ryan 544872 User manual

Brand: ryan

Model: 544872

Category: Mini tillers

Type: User manual

This manual is also suitable for

GA 24

Technical

Manual

GA 24 Aerator

Model 544872

522648-Rev E

1 GENERAL INFORMATION

250–2–00–CU

2000 Textron Inc.

Printed in U.S.A.

1.1 GENERAL INFORMATION

IMPORTANT!

THIS MANUAL WILL AID YOU IN THE SAFE

OPERATION AND PROPER MAINTENANCE OF

YOUR EQUIPMENT. READ MANUAL THOROUGHLY

BEFORE ATTEMPTING OPERATION. IF ANY

PORTION IS NOT CLEARLY UNDERSTOOD,

CONTACT AN AUTHORIZED DEALER FOR

CLARIFICATION.

To make sure you are fully aware of safety and service

information, the following two symbols are used

throughout this manual.

This symbol is used throughout the manual to

alert you to information about unsafe actions or

situations, and will be followed by the word DANGER,

WARNING, or CAUTION. DANGER indicates

immediate hazards that may result in severe injury or

death. WARNING indicates unsafe actions or situations

that may cause severe injury, death and/or major

equipment or property damage. CAUTION indicates

unsafe actions or situations that may cause injury, and/or

minor equipment or property damage.

NOTE: This appears next to information or instructions

which will help you operate and maintain your

equipment the right way.

WARNING

The information and instructions included in

this manual alert you to certain things you

should do very carefully. If you do not, you

could:

• hurt yourself or others

• hurt the next person who operates the

equipment

• damage the equipment.

This manual contains essential operation and

safety information and must remain with the

unit at all times, within easy access of any op-

erator.

Additional manuals are available through your dealer.

IMPORTANT!

THIS EQUIPMENT SHOULD NOT BE MODIFIED OR

ADDED TO WITHOUT THE MANUFACTURER’S

AUTHORIZATION.

WARNING

Altering this equipment in any manner which

adversely affects the equipments operation,

performance, durability or use, may cause haz-

ardous conditions.

Direct any inquiries to:

Textron Golf, Turf & Specialty Products

Attn: Director of Engineering

P.O. Box 7708

Charlotte, NC 28241–7708 USA

SPECIFICATION INFORMATION

All information contained in this manual is the latest

available at the time of printing. Textron Turf Care and

Specialty Products reserves the right to make changes

at any time without notice.

Whenever a name brand product is specified, an

equivalent product may be used unless stated otherwise.

CHANGE OF OWNERSHIP OR ADDRESS

Textron Turf Care and Specialty Products makes every

effort to keep owners informed of all safety related

information. Therefore, changes in ownership and/or

address should be reported to the manufacturer.

Your dealer has REGISTRATION CHANGE FORMS

which will be filled out and filed by the dealer for his

records, and a copy will be sent to the manufacturer.

DEALER INFORMATION

For your nearest dealer location write to:

Textron Golf, Turf & Specialty Products

Attn: Sales

P.O. Box 7708

Charlotte, NC 28241–7708 USA

In the USA and Canada call 1–800–228–4444 (dealer

information only).

TABLE OF CONTENTS

SECTION PAGE

1 General Information Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 General Information Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Vehicle Identification 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Identification 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Controls 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Master Cylinder 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Throttle 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Shift Control Lever 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Shifting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Tine Lever 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Starting Engine 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Aerating 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Transporting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Stopping 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Storage 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Daily 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Extended 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Service 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 General Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Tire Pressure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Adjustments 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Chain Replacement 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 Tine Replacement 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 Slide & Push Rod Replacement 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 Hydraulic Hose Replacement 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 Dog Clutch Adjustment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 Timing, Crankshaft & Camshaft 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 Connector Rod & Wrist Pin Replacement 17. . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 Differential (8720 And Later) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12 Differential (8710 And Prior) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 Camshaft Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 Camshaft Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 Master Clutch 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.16 Brake/Clutch Adjustment 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.17 Lubrication 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.18 Touch–up Paint 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.19 Trouble Shooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Parts

8.1 Engine 30–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Clutch 32–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Clutch Controls 34–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Differential (8710 & Prior) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Differential (8720 & Later) 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Turf Guard 38–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7 Controls 40–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8 Chassis 42–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9 Shrouding 46–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10 Aerator 48–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11 Main Drive 52–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12 Hydraulics 56–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13 Decals 60–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.14 Tines & Holders 62–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Attachment 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Windrow Attachment 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Torque Chart 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 IDENTIFICATION

2.1 VEHICLE IDENTIFICATION

The identification nameplate/decal with the model num-

ber and serial number, is located on the engine mounting

frame (See FIGURE 1 ).

3812

FIGURE 1

These identification numbers must appear on all corres-

ponence concerning this equipment

SPECIFICATIONS 3

3.1 SPECIFICATIONS

Equipment Weight 800 lbs. (363kg). . . . . . . . . . . . . . . . .

Equipment Width 49 1/2″ (1372mm). . . . . . . . . . . . . . .

Swath Width 24″ (609mm). . . . . . . . . . . . . . . . . . . . . . . .

Speed:

Engine 3600RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aerate 6000 sq. ft. (557m

) green in 45 min.. . . . . . . .

Transport 4 MPH (7km/h) max.. . . . . . . . . . . . . . . . . . .

Tines:

Type Hollow, tapered . . . . . . . . . . . . . . . . . . . . . . . . . . .

Material Case Hardened Steel. . . . . . . . . . . . . . . . . . . .

Quantity Two sets 1/2″ (13mm) dia. tines std.. . . . . .

Option 1/4″ (6mm), 3/8″ (9mm) or 5/8″ (17mm). . . . .

hollow tines, and 1/4″ (6mm) solid quad tines.

Depth of Penetration 3″ (76mm) max.. . . . . . . . . . . . . . .

Spacing of Penetration 2″ (51mm) on center. . . . . . . . .

Engine:

Type Kohler 8 HP, 4 cycle. . . . . . . . . . . . . . . . . . . . . . .

Model M8RT, Spec PA–301521

Gear Reduction 6 to 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Roller chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Automotive type. . . . . . . . . . . . . . . . . . . . . .

Master Clutch Multi–disc, w/ integral brake. . . . . . . .

Tires:

Front 11 x 4.00–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear 13 x 6.50–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Pressure 14 to 16 PSI. . . . . . . . . . . . .

(97 to 110 kPa)

Hydraulic Pump Fluid API grade CC or SF-FG . . . . . .

SAE 20-20w oil

4 CONTROLS

4.1 MASTER CYLINDER

The Master Clutch, located on the side of the control

panel, engages and releases power to all functions

except the hydraulic pump. Pull lever forward, slowly, to

engage the master clutch. Push the lever back to

release.

3777

FIGURE 2

1. Master Clutch Lever (engaged)

4.2 THROTTLE

STOP This position grounds the engine ignition system

and shuts the engine off.

SLOW – FAST Moving the throttle between these posi-

tions will adjust engine to desired speed.

3778

FIGURE 3

1. Throttle Control Lever

4.3 SHIFT CONTROL LEVER

TRANSPORT Provides forward movement without tine

operation. Tines must be in raised position.

NEUTRAL Disengages all clutches. Unit will not move,

tines will not operate.

TINES Operates tines only, unit will not move. Use only

to check alignment and positioning of turf guard.

AERATE Provides forward movement and tine opera-

tion. Normal position for aerating.

3779

FIGURE 4

1. Shift Control Lever

2. Transport

3. Neutral

4. Tines

5. Aerate

4.4 SHIFTING

1. Disengage Master Clutch.

2. Set engine speed to slow.

3. Move Shift Control lever to desired position. (DO

NOT force control lever, engage clutch lightly until

control linkage engages.)

4. Stand to side of unit, not in front, – engage Master

Clutch slowly.

(Forward motion is in direction of the handle)

5. Adjust engine speed for desired transport or operat-

ing speed after unit is in motion.

CONTROLS 4

4.5 TINE LEVER

RAISE Hydraulically lifts the tines and turf guard from the

ground.

LOWER Relieves hydraulic pressure in the cylinders,

lowering the tines and turf guard to the ground.

3778

FIGURE 5

1. Tine Control Lever

2. Raise

3. Lower

WARNING

The Tine Control lever MUST return to the neu-

tral position after raising or lowering the unit. If

the lever sticks in the “Raise” or “Lower” posi-

tion, the hydraulic fluid will over heat. This

could cause a hydraulic line to rupture, releas-

ing hot hydraulic fluid.

Escaping hydraulic fluid, under pressure, can

have sufficient force to penetrate the skin,

causing serious injury.

If a leak is suspected, use a piece of wood or

cardboard, not your hand, to check for leaks.

If injured by escaping fluid, see a doctor

immediately. Serious infection or reaction can

develop if proper medical treatment is not

promptly administered.

Do not use a unit with a leaking hydraulic sys-

tem. See your authorized RYAN dealer for nec-

essary repairs.

5 OPERATION

WARNING

BEFORE OPERATING:

Check grounds area and remove foreign

objects that may be a tripping hazard to the

operator or might damage the unit.

Make sure all shields and guards are in place.

Before starting engine, always make sure the

master clutch is disengaged.

To prevent sudden movement of unit when

engaging master clutch, set throttle to SLOW

and stand beside unit not in front of it.

WHEN OPERATING:

Never start or run engine inside where exhaust

fumes can collect. Carbon monoxide present

in the exhaust is an odorless and deadly gas.

Provide adequate ventilation.

Do not operate unit under low overhangs (tree

limbs, etc.) or through narrow openings that

may force operator too close to the unit.

Do not operate in explosive environment. Elec-

trical and exhaust systems of this unit can

create sparks which could cause explosion.

Do not ride on unit at any time.

During transport or aerating, operate unit in

such a manner to allow you to see the path

ahead and quickly move away from the unit

should you accidentally lose control.

WHEN STORING:

To prevent possible fire or explosion, do not

store this unit with fuel in tank or carburetor in

an enclosure with an open flame (Furnace or

water heater pilot light).

5.1 STARTING ENGINE

Before Starting Engine:

Check the engine crankcase and gear reduction case oil

levels. Fill if necessary according to engine manufactur-

er’s recommendation for type and quantity.

Fill fuel tank with fuel recommended by engine manufac-

turer.

Gasoline is extremely flammable and explo-

sive under certain conditions. Stop engine,

and stay away from open flame or sparks while

refueling or performing maintenance involv-

ing gasoline.

Do not operate unit without approved fuel tank

filler or cap.

Remove cap from tank slowly. Fuel may be

under pressure. Spray may cause injury.

DANGER

Starting Engine:

1. Check fuel valve to be sure it is open. (Valve is

located under fuel tank on the sediment bowl.)

2. Make sure Shift Control and Tine Control levers are

in neutral.

3. Make sure master clutch is disengaged. (Push to

rear to disengage.)

4. Set throttle to half speed.

5. Pull recoil starter. Choke as required to start engine.

Allow engine to warm up.

NOTE: All clutches except the master clutch are dog

clutches. The dogs and slots must be aligned for

proper engagement. Slight movement of the master

clutch (engage and disengage lightly) may be

required to align dogs and slots.

5.2 AERATING

1. Set engine speed to slow.

2. Raise tines by lifting Tine Control lever.

3. Move Shift Control lever to “Aerate” position. (DO

NOT force control lever, engage clutch lightly until

control linkage engages.)

4. With tines raised and engine speed at slow, stand to

the side of the unit and engage the master clutch

slowly. The unit will start to move forward.

5. At proper starting point on turf, push down on Tine

Control lever to lower tines.

6. Adjust throttle for desired operating speed after unit

is in motion.

OPERATION 5

7. To stop aerating, pull up on Tine Control lever to raise

tines.

Operating Tines Only

The “Tines” position of the Shift Control lever is only used

to check mechanical functions of the unit.

1. Set engine speed to slow.

2. Move Tine Control lever to “Tines”. (DO NOT force

control lever, engage clutch lightly until control link-

age engages.)

3. Engage master clutch slowly. Check for proper align-

ment of tine with turf guard fingers and proper

mechanical function.

CAUTION

If malfunction is detected, stop operation

immediately. Do not operate unit until condi-

tion is corrected.

5.3 TRANSPORTING

To move unit short distances to, from and between work

areas:

1. Set engine speed to slow.

2. Pull up Tine Control lever to raise tines.

3. Move Tine Control lever to “Transport”. (DO NOT

force control lever, engage clutch lightly until control

linkage engages.)

4. Stand to the side of the unit and engage the master

clutch slowly. The unit will start to move forward.

5. Adjust throttle speed to operator’s desired walking

speed.

NOTE: If using a ramp for loading unit, tines may drag or

catch. To prevent pushrods from being bent,

remove the two(2) lowest positioned tines assem-

blies.

5.4 STOPPING

1. Disengage master clutch by pushing clutch lever

back.

2. Reduce engine speed.

3. Move Shift Control lever to “Neutral.”

4. Move throttle Control lever to “Stop.”

Brake

This unit is equipped with a brake that is automatically

applied when the master clutch is disengaged and the

Shift Control lever is in either “Transport” or “Aerate”

position (See brake adjustment page 27).

6 STORAGE

WARNING

To prevent possible fire or explosion, do not

store this unit with fuel in tank or carburetor in

an enclosure with an open flame (Furnace or

water heater pilot light).

6.1 DAILY

Inspect and clean tines. Replace if damaged.

6.2 EXTENDED

When the unit is to be stored without use for more than 30

days, the following procedures should be performed.

1. Remove and thoroughly clean tines. Coat lightly with

oil to prevent rust.

2. Clean pushrods and coat lightly with oil.

3. Lower tines by pushing down on Tine Control lever,

to relieve hydraulic system pressure.

4. Drain all fuel from tank and lines. (Use hose or fuel

line routed from sediment bowl assembly to con-

tainer)

5. Start engine and run until all fuel is used from carbu-

retor float bowl.

6. While the engine is still warm, drain oil from crank-

case. Replace with proper weight oil corresponding

to the season in which the unit will be used next.

7. Remove the spark plug and squirt a small amount of

oil into the cylinder. Pull recoil starter two or three

times to coat cylinder with oil. Replace spark plug.

To put unit back into operation after extended storage: fill

fuel tank, check crankcase and gear reduction case oil

levels and start engine. Check fuel system for leaks.

SERVICE 7

WARNING

When replacement parts are required, use gen-

uine RYAN parts or parts with equivalent char-

acteristics including type, strength and mate-

rial. Failure to do so may result in product mal-

function and possible injury to operator and/or

bystanders.

Any warning decal that becomes illegible

should be replaced immediately.

Do not operate unit without shields in place.

Do not make any adjustments or perform any

maintenance while the engine is running.

7.1 GENERAL MAINTENANCE

To keep the Greensaire 24 in good operating condition,

the following procedures should be routinely performed.

• Lubricate as recommended in page 27.

• Change engine oil according to engine manual.

Daily, before use:

√ Check oil levels in the crankcase, gear reduction

case and cam case while unit is in raised position.

√ Check for loose screws and connections.

√ Check roller chain tension.

√ Check condition of tines.

√ Check for proper tire pressure.

√ After every use, wash unit with water.

NOTE: Do not wash hot engine with cold water. Dam-

age may result.

7.2 TIRE PRESSURE

Keep tires inflated to recommended pressure.

Tires:

Front 11 x 4.00–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear 13 x 6.50–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure 14 to 16 PSI (97 to 110 kPa). . . . . . . . . . . . .

NOTE: Improper inflation will shorten tire life con-

siderably.

CAUTION

Check pressure in a partially inflated tire

BEFORE connecting air hose. Due to low air

volume requirements of small tires, over infla-

tion may occur in a matter of two or three

seconds. Over inflation may cause tire to

explode.

7.3 ADJUSTMENTS

Chain Adjustments

Remove shields to provide access to chain drives on

both sides of unit.

Aerator chain idlers (Item 1 in FIGURE 6 and

FIGURE 7) are spring loaded and need no adjustment.

Springs should be routinely checked to be sure they are

hooked.

Drive chain idlers (Item 2 in FIGURE 6 and FIGURE 7)

are adjustable. Chain tension should be routinely

checked and adjusted if necessary.

To adjust idlers:

1. Loosen the nut securing idler sprocket to bracket.

2. Slide the idler sprocket along slot in bracket until

proper chain tension is reached.

Chain deflection opposite idler sprocket should be

1/4”(6mm) max. to 1/8”(3mm) min.

NOTE: Proper chain tension is essential. A tight chain

will cause excessive bearing load. A loose chain will

cause noisy operation and chain pulsations, which

result in irregular sprocket speed and abnormal

chain and sprocket wear.

3. Tighten idler sprocket hardware.

4. Lubricate fittings and roller chains according to

lubrication instructions on page 27.

5. Replace all shields before operating unit.

7 SERVICE

3781

FIGURE 6

(Right Side)

1. Spring Loaded Idler

2. Adjustable Idlers

3780

FIGURE 7

(Left Side)

1. Spring Loaded Idler

2. Adjustable Idler

7.4 CHAIN REPLACEMENT

1. Remove shields.

2. Loosen idler to release chain tension.

3. Take out master link and remove chain.

NOTE: Timing should not be disturbed. Make sure nei-

ther sprocket is rotated while the chain is off.

4. Install new chain and adjust tension. (See chain

adjustment)

5. Lubricate chain according to lubrication instructions

on page 27.

6. Replace all shields before operating unit.

7.5 TINE REPLACEMENT

1. Raise tines and stop engine.

WARNING

Support upper frame with blocks when work-

ing on unit with tines raised.

Hydraulic lines may rupture or lever could be

tripped by bystanders, causing unit to drop

rapidly.

2. Loosen screw securing tine in tine holder and

remove tine. Insert new tine and tighten screw.

3. Check to make sure tines are properly centered

between fingers of turf guard.

7.6 SLIDE & PUSH ROD REPLACEMENT

1. Raise tines, stop engine and block frame to prevent it

from dropping.

2. Remove shields and rear door assembly.

3. Take out the cam case dip stick and remove screws

securing cam case cover.

4. Remove cam case cover by lifting dipstick tube and

sliding cover forward and out. (See FIGURE 8. )

3782

FIGURE 8

1. Cam Case Cover

SERVICE 7

At this point you will be able to check alignment of the

slides and cams. To replace slides continue with the fol-

lowing steps.

5. Loosen screw in tine holder and remove tine holder

assembly from push rod.

6. Loosen screws in push rod and connecting rod,

remove bearings and drive wrist pin out of connect-

ing rod. (See FIGURE 9.)

3783

FIGURE 9

1. Connecting Rod

2. Push rod

3. Bearings

4. Wrist Pin

7. Swing connecting rod up out of the way and pull push

rods up out of slides.

NOTE: Reinsertion of push rod into slide requires seal

protector tool. (See FIGURE 13.)

8. Cut plastic tie securing dust boot to slide and remove

boot.

9. Disconnect spark plug wire, move Shift Control lever

to “tines only”, and engage clutch. Slowly pull starter

rope until slide is pushed out. Place a 1/2” block of

wood between slide and slide guide, pull starter rope

until slide comes back to rest against the block of

wood. (See FIGURE 10.) This releases the spring

tension of the roller against the cam.

3785

FIGURE 10

1. Slide

2. Wood Block

3. Slide Guide

10. Remove four screws securing the slide guide and

remove slide and guide by pulling straight out.

NOTE: Remove only one slide at a time.

11. Remove 1/2” wood block from between slide and

slide guide. Loosen hardware holding roller and

spring retainer. Compress spring slightly and

remove screw. Remove spring retainer and spring,

separate slide and slide guide.

Slide Repair:

• Remove sealant from expansion plug. Pry out plug

or drill hole in plug and pull out.

• Remove seals, bushings and felt discs (older models

may have felt strips that should be removed and not

replaced). DO NOT remove the star retainer from the

slide tube.

NOTE: If star retainer is removed, a new retainer must

be used when reassembling. Install against lip in

slide tube on newer models, or 1 7/8”(48mm) from

plug end of slide tube on older models.

• Thoroughly clean slide before installing new parts.

• Soak felt discs in clean 30W oil.

• Install felt discs against star retainer.

• Install new bushings with bushing driver. Check pas-

sage with push rod before installing seals.

• Install new seals and expansion plug. Seal around

the expansion plug with silicon sealant.

7 SERVICE

NOTE: Inside surface of bushings has a special coating.

DO NOT ream or sand inside surface.

Guide Repair:

• Remove seal and bushings.

• Press in new bushings and check passage with slide.

• Install seal flush with guide surface.

NOTE: Inside surface of bushings has a special coating.

DO NOT ream or sand inside surface.

Apply H.D. 85–140W oil to lip of seal, bushings and

black surface of slide assembly prior to installing

slide into guide.

12. Reassemble slide, slide guide and spring. Compress

spring and install spring retainer, roller, screw and

nut. Torque nut to 26 ft. lbs. (35 N·m) and apply Loc-

tite #290 or equivalent where threads make contact

with nut.

13. Compress spring and replace 1/2”(13mm) wood

block previously removed.

14. Apply 3M Sealer #EC847 or equivalent to slide guide

and screws before installing slide guide to cam case.

NOTE: When installing slide guides, make sure the slot

in guide is on top. (See FIGURE 11.)

3786

FIGURE 11

1. Slot

2. Slide Guide

3. Slide

4. Wood Block

5. Spring

6. Roller

7. Screw and Nut

15. Check to make sure cam and roller of slide are

aligned properly. To align, loosen cam screw and

slide cam on shaft until it is centered on roller.

Tighten cam screw. (See FIGURE 12.)

3787

FIGURE 12

1. Slide Roller

2. Cam

3. Cam Screw

16. Rotate cam so that slide is pushed out and remove

wood block.

17. Reinstall cam case cover. Replace gasket if broken

or damaged.

18. Refill cam case with oil (see lubrication section for

recommended type). Check level with unit in raised

position.

NOTE: To reinstall push rods to slides, a seal protector

tool (P.N. 517693) is required to prevent damage to

triple lip seals. (See FIGURE 13.)

3789

FIGURE 13

1. Push Rod

2. Seal Protector Tool

SERVICE 7

19. Reinstall push rod and reattach push rods to con-

necting rods with wrist pin and bearings.

20. Replace all shields before operating unit.

7.7 HYDRAULIC HOSE REPLACEMENT

WARNING

DO NOT attempt to replace hydraulic hoses

while unit is in raised position. Hoses are under

extreme pressure. Releasing pressure improp-

erly could cause unit to drop rapidly.

Hydraulic fluid escaping under pressure can

have sufficient force to penetrate skin, causing

serious injury.

If a leak is suspected, use a piece of cardboard

or wood, not your hand, to check for leaks.

If injured by escaping fluid, see a doctor at

once. Serious infection or reaction can develop

if proper medical treatment is not administered

immediately.

Do not use a unit with a leaking hydraulic sys-

tem. See your authorized CUSHMAN dealer for

necessary repairs.

1. With engine stopped, move the Tines Control lever

to “Raise” for approximately 10 seconds. Then to

“Lower” for approximately 10 seconds. This releases

all pressure from the hydraulic hoses and cylinders.

2. Remove damaged hoses and install new ones using

pipe sealant on threads of each fitting.

3. Start engine and check for leaks while raising and

lowering the tines several times.

4. Check hydraulic fluid lever in reservoir, add if neces-

sary.

7.8 DOG CLUTCH ADJUSTMENT

(Refer to diagram, page 15.)

1. Raise unit, stop engine and block chassis to prevent

dropping.

2. Remove shields.

3. Disconnect connecting link (item 1 in diagram) from

transport clutch bell crank by removing clevis pin (5).

Remove rod connector link (3). Loosen connector

link (2) by backing both locknuts away from the

swivel pin.

4. Make sure clutches slide easily on shaft and engage

fully. If not, clean and lubricate shaft and clutch.

5. Tighten any play that may exist at joints where levers

clamp onto fork shafts.

6. Set Shift Control lever to “Neutral”. Hold or block the

lever so that it is tight against the top of its detent

hole.

7. Move clutch lever (9) to attain a clearance of

.015”(.38mm) between the faces of the transport

clutch dogs. (See FIGURE 14.)

.015” (.38mm)

Sprocket

Dog Clutch

FIGURE 14

Transport Clutch Clearance (Neutral)

8. Tighten locknuts on connector link (2) against swivel

pin to maintain clearance.

9. Move shift control lever to “Aerate”.

10. Move lever (4) to fully engage aerate clutch with

.015”(.38mm) clearance. (See FIGURE 15.)

[Transport clutch should now be 1/16–3/32”

(1.5–2.5mm) from the edge of the drive shaft.]

7 SERVICE

.015” (.38mm)

Sprocket

Dog Clutch

FIGURE 15

11. Adjust link (3) between aerate clutch lever and trans-

port clutch lever to maintain clearance.

12. Move Shift Control lever to “Tines Only” and check

aerate clutch for complete disengagement.

13. Set spring on connector link (1) to 3”(76mm) by

adjusting nut (6).

14. Hold or block Shift Control lever to the top of the

“Tines Only” detent hole. Move tines clutch lever (10)

so that clutch is fully engaged with a clearance of

.015”(.38mm) See FIGURE 15.

15. Set eccentric stop (7) to maintain clearance.

16. Adjust clevis (8) on connector link (1) so that clevis

pin (5) drops through hole in transport clutch lever

(9). Make sure lever (10) is held against stop (7)

while adjusting connector link (1).

17. Check for proper engagement and full disengage-

ment of all clutches as selected with Shift Control

lever.

18. Replace all shields before operating unit.

SERVICE 7

DOG CLUTCH ADJUSTMENT DIAGRAM

Master Clutch Lever

Tines Clutch

Fork

Aerate Clutch Fork

Transport Clutch

Fork

Locknuts

Shift Control

Lever

7 SERVICE

7.9 TIMING, CRANKSHAFT & CAMSHAFT

NOTE: Improper timing between the aerating crank-

shaft and the camshaft will cause elongated holes

while aerating and excessive noise in the camcase.

To set timing:

1. Remove shields.

2. Remove chains connecting camshaft and crankshaft

on both sides of unit.

3. Loosen center stud in crankshaft. (See

FIGURE 16.)

3790

FIGURE 16

1. Aerator Crankshaft

2. Center Stud

4. Position right camshaft sprocket so that the first

tooth to the right of the timing mark points to the cen-

ter rib of the clutch bracket. Keyway should be level

and point straight forward. (See FIGURE 17.)

Rotation

Front of Unit

Timing mark

Center

Rib of

Clutch

Bracket

FIGURE 17

Camshaft Sprocket, Right Side Of Unit

5. Position right crankshaft sprocket so that timing

mark is horizontal. Keyway should be 45° clockwise

from straight up. (See FIGURE 18.)

Rotation

Front of Unit

Timing mark

FIGURE 18

Crankshaft Sprocket, Right Side Of Unit

6. Reinstall chain on camshaft and crankshaft sprock-

ets on right side of unit. Crankshaft may be rotated

clockwise only (Approximately 5°) to properly mesh

with chain.

7. Position left crankshaft sprocket so that timing mark

is vertical. Keyway should be 45° counterclockwise

from straight down. (See FIGURE 19.)

Rotation

Front of Unit

Timing mark

FIGURE 19

Crankshaft Sprocket, Left Side Of Unit

8. Reinstall chain on camshaft and crankshaft sprock-

ets on left side of unit. Crankshaft may be rotated

counterclockwise only (approximately 5°) to properly

mesh with chain.

9. Tighten center stud in crankshaft.

10. Replace all shields before operating unit.

SERVICE 7

7.10 CONNECTOR ROD & WRIST PIN

REPLACEMENT

1. With the unit raised, move throttle to the off position

and disconnect spark plug wire.

2. Move Shift Control lever to “Tines Only” and engage

the master clutch.

3. Open door at rear of unit and pull recoil starter to

rotate crankshaft for best access to cap screws.

4. Remove screws from connector rod cap. Remove

cap and inserts. Replace worn inserts. (See

FIGURE 20.)

3791

FIGURE 20

1. Connector Rod

2. Cap

3. Inserts

5. Loosen set screws securing bearings at bottom of

connector rod. Remove bearings.

6. Loosen set screw in push rod and drive out wrist pin.

(See FIGURE 21.)

3784

FIGURE 21

1. Set Screws

2. Bearings

3. Wrist Pin

4. Push Rod

7. Remove and replace connector rod.

NOTE: If connector rod is not damaged, only new bear-

ing inserts may be needed.

8. Lubricate connector rod bearings before operation.

9. Reconnect spark plug wire before attempting to start

engine.

7.11 DIFFERENTIAL

(8720 and later)

1. Remove shields and jack unit up. Set on jack stands

so that both rear wheels are off the ground.

WARNING

Use jack stands to support unit. DO NOT rely

on hydraulic or mechanical jacks.

2. Remove both rear wheels.

3. On left side of unit, remove hub, key and spacer.

Loosen set screws in locking collar on pillow block.

(See FIGURE 22.)

7 SERVICE

3792

FIGURE 22

1. Hub

2. Spacer

3. Locking Collar Set Screws

4. On right side of unit, remove drive chain.

5. Loosen set screws in locking collar on pillow block

and pull differential and axle out right side. (See

FIGURE 23.)

3793

FIGURE 23

1. Locking Collar Set Screws

2. Hub

3. Washer

4. Axle Nuts

6. Remove axle nuts, washer and hub from axle.

7. Slide differential in toward center of axle and remove

key. Then slide differential off end of axle. (See

FIGURE 24.)

NOTE: If axle is secured in vise to remove differential,

use shop towel or other protection to prevent dam-

age to axle.

3794

FIGURE 24

1. Differential

2. Key

8. Remove six nuts and separate parts of the differen-

tial. Remove and clean all internal parts. Inspect for

damage and wear.

NOTE: Some differentials will have spacers with

threaded studs at both ends(as shown in

FIGURE 25). Some will have screws that are

inserted from the sprocket end and spacers that

slide onto them.

When ordering parts, spacers with threaded studs

will be supplied and can be used interchangeably

with the other style.

Be sure to order nuts for both ends of spacer.

3795

FIGURE 25

1. Spacers With Threaded Studs

NOTE: Many times, when removing spacers with nuts

on both ends, only one nut will loosen. The remain-

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ryan 544872 User manual

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Model: 544872

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