end of the wheel facing up, ll the area inside the wheel around the axle full of NGLI grade #1 multi-purpose grease.

11. Insert the second bearing and new seal into the wheel.

12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench ats facing outward.

13. Torque the nut to 8-9 Nm (75-80 in-lbs.); loosen, then re-torque to 2-3 Nm (20-25 in-lbs.). Make sure axle does not extend beyond either nut.

14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully.

Important: To prevent seal and bearing damage,

6. Pack the bearings with a NGLI grade #1 multipurpose grease.

7. Insert one bearing, one new seal into the wheel.

Note: Replace the seals.

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Toro 30” Aerator Service Manual

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