Toro 30140, 30150, 30161, 30164, 30167 Service Manual

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LCE Products

Mid-Size Walk Behind

Service Manual

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ABOUT THIS MANUAL

This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. The Toro Company has made every effort to make the information in this manual complete and correct.

For service information specific to the engines used on these products, refer to the appropriate engine manufacturer’s service and repair instructions.

Additional resources:

• Interactive Electrical Troubleshooting CD (PN 492-4757).

• Interactive Hydraulic Troubleshooting CD (PN 492-4777).

• Hydro-Gear Hydraulic Pump Service and Repair Manual (PN 492-4749).

• Ross Wheel Motor Service and Repair Manual (PN 492-4753).

We hope you will find 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 Landscape Contractors Equipment Division 8111 Lyndale Avenue South Bloomington, MN 55420

The Toro Company reserves the right to change product specifications or this manual without notice.

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Safety Information

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

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

Specifications & Maintenance

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

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

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

Other Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4

Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7

Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10

Model ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 15

Maintenance Schedule, Floating Deck Models . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 16

Maintenance Schedule, Fixed Deck Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 17

TABLE OF CONTENTS

Engine

Chassis

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5

Engine Assembly, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6

Model and Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1

Engine Model and Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1

Greasing and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1

Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2

Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3

Pistol Grip - Gear Drive - Fixed Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3

Pistol Grip - Gear Drive - Floating Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3

Pistol Grip - Hydro - Fixed Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5

Pistol Grip - Hydro - Floating Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5

T-Bar - Gear Drive - Fixed Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6

T-Bar - Gear Drive - Floating Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

Brake Band (T-Bar - Gear Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8

Mid-Size Walk Behind Service Manual i

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TABLE OF CONTENTS

Chassis (cont’d)

Drum Brake / Pulley Assembly Removal (Gear Drive) . . . . . . . . . . . . . . . . . . . . . 4 - 12

Parking Brake Linkage (Pistol Grip Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16

Fuel Tank Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19

Electric (PTO) Clutch (Floating Deck Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20

Replacing the Drive Belt (Gear Drive - Floating Deck) . . . . . . . . . . . . . . . . . . . . . 4 - 21

Replacing the Drive Belt (Fixed Deck Pistol Grip) . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21

Replacing the Traction Belt (Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22

Replacing the Traction Belt (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22

Adjusting Grass/Mud Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23

Hydraulic Drive Systems

Hydraulic Drive System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

Servicing the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

By-Pass Valve (T-Bar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6

Neutral Adjustment (T-Bar Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

Handle and Control Rods (T-Bar Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

Install Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8

Hydro Linkage Adjustments (Pistol Grip Floating Deck) . . . . . . . . . . . . . . . . . . . . 5 - 10

Speed Control Linkage (Pistol Grip Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10

Neutral Control Linkage Adjustment (Pistol Grip Floating Deck) . . . . . . . . . . . . . 5 - 11

Hydro Control Linkage Adjustment (Pistol Grip Floating Deck) . . . . . . . . . . . . . . 5 - 12

Control Rod Adjustment (Pistol Grip Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . 5 - 14

Tracking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15

Motion Control Linkage Removal (Pistol Grip Floating Deck) . . . . . . . . . . . . . . . . 5 - 15

Hydraulic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23

Wheel Motor Removal and Installation - Floating Deck . . . . . . . . . . . . . . . . . . . . 5 - 25

Wheel Motor Removal - Fixed Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26

Wheel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27

Gear Drive Transmission

Transmission Removal - Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

Control Linkage Removal (T-Bar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5

Control Linkage Adjustment (T-Bar Gear Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6

Installing the Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7

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Mower Decks

Setting Up the Frame (Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1

Checking the Deck Level Side-to-Side (Floating Deck) . . . . . . . . . . . . . . . . . . . . . .7 - 2

Checking the Deck Front-to-Rear Blade Slope (Floating Deck) . . . . . . . . . . . . . . . .7 - 3

Adjusting the Deck Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3

Adjusting the Side-to-Side Level (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4

Matching Height-of-Cut (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4

Replacing the Mower Belt (Floating Deck) 36 in. (91cm) . . . . . . . . . . . . . . . . . . . . .7 - 5

Replacing the PTO Drive Belt (Floating Deck) 36 in. (91cm) . . . . . . . . . . . . . . . . . .7 - 5

Replacing the Deck Belt (Floating Deck) 44 & 52 in. (111 & 132cm) . . . . . . . . . . . .7 - 6

Replacing the PTO Drive Belt (Floating Deck) 44 & 52 in. (111 & 132cm) . . . . . . . .7 - 6

Mower Deck Belt Replacement (Fixed Deck Models) . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Mower Deck Belt Guide Adjustment (Fixed Deck Models) . . . . . . . . . . . . . . . . . . .7 - 8

Replacing the Mower Belt (Fixed Deck Gear Drive) 36 in. (91cm) . . . . . . . . . . . . .7 - 8

Replacing the Mower Belt (Fixed Deck) 32 in. (81cm) . . . . . . . . . . . . . . . . . . . . . .7 - 9

Replacing the Mower Belt (Fixed Deck Gear Drive) 48 in. (122cm) . . . . . . . . . . .7 - 10

Mower Deck Drive Belt Adjustment (Fixed Deck Models) . . . . . . . . . . . . . . . . . . .7 - 12

Blade Engagement Adjustment (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 13

Blade Safety Switch Adjustment (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 14

Adjusting the Blade Brake (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 14

Replacing the Mower Belt (Fixed Deck Hydro, Pistol Grips) . . . . . . . . . . . . . . . . .7 - 15

Adjusting Mower Belt Tension (Fixed Deck) - All . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 16

Servicing the Cutting Blades (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 17

Correcting Uneven Cutting (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 19

Replace Spindle Bearings (Fixed Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 20

Replace Spindle Bearings (Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21

Replacing the Castor Wheel Fork Bushings (All Models) . . . . . . . . . . . . . . . . . . . .7 - 26

Castor Wheel and Bearings Service (Floating Deck) . . . . . . . . . . . . . . . . . . . . . . .7 - 26

Replacing the Grass Deflector (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 27

Mower Deck Removal (Fixed Deck Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28

Mower Deck Removal (Floating Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29

TABLE OF CONTENTS

Electrical

Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 2

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 2

Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 2

Servicing the Fuse (T-Bar and Pistol Grip Models) . . . . . . . . . . . . . . . . . . . . . . . . .8 - 2

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 2

Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 4

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 5

Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 6

Testing the Clutch Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 7

PTO Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 10

Transmission Switch (Gear Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 10

Mid-Size Walk Behind Service Manual iii

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TABLE OF CONTENTS

Electrical (cont’d)

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11

Switch (65-7410 & 1-513051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11

Switch (95-1653) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12

Bail Switch (82-2190) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12

Rocker Switch (82-2300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12

Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13

Delay Module (2000 and Earlier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14

Delay Module 104-8141 (T-Bar Floating Deck Electric Clutch 2001 & Up. . . . . . . 8 - 14

Interlock Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15

Wiring Diagrams

T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16

T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17

T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18

T-Bar (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19

T-Bar (Floating Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20

T-Bar (Floating Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21

T-Bar (Floating Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22

T-Bar (Floating Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23

T-Bar (Floating Deck - Gear and 1988 / 1999 Hydro) . . . . . . . . . . . . . . . . . . . . . . 8 - 24

T-Bar (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26

T-Bar (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27

T Bar (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28

T-Bar (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29

T-Bar (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30

Pistol Grip (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31

Pistol Grip (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32

Pistol Grip (Fixed Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33

Pistol Grip (Fixed Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34

Pistol Grip (Fixed Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35

Pistol Grip (Floating Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36

Pistol Grip (Floating Deck - Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 41

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 42

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44

Pistol Grip (Floating Deck - Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45

iv Mid-Size Walk Behind Service Manual

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General Information

This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death.

This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the MidSize Walk Behind mower. The Mid-Size Walk Behind

Think Safety First

SAFETY INFORMATION

Mower and attachment operator’s manuals contain 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 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.

Avoid burns...

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

Avoid fires 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 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 flames away from the battery.

Avoid injury due to inferior parts...

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

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 modifications...

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

Avoid asphyxiation...

Never operate an engine in a confined area without proper ventilation.

Mid-Size Walk Behind Service Manual 1 - 1

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.

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THIS PAGE INTENTIONALLY LEFT BLANK

1 - 2 Mid-Size Walk Behind Service Manual

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SPECIFICATIONS

Torque Specifications

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.

These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (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 specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.

Fastener Identification

Inch Series Bolts and Screws

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

Figure 1

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.

Figure 2

Metric Bolts and Screws

(A) Class 8.8 (B) Class 10.9

Mid-Size Walk Behind Service Manual 2 - 1

Page 10

SPECIFICATIONS

Standard Torque for Dry, Zinc Plated, and 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: 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. 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 Mid-Size Walk Behind Service Manual

Page 11

SPECIFICATIONS

Standard Torque for Dry, Zinc, and 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

Class 10.9 Bolts, Screws, and Studs with

Regular Height Nuts (

Class 10 or Strong Nuts)

nuts. Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Mid-Size Walk Behind Service Manual 2 - 3

Page 12

SPECIFICATIONS

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb

5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb

3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb

1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23, or Type F

Thread Size Baseline Torque*

No. 6 - 32 UNC 20 ± 5 in-lb

Wheel Bolts and Lug Nuts

Thread Size Recommended Torque**

7/16 - 20 UNF

Grade 5

1/2 - 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

65 ± 10 ft-lb 88 ± 14 N-m

80 ± 10 ft-lb 108 ± 14 N-m

** For steel wheels and non-lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 ± 5 in-lb

Threads per Inch

Baseline Torque*

Typ e A Typ e B

No. 8 - 32 UNC 30 ± 5 in-lb

No.10 - 24 UNC 38 ± 7 in-lb

1/4 - 20 UNC 85 ± 15 in-lb

5/16 - 18 UNC 110 ± 20 in-lb

3/8 - 16 UNC 200 ± 100 in-lb

Conversion Factors

in-lb X 11.2985 = N-cm

ft-lb X 1.3558 = N-m

No. 8 15 18 30 ± 5 in-lb

No. 10 12 16 38 ± 7 in-lb

No. 12 11 14 85 ± 15 in-lb

* Hole size, material strength, material thickness and finish must be considered when determining specific torque values. All torque values are based on nonlubricated fasteners.

N-cm X - 0.08851 = in-lb

N-cm X 0.73776 = ft-lb

2 - 4 Mid-Size Walk Behind Service Manual

Page 13

SPECIFICATIONS

Equivalents and Conversions

Decimal and Millimeter Equivalents

Fractions Decimals mm Fractions Decimals mm

1/64 0.015625 0.397 33/64 0.515625 13.097

1/32 0.03125 0.794 16/32 0.53125 13.484

3/64 0.046875 1.191 35/64 0.546875 13.891

1/16 0.0625 1.588 9/16 0.5625 14.288

5/64 0.078125 1.984 37/64 0.578125 14.684

3/32 0.9375 2.381 19/32 0.59375 15.081

1/8 0.1250 3.175 5/8 0.6250 15.875

9/64 0.140625 3.572 41/64 0.640625 16.272

5/32 0.15625 3.969 21/32 0.65625 16.669

11/64 0.171875 4.366 43/64 0.671875 17.066

3/16 0.1875 4.762 11/16 0.6875 17.462

13/64 0.203125 5.159 45/64 0.703125 17.859

7/32 0.21875 5.556 23/32 0.71875 18.256

15/64 0.234375 5.953 47/64 0.734375 18.653

1/4 0.2500 6.350 3/4 0.7500 19.050

17/64 0.265625 6.747 49/64 0.765625 19.447

9/32 0.28125 7.144 25/32 0.78125 19.844

19/64 0.296875 7.541 51/64 0.796875 20.241

5/16 0.3125 7.541 13/16 0.8125 20.638

21/64 0.328125 8.334 53/64 0.828125 21.034

11/32 0.34375 8.731 27/32 0.84375 21.431

23/64 0.359375 9.128 55/64 0.859375 21.828

3/8 0.3750 9.525 7/8 0.8750 22.225

25/64 0.390625 9.922 57/64 0.890625 22.622

13/32 0.40625 10.319 29/32 0.90625 23.019

27/64 0.421875 10.716 59/64 0.921875 23.416

7/16 0.4375 11.112 15/16 0.9375 23.812

29/64 0.453125 11.509 61/64 0.953125 24.209

15/32 0.46875 11.906 31/32 0.96875 24.606

31/64 0.484375 12.303 63/64 0.984375 25.003

1/2 0.5000 12.700 1 1.000 25.400

1 mm = 0.03937 in. 0.001 in. = 0.0254 mm

Mid-Size Walk Behind Service Manual 2 - 5

Page 14

SPECIFICATIONS

To C o n v e r t Into Multiply By

Miles Yards

Linear Measurement

Area

Volume

Weight

Pressure

Work

Liquid Volume

Liquid Flows

Tempe r atur e

Feet Feet Inches Inches Inches

Square Miles Square Feet Square Inches Acre

Cubic Yards Cubic Feet Cubic Inches

Tons (Short) Pounds Ounces

Pounds/Sq. In. Kilopascal

Foot-pounds Foot-pounds Inch-pounds

Quarts Gallons

Gallons/Minute Liters/Minute

Fahrenheit Celsius

U.S. to Metric Conversions

Kilometers Meters Meters Centimeters Meters Centimeters Millimeters

Square Kilometers Square Meters Square Centimeters Hectare

Cubic Meters Cubic Meters Cubic Centimeters

Metric Tons Kilograms Grams

Newton-Meters Kilogram-Meters Kilogram-Centimeters

Liters Liters

1.609

0.9144

0.3048

30.48

0.0254

2.54

25.4

2.59

0.0929

6.452

0.4047

0.7646

0.02832

16.39

0.9078

0.4536

28.3495

6.895

1.356

0.1383

1.152144

0.9463

3.785

1. Subtract 32°

2. Multiply by 5/9

2 - 6 Mid-Size Walk Behind Service Manual

Page 15

Chassis PG T-Bar

Hydro

Gear

Trac tion

Floating

SPECIFICATIONS

Drive

Unit

Deck

Deck Fixed

RPM Low

RPM High

Oil Capacity w/

Deck

Speed

Filter Change

Power

30140 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 48” SD X X X

30150 Kawasaki 13 58 oz. (1.7 l) 3600+-100 1550 32" SD X X X

30159 Kohler 15 64 oz. (1.9 l) 3200+-100 1400+-200 X X X

30161 Kawasaki 13 58 oz. (1.7 l) 3600+-100 1550 36" SD X X X

30164 Briggs & Stratton 10.5 48 oz. (1.4 l) 3600+-100 --- 32" SD X X X

30167 Kawasaki 12.5 48 oz. (1.4 l) 3,350 1400 X X X

30168 Kawasaki 15 58 oz. (1.7 l) 3200+-100 1400 X X X

30169 Kawasaki 17 58 oz. (1.7 l) 3200+-100 1400 X X X

30171 Kawasaki 12.5 48 oz. (1.4 l) 3600+-100 1400 32" SD X X X

30177 Kohler 15 64 oz. (1.9 l) 3600+-100 900 to 1,000 X X X

30178 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30182 Briggs & Stratton 16 56 oz. (1.7 l) 3200+-100 1400+-200 X X X

30183 Kohler 18 64 oz. (1.9 l) 3250+-75 1400+-75 X X X

30184 Kohler 13 64 oz. (1.9 l) 3600+-50 1500 91cm SD X X X

30187 Kohler 15 64 oz. (1.9 l) 3200+-100 1400+-200 X X X

30188 Briggs & Stratton 16 56 oz. (1.7 l) 3200+-100 1400+-200 X X X

30189 Briggs & Stratton 16 56 oz. (1.7 l) 3200+-100 1400+-200 X X X

30192 Kohler 20 64 oz. (1.9 l) 3200+-100 1400+-200 X X X

30193 Kawasaki 12.5 48 oz. (1.4 l) 3600+-100 1400 36" SD X X X

30194 Kohler 13 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30195 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 48" SD X X X

30196 Kawasaki 14 54 oz. (1.6 l) 3600+-100 1550 48" SD X X X

30197 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 48" SD X X X

30250 Kawasaki 12.5 48 oz. (1.4 l) 3600+-100 1400 36" SD X X X

30252 Kohler 13 64 oz. (1.9 l) 3200+-100 1400+-200 32" SD X X X

30253 Kohler 15 64 oz. (1.9 l) 3600+-50 1550 36" SD X X X

30254 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 44" SD X X X

30255 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 52" SD X X X

30257 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30258 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30259 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30260 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30290 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30291 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 44" SD X X X

Model Engine Make Horse

30292 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 52" SD X X X

Product Specifications

Mid-Size Walk Behind Service Manual 2 - 7

Page 16

SPECIFICATIONS

Chassis PG T-Bar

Drive

Hydro

Gear

Drive

Unit

Trac tion

Deck

Floating

Deck Fixed

RPM Low

RPM High

Oil Capacity w/

Deck

Speed

Filter Change

Power

30297 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30314 Kawasaki 13 60 oz. (1.8 l) 3600+-100 1550 91cm SD X X X

30316 Kohler 13 64 oz. (1.9 l) 3200+-100 1400+-200 32" SD X X X

30317 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30318 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 44" SD X X X

30319 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 52" SD X X X

30320 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30321 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30322 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30326 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30327 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30329 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30332 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30333 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30334 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30335 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30338 Kawasaki 15 64 oz. (1.9 l) 3600+-100 44" SD X X X

30339 Kawasaki 15 64 oz. (1.9 l) 3600+-100 1550 52" SD X X X

30340 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30341 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30342 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30430 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30431 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30432 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30433 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30434 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30435 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30436 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30437 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30438 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30439 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30440 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 44" SD X X X

30441 Kawasaki 17 58 oz. (1.7 l) 3600+-100 1550 52" SD X X X

30518 Kawasaki 13 58 oz. (1.7 l) 3600+-100 1550 32" SD X X X

30519 Kawasaki 13 58 oz. (1.7 l) 3600+-100 1550 36" SD X X X

Model Engine Make Horse

30520 Kawasaki 12.5 48 oz. (1.4 l) 3600+-50 1400 32" SD X X X

2 - 8 Mid-Size Walk Behind Service Manual

Page 17

Chassis PG T-Bar

Hydro

Gear

Trac tion

SPECIFICATIONS

Drive

Unit

Floating

Deck Fixed

RPM Low

RPM High

Oil Capacity w/

Deck

Speed

Filter Change

X X X

Power

30521 Kawasaki 12.5 48 oz. (1.4 l) 3600+-50 1400 36" SD X X X

30523 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 48" SD X X X

30524 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 36" SD X X X

30526 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 48" SD X X X

30527 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30528 Kohler 15 64 oz. (1.9 l) 3600+-100 1400+-200 48" SD X X X

30529 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 36" SD X X X

30530 Kohler 15 64 oz. (1.9 l) 3600+-50 1400+-200 48" SD X X X

Model Engine Make Horse

30531 Kawasaki 15 58 oz. (1.7 l) 3600+-100 1550 48" SD X X X

30172TE Kawasaki 12.5 54 oz. (1.6 l) 2800 1400 X X X

30250TE Kawasaki 12.5 54 oz. (1.6 l) 2800 1400 36" SD X X X

30261TE Kawasaki 12.5 54 oz. (1.6 l) 2760 1400 91cm SD X X X

30291TE Kohler 15 64 oz. (1.9 l) 2800 1400+-200 44" SD X X X

30299TE Kawasaki 15 58 oz. (1.7 l) 2800+-100 1400+-200 112cm

Mid-Size Walk Behind Service Manual 2 - 9

Page 18

SPECIFICATIONS

15 PSI (103 kPa)

(103 kPa)

15 PSI (103 kPa)

Tire Dimensions Tire Pressure

kPa)

7kPa)

Front Rear Front Rear

(lbs.)

kPa)

Model Years Width Height Length Weight

35.0" 44.5" 40.0" 270 NA 15x6.00" - 6 NA 15 PSI (103 kPa)

2004

30168 2000 35.0" 44.5" 40.0" 270 NA 15x6.00" - 6 NA 15 PSI (103 kPa)

30140 2004 35.0" 41" 72" 435 9" X 3.5" 13x6.50"-6 25-30 PSI (172-20

30150 2004 32.0" 40" 74" 374 9" X 3.5" 13x6.50"-6 25-30 PSI (172-207

30159 1997-2000 30.0" 43.5" 40.0" 258 NA 15x6.00" - 6 NA 15 PSI (103 kPa)

30164 2000-2002 42" 41" 78" 374 9"x3.5-4" 13x6.50"-6 25-30 PSI (172-207

30161 2004 35.0" 41" 74" 392 9" X 3.5" 13x6.50"-6 25-30 PSI (172-207

30169 2000, 2002 &

30167 1996-2002 35.0" 44.5" 45.0" 260 NA 15x6.00" - 6 NA 15 PSI (103 kPa)

35.0" 44.5" 40.0" 261 NA 15x6.00" - 6 NA 15 PSI (103kPa)

2004

30182 1996-1999 35.0" 44.5" 40.0" 270 NA 15x6.00" - 6 NA 15 PSI (103 kPa)

30177 1996-2002 &

30178 2003-2004 35.0" 41" 74" 392 NA 13x6.50"-6 25-30 PSI (172-207

30171 2000-2003 42" 41" 78" 374 9"x3.5-4" 13x6.50"-6 25-30 PSI (172-207

30183 1996-1999 35.0" 44.5" 45.0" 294 NA 15x6.00" - 6 15 PSI (103 kPa) 15 PSI (103 kPa)

33.0” 44.5” 43.0” 340 NA 15x6.00" - 6 NA 15 PSI

02 & 04

30187 1997-2000 &

30188 1997 & 2000 33.0” 44.5” 43.0” 340 NA 13x6.50"-6 NA 15 PSI

30184 1998-2000 35.0" 41.0" 74.0" 392 9"x3.5-4" 9x3.50" - 4 25-30 PSI (172-207

30189 1997-1998 33.0” 44.5” 43.0” 340 NA 15x6.00" - 6 NA 15 PSI

33.0" 44.5" 43.0" 375 NA 13x6.50"-6 NA 15 PSI

30192 1997-1998 &

30193 1997-2000 46" 41" 74" 392 9"x3.5-4" 13x6.50"-6 25-30 PSI (172-207

30194 1998-2002 46" 41" 74" 392 9"x3.5-4" 13x6.50"-6 25-30 PSI (172-207

30195 2003 35.0" 41" 72" 435 9"x3.5-4" 6.5" X 13" 25-30 PSI (172-207

Product Dimensions

2 - 10 Mid-Size Walk Behind Service Manual

Page 19

SPECIFICATIONS

Tire Dimensions Tire Pressure

kPa)

15 PSI (103 kPa)

12-14 PSI (83-97

kPa)

20-24 PSI (138-165

(40.6x16.5 – 20.3 mm)

Front Rear Front Rear

kPa)

15 PSI

(103 kPa)

12-14 PSI (83-97

kPa)

20-24 PSI (138-165

(40.6x16.5 – 20.3 mm)

20-24 PSI (138-165

25-30 PSI (172-207

16x6.50" – 8

(40.6x16.5 – 20.3 mm)

9 X 3.5 - 4" (23 X

15 PSI (103 kPa)

kPa)

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

kPa)

25-30 PSI (172-207

16x6.50" – 8

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

Model Years Width Height Length Weight

(lbs.)

30196 1998-2002 64" 41" 72" 429 9"x3.5-4" 13x6.50"-6 25-30 PSI (172-207

30197 1998-2004 64" 41" 72" 429 9"x3.5-4" 13x6.50"-6 25-30 PSI (172-207

30250 2001 48" 44" 83.5" 416 11"x4.00-5" 16x6.50" – 8

30252 2001-2002 32" 42" 76.5" 388 6.25"x3" 14x5.00"-6 15 PSI (103kPa) 15 PSI (103 kPa)

30253 2001 48" 44" 83.5" 417 11"x4.00-5" 16x6.50" – 8

30254 2001 56" 44" 80" 448 11"x4.00-5" 16x6.50" – 8

30255 2001 64" 44" 80" 451 11"x4.00-5" 16x6.50" – 8

30257 2001 56" 44" 80" 458 11"x4.00-5" 16x6.50" – 8

30258 2001 66.5" 47.0" 82.3" 528 11"x4.00-5" 16X7.50"-8 20-24 PSI (138-165

30259 2001 56" 44" 80" 460 11"x4.00-5" 16x6.50" – 8

30260 2001 64" 44" 80" 463 11"x4.00-5" 16x6.50" – 8

30290 2001 48" 44" 83.5" 496 11"x4.00-5" 16x6.50" – 8

30291 2001 56" 44" 80" 527 11"x4.00-5" 16x6.50" – 8

465 lbs.

80.5"

45.5"

30292 2001 64" 44" 80" 530 11"x4.00-5" 16x6.50" – 8

30314 2004 48.3"

(211 Kg)

(264.5 cm)

(115.6 cm)

(122.7 cm)

30316 2003-2004 32.0" 43.5" 73.0" 388 6.25"x3" 14X5.00--6 NA 15 PSI

30317 2003-2004 48.3" 45.5" 80.5" 477 9 X 3.5 - 4" (23 X

30318 2003-2004 58.7" 45.5" 79.6" 511 9 X 3.5 - 4" (23 X

30319 2003-2004 66.6" 45.5" 80.7" 585 9 X 3.5 - 4" (23 X

30320 2003 58.7" 45.5" 79.6" 494 9 X 3.5 - 4" (23 X

Mid-Size Walk Behind Service Manual 2 - 11

Page 20

SPECIFICATIONS

kPa)

15 PSI (103 kPa)

kPa)

12-14 PSI (83-97

kPa)

12-14 PSI (83-97

kPa)

Tire Dimensions Tire Pressure

(lbs.)

25-30 PSI (172-207

16x6.50" – 8

(40.6x16.5 – 20.3 mm)

Front Rear Front Rear

9 – 10 cm)

15 PSI (103 kPa) 15 PSI (103 kPa)

25-30 PSI (172-207

16x6.50" – 8

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

20-24 PSI (138-165

16x6.50" – 8

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

16x6.50" – 8

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

9 X 3.5 - 4" (23 X

KG)

30321 2003-2004 58.7" 45.5" 79.6" 494 9 X 3.5 - 4" (23 X

30322 2003-2004 66.6" 45.5" 80.7" 568 9 X 3.5 - 4" (23 X

30326 2004 58.7" 45.5" 79.6" 494 9 X 3.5 - 4" (23 X

30327 2004 58.7" 45.5" 79.6" 494 9 X 3.5 - 4" (23 X

30329 2001 48" 44" 83.5" 417 11"x4.00-5" 16x6.50" – 8

30332 2001 56" 44" 80" 458 11"x4.00-5" 16x6.50" – 8

30333 2001 64" 44" 80" 461 11"x4.00-5" 16x6.50" – 8

30334 2001 64" 44" 80" 463 11"x4.00-5" 16x6.50" – 8

30335 2001 48" 44" 83.5" 496 11"x4.00-5" 16x6.50" – 8

30338 2001 56" 44" 80" 527 11"x4.00-5" 16x6.50" – 8

30339 2001 64" 44" 80" 530 11"x4.00-5" 16x6.50" – 8

30340 2001 56" 44" 80" 550 11"x4.00-5" 16x6.50" – 8

30341 2001 64" 44" 80" 560 11"x4.00-5" 16x6.50" – 8

30342 2004 66.6 45.5 80.7" 568 9 X 3.5 - 4" (23 X

30430 2003-2004 48.3 44.2 82.3 477 (216

30431 2003-2004 58.7" 44.2" 81.5" 496 (225

30432 2003-2004 66.6" 44.2" 82.3" 570 (258

30433 2003-2004 48.3 44.2 82.3 528 (239

Model Years Width Height Length Weight

30434 2003-2004 58.7" 44.2" 81.5" 546 (248

2 - 12 Mid-Size Walk Behind Service Manual

Page 21

SPECIFICATIONS

kPa)

12-14 PSI

(83-97 kPa)

12-14 PSI (83-97

kPa)

20-24 PSI (138-165

20-24 PSI

(138-165 kPa)

15 PSI (103 kPa)

kPa)

15 PSI (103 kPa)

kPa)

12-14 PSI (83-97

kPa)

20-24 PSI (138-165

15 PSI (103 kPa)

12-14 PSI (83-97

kPa)

20-24 PSI (138-165

15 PSI (103 kPa)

kPa)

Tire Dimensions Tire Pressure

(lbs.)

13 x 5.0-6 20-24 PSI (138-165

13x6.50"-6 20-24 PSI (138-165

16x6.50" – 8

16x6.50 – 8"

(40.6x16.5 – 20.3 mm)

Front Rear Front Rear

9 – 10 cm)

9 X 3.5 - 4" (23 X

(261 KG)

9 – 10 cm)

(295 KG)

9 – 10 cm)

(23 X 9 – 10 cm)

13x6.50"-6 25-30 PSI (172-207

9 – 10 cm)

6.5" X 13" 20-24 PSI (138-165

13x6.50"-6 25-30 PSI (172-207

9 – 10 cm)

16x6.50 – 8"

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

6.5" X 13" 20-24 PSI (138-165

16x6.50 – 8"

(40.6x16.5 – 20.3 mm)

9 – 10 cm)

6.5" X 13" 20-24 PSI (138-165

9 – 10 cm)

30435 2003-2004 58.7" 44.2" 81.5" 576 LBS

30436 2003 66.6" 44.2" 82.3" 650 LBS

30437 2004 58.7 44.2 81.5 496 9 X 3.5 - 4" (23 X

30438 2004 66.6 44.2 82.3 570 9 X 3.5 - 4" (23 X

30439 2004 58.7 44.2 81.5 546 9 X 3.5 - 4" (23 X

30440 2004 58.7 44.2 81.5 576 9 X 3.5 - 4" (23 X

30441 2004 66.6 44.2 82.3 650 9 X 3.5 - 4"

30518 2004 32.0" 40" 78" 420 9 X 3.5 - 4" (23 X

Model Years Width Height Length Weight

30519 2004 35.6" 41" 78" 430 9 X 3.5 - 4" (23 X

30520 2002-2003 32.0" 40.0" 78" 420 9 X 3.5 - 4" (23 X

30521 2002-2003 35.6" 41.0" 78" 430 9 X 3.5 - 4" (23 X

30523 2002-2004 35.0" 41" 72" 475 9 X 3.5 - 4" (23 X

30524 2002-2004 46.1 43.2" 78" 433 9 X 3.5 - 4" (23 X

30526 2002-2003 58.2" 43.2" 73" 483 9 X 3.5 - 4" (23 X

30527 2003-2004 46.1" 43.2 78" 430 9 X 3.5 - 4" (23 X

30528 2003-2004 58.2" 43.2" 73" 483 9 X 3.5 - 4" (23 X

30529 2003-2004 35.6" 41" 78" 430 9 X 3.5 - 4" (23 X

30530 2003-2004 35.0" 41" 72" 475 9 X 3.5 - 4" (23 X

30531 2004 35.0" 41" 72" 475 9 X 3.5 - 4" (23 X

Mid-Size Walk Behind Service Manual 2 - 13

Page 22

SPECIFICATIONS

kPa)

12-14 PSI (83-97

Tire Dimensions Tire Pressure

(lbs.)

NA 12-14 PSI (83-97

Front Rear Front Rear

11"x4.00-5" 16x6.50" – 8

20-24 PSI (138-165

(40.6x16.5 – 20.3 mm)

11"x4.00-5" 16x6.50" – 8

KG)

kPa)

(40.6x16.5 – 20.3 mm)

KG)

kPa)

20-24 PSI (138-165

16x6.50" – 8

(40.6x16.5 – 20.3 mm

10cm)

9x3.5-4 (23x9-

KG)

kPa)

20-24 PSI (138-165

16x6.50 – 8"

(40.6x19.4 – 20.3 mm)

(40.6x16.5 – 20.3 mm)

11"x4.00-5" 16x7.50" – 8

9 – 10 cm)

KG)

Model Years Width Height Length Weight

30172TE 2001 48.31 44.1 83.55 250 (113

30261TE 2003-2004 48.3 45.5 80.5 469 (213

30250TE 2001 48.31 44.1 83.55 469 (213

30528 2003-2004 58.2" 43.2" 73" 483 9 X 3.5 - 4" (23 X

30291TE 2001 58.73 44.1 79.92 560 (254

2 - 14 Mid-Size Walk Behind Service Manual

Page 23

SPECIFICATIONS

Floating Deck

Classic T-Bar / Gear Drive /

Only

Classic T-Bar / Gear / Traction Unit

Deck

Pistol Grip / Hydro Drive / Floating

30183

30185

30225

Floating Deck

T-Bar / Hydro Drive /

30441

Model ID

Fixed Deck

Pistol Grip / Hydo Drive /

Fixed Deck

Pistol Grip / Gear Drive /

Deck

T-Bar / Gear Drive / Fixed

30140 30518 30524 30119 30316

Floating Deck

Pistol Grip / Gear Drive /

30258 30431 30436

30259 30432 30338

30260 30437 30439

30317 30438 30440

30318

30319

30320

30321

30322

30326

30327

30342

Floating Deck

T-Bar / Gear Drive /

30187 30250 30329 30290 30339

30188 30251 30332 30291 30340

30189 30253 30333 30292 30341

30191 30254 30334 30297 30433

30150 30519 30526 30159

30161 30520 30527 30165

30164 30521 30528 30167

30171 30523 30168

30178 30529 30169

30184 30530 30177

30193 30531 30182

30194

30195

30196

30197

/ Traction Unit Only

Classic T-Bar / Hydro Drive

30192 30255 30335 30296 30434

*30299TE 30257 30430 30291TE 30435

30172TE

30250TE

30261TE

30314TE

Mid-Size Walk Behind Service Manual 2 - 15

Page 24

MAINTENANCE

Maintenance Schedule, Floating Deck Models

Maintenance Service Interval Maintenance Procedure

Each Use • Engine Oil—check level

• Safety System—check

• Brake—check

• Engine—clean outside

• Mower Housing—clean

8 Hours • Engine Oil—change

• Cutting Blades—check

• Mower Housing—clean

• Caster Wheels—grease

25 Hours

• Foam Air Cleaner—clean

• Paper Air Cleaner—check, replace if dirty

40 Hours • Deck Belt Idler Arm—grease

• Deck Belt Idler Arm—grease

• Tires—check pressure

•Hydraulic Oil—check 50 Hours • Belts—check for wear/cracks 100 Hours

• Engine Oil—change

• Spark Plug(s)—check

• Electric Clutch–Adjust

• Engine—clean outside

• Paper Air Cleaner—replace

200 Hours • Engine Oil Filter—change (200 hours or every other oil change)

• Fuel Filter—replace 250 Hours

400 Hours

• Transmission Couplings—grease

• Wheel Bearings—grease

At Storage • Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storage

More often in dusty, dirty conditions.

2 - 16 Mid-Size Walk Behind Service Manual

Page 25

Maintenance Schedule, Fixed Deck Models

MAINTENANCE

Service Operation Each

Use8Hours25Hours50Hours

Oil—check level X X

Oil—change* Initial X X

Oil Filter—change (200 hours or every other oil change)

Safety System—check X X

Brakes—check X X

Cutting Blades — check X X X

Wheel Bearings—grease* X X

Transmission Couplers — grease* X X

Idler Pivots — grease* X X

Belt Blade Idler Pivots — grease* X X

Foam Air Cleaner—service* X X

Paper Air Cleaner—replace* X X

Spark Plug(s)—check XX

Belts—check for wear/cracks X X

PTO Belt—check tension Initial X X

Gasoline—drain X

Engine—clean cooling system X X X

Fuel Filter—replace XX

Tires—check pressure X X

Chipped Surfaces—paint X

* More often in dusty, dirty conditions

100

Hours

200

Hours

Storage

Service

Mid-Size Walk Behind Service Manual 2 - 17

Page 26

THIS PAGE INTENTIONALLY LEFT BLANK

2 - 18 Mid-Size Walk Behind Service Manual

Page 27

ENGINE

Engine Removal

1. Turn the fuel valve to the “off” position.

2. Drain the engine oil into a suitable container.

3. Remove the fuel line by sliding clamp down and remove the line from fuel pump (Figure 3). Drain fuel in line into a suitable container.

6. Cut the tie wrap and disconnect the mag wire (red from black) bullet connector (Figure 5).

Figure 5

7. Remove the screw attaching the ground wire to the air shroud.

8. Remove the bolt securing the harness to the engine block.

0602-12

Figure 3

4. Remove bolt that clamps the fuel line to engine block (Figure 4).

Figure 4

5. Slide the wiring out from under the clip on the air shroud.

mvc-048

mvc-409

9. Pull the harness out from behind the oil fill tube and move it away from the engine to prevent damage.

On Floating Deck Models:

10. Disconnect the alternator wire connector (red to pink) (Figure 6).

Figure 6

Mid-Size Walk Behind Service Manual 3 - 1

0819-32

Page 28

ENGINE

11. Separate the electric clutch connector and push the connector and grommet through the frame (Figure 7).

Figure 7

12. Remove the air cleaner cover.

13. Then remove the clamps holding the throttle and choke cables to the engine (Figure 8). Mark the cable housings for the clamp locations to assist in reassembly. Remove the throttle and choke cables.

0819-30

15. If the unit is up, no need to remove the deck covers.

16. Remove deck drive belt from deck idler and drive pulley (Figure 9).

Figure 9

17. Remove hydro pump drive belt (Figure 10).

mvc-412

Figure 8

(A) Choke (B) Throttle

14. Remove the drive pulleys.

0602-10

Figure 10

mvc-415

3 - 2 Mid-Size Walk Behind Service Manual

Page 29

ENGINE

18. Remove PTO clutch arm from housing (Figure 11).

Figure 11

19. Sometimes it is necessary to remove the PTO clutch brake pulley to have better access for removing the clutch bolt (Figure 12 and Figure

14).

0820-05

20. On gear drive models, remove the V belt from the transmission sheave (Figure 13).

Figure 13

mvc-417

Figure 14 mvc-418

Figure 12

Mid-Size Walk Behind Service Manual 3 - 3

mvc-417

Page 30

ENGINE

21. Remove pulley cover (Figure 15).

Figure 15

22. Unbolt clutch bolt, remove clutch and engine pulley (Figure 16 and Figure 17).

mvc-419

Figure 17 mvc-424

23. Remove the nuts and bolts that mount engine to chassis (Figure 18).

Figure 18

Figure 16

3 - 4 Mid-Size Walk Behind Service Manual

mvc-421

Reverse order for reassembly - Torque clutch bolt to 55 to 60 ft. lbs. (75 to 81 N-m).

mvc-423

Page 31

ENGINE

On Fixed Deck Models:

1. Engage the PTO and block the mower blades to prevent the crankshaft from turning (Figure 19).

Figure 19

2. Then loosen the pulley bolt (Figure 20).

0602-11

3. Remove tension from the hydraulic pump belt by using the cold start assist ring (Figure 21).

Figure 21

4. Disengage the PTO. Finish removing the pulley bolt along with the 4 washers.

5. Slide the PTO pulley, 2 spacers, and the pump drive pulley from the crankshaft, taking care not to lose the 2 keys which locate the pulleys on the crankshaft.

0602-09

Figure 20

0602-08

6. Mark the position of the belt guide attached with the left rear mounting bolt (Figure 22).

Figure 22

7. Remove the 4 engine mounting bolts and remove the engine from the chassis.

0602-04

Engine Installation

Follow the removal procedures in reverse.

Mid-Size Walk Behind Service Manual 3 - 5

Page 32

ENGINE

Engine Assembly, Typical

Ref. No. Qty. Description Ref. No. Qt. Description

1 *2 3 4 5 6 7 8 9 10 11 12 13 14 15

* Not serviced separately

1 1 1 1 1 1 1 1 4 2 1 1 1 4 2

Filter - Fuel Engine - Kawasaki, Fh500v-As29 Clamp - Cable Decal - Warning, Hot Surfaces Clip - Closed, Insulated Adapter Valve - Drain, Oil Harness - Wire Nut - Lock, NI Nut - HF Washer - Lock Grommet Tube - Retainer Washer Grommet - Brake

16 17 18 19 20 22 23 24 25 26 27 28 29 99

2 1 1 5 5 1 1 1 1 1 1 1 1 1

Spacer - Grommet Strap - Clutch/Brake Screw - HH Washer - Flat Screw - HH Screw - HH Washer Clutch/Brake Pulley - Drive

Key - Square Cover - Pulley Muffler Clamp - Muffler Hose - Drain, Oil

3 - 6 Mid-Size Walk Behind Service Manual

Page 33

CHASSIS

Model and Serial Number Location

The model and serial number plate is located on the traction unit. (Figure 23 and Figure 24).

Figure 23

(1) Location of the model and serial numbers on

Floating Deck

m-4189

Greasing and Lubrication

Service Interval/Specification

Refer to the Check Service Reference Aid decal for location and interval of greasing and lubrication (Figure

25).

Grease with No. 2 general purpose lithium base or molybdenum base grease.

How to Grease

1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

2. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings.

Figure 24 m-3775

(2) Location of the model and serial numbers on Fixed

Deck

Engine Model and Serial Number Identification

4. Wipe up any excess grease.

Where to Add Grease

Lubricate the grease fittings as

Service Reference

Lubricating the Castor and Wheel Bearings

Aid decal (Figure 25).

Figure 25

shown on the Check

service ref aid-1

Consult the appropriate engine manufacturer’s service literature for the location of the engine model and serial number information.

Mid-Size Walk Behind Service Manual 4 - 1

1. Lubricate the front wheel bearings and front spindles until grease begins to ooze out of the bearings (Figure 26).

Page 34

CHASSIS

2. Remove rear wheel grease cap. Lubricate the rear wheel bearing (Figure 26).

Note: Make sure the rear wheel grease caps are removed before lubricating rear wheels.

Figure 26

Lubricating the Transmission Couplers

m-2147

Greasing the PTO Drive Belt Idler and Deck Belt Idler

1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Grease the idler pulley pivots (Figure 28).

Note: You’ll have to remove the carrier covers to access the grease fitting for the deck.

3. Grease the idler pulley pivots (Figure 28).

1. Lubricate the transmission couplers located in the back of the machine with general purpose grease (Figure 27).

Figure 27

m-5191

Figure 28

m-5194

Cleaning the Cooling System

Service Interval/Specification

Before each use, check and clean engine cooling system. Remove any build-up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetorgovernor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.

4 - 2 Mid-Size Walk Behind Service Manual

Page 35

CHASSIS

Brake Service

Service Interval/Specification

Before each use, check brakes for proper operation.

Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required.

Pistol Grip - Gear Drive - Fixed Deck

Checking the Brake

1. Park the machine on a level surface, disengage the blade control (PTO) and push the neutral/ brake lock forward to set the brake.

2. Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock. Refer to ”Adjusting the Brake" on page 4 - 3.

4. Position wing nut so the brakes will engage when the drive levers are squeezed enough to place neutral/brake lock forward and set the brake.

5. Check the brake operation again; refer to ”Pistol Grip - Gear Drive - Fixed Deck" on page 4 - 3.

Important

wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved, contact your service dealer immediately.

With the parking brake released, the rear

3. Release the brake and move neutral/brake lock to neutral. Move the machine slightly, approximately 1/2 in. (13mm). Wheels should rotate freely.

4. If both conditions are met, no adjustment is required.

Adjusting the Brake

If the parking brake does not hold securely, an adjustment

1. Check the brake before you adjust it; refer to

2. Release the parking brake.

3. To adjust brake, rotate the wing nuts on the brake

is required.

”Pistol Grip - Gear Drive - Fixed Deck" on page 4 -

rods (Figure 29). Rotate clockwise to tighten the brake and counterclockwise to loosen the brake.

Figure 29

(1) Brake rod (2) Wing nut

m-5372

Pistol Grip - Gear Drive - Floating Deck

Checking the Brake

1. Park the machine on a level surface, disengage the PTO.

2. Stop the engine, remove the key and wait for all moving parts to stop before leaving the operating position.

3. Push the neutral/brake lock forward to set the brake.

4. Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock. Refer to ”Adjusting the Brakes" on page 4 - 4.

Mid-Size Walk Behind Service Manual 4 - 3

Page 36

CHASSIS

5. Release the brake and move the neutral/brake lock to the neutral position. Move the machine lightly, approximately 1/2 in. (13mm). Wheels should rotate freely.

6. If both conditions are met, no adjustment is required.

Adjusting the Brakes

The brake lever is on the upper control bar (Figure 31). If the parking brake does not hold securely, an adjustment is required.

Note: For the initial adjustment, adjust the wing nut until it is 1-1/4 inches (32mm) from the top of the rod (Figure 30).

1. Park the machine on a level surface, disengage the PTO, and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Check the brake before you adjust it; refer to ”Checking the Brake" on page 4 - 3.

4. Release the parking brake; refer to ”Releasing the Parking Brake" on page 4 - 4.

10. Check the brake operation again refer to ”Checking the Brake" on page 4 - 3.

Figure 30

(1) Brake rod (2) Wing nut

Releasing the Parking Brake

1. Squeeze the drive levers back to the grip (Figure

31).

2. Place thumbs on the upper part of locks and rotate them rearward until in forward speed slot (Figure

31).

m-5372

5. To adjust the brake remove the hair pin cotter and washer from the bell crank and trunnion (Figure

30).

6. Rotate the wing nut clockwise to increase the braking pressure.

7. Rotate the wing nut counterclockwise to decrease the braking pressure.

8. Install the trunnion into the hole for the brake rod (Figure 30). Tighten the wing nut.

9. Secure trunnion to brake lever with washer and hair pin cotter (Figure 30).

Figure 31

(1) Handle (2) Neutral/parking brake

lock (3) Park position (4) Neutral position

m-6580

(5) Drive lever (6) Full speed forward

position (7) Grip (8) Forward speed slot

4 - 4 Mid-Size Walk Behind Service Manual

Page 37

CHASSIS

Pistol Grip - Hydro - Fixed Deck

Checking the Parking Brake

1. Move the machine onto a level surface.

2. Disengage the power take off (PTO) and stop the engine.

3. Set the parking brake.

Note: Setting the parking brake should take a reasonable amount of force. If it engages too hard or too easily, adjustment is required. Refer to ”Adjusting the Parking Brake" on page 4 - 5.

Adjusting the Parking Brake

The parking brake lever is on the right side of the machine (Figure 32). If the parking brake does not hold securely, adjust it.

1. Check the parking brake before you adjust it; refer to ”Checking the Parking Brake" on page 4 - 5.

6. Check the brake operation again; refer to ”Checking the Parking Brake" on page 4 - 5.

Figure 32

(1) Brake linkage yoke (2) Flat bar (parking brake

lever in the released position)

(3) Clevis pin (4) Hair pin cotter (5) 1/4 in. (6 mm)

m-6182

2. Release the parking brake; refer to ”Releasing the Parking Brake" on page 4 - 4.

3. Remove the hair pin cotter and the clevis pin from the lower brake lever (Figure 32).

4. Rotate the brake linkage yoke in to tighten the parking brake; rotate the brake linkage yoke out to loosen the parking brake (Figure 32).

Note: There should be approximately 1/4 inch (6.3mm) clearance between the tire and the flat bar when the parking brake is in the released position (Figure 32).

5. Secure the brake linkage yoke to the lower brake lever with the hair pin cotter and the clevis pin (Figure 32).

Pistol Grip - Hydro - Floating Deck

Checking the Brake

1. Park the machine on a level surface.

2. Disengage the PTO and set the parking brake.

3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. To set the parking brake, it should take a reasonable amount of force. If it engages too hard or easily, adjustment is required. Refer to ”Adjusting the Brake" on page 4 - 6.

Note: When the brake is engaged, the brake handle should be close to the 1 o’clock position.

5. If there is a reasonable amount of force, no adjustment is required.

Mid-Size Walk Behind Service Manual 4 - 5

Page 38

CHASSIS

Adjusting the Brake

The brake handle is on the left side of the machine (Figure 33). If the parking brake does not hold securely, and adjustment is required.

1. Check the brake before you adjust it; refer to ”Checking the Brake" on page 4 - 5.

2. Release the parking brake; refer to ”Releasing the Parking Brake" on page 4 - 4.

3. Loosen the top and bottom jam nuts (Figure 33).

4. To adjust the brake, remove the hair pin cotter and clevis pin from the lower brake lever (Figure 33).

5. Rotate the brake rod in the yokes. To tighten the brake, lengthen the rod between the yokes. To loosen the brake, shorten the rod between the yokes (Figure 33).

Note: The brake rod should be threaded into both yokes the same distance.

6. Secure the yoke to lower brake lever with the hair pin cotter and clevis pin (Figure 33).

7. Tighten the top and bottom jam nuts (Figure 33).

8. Check the brake operation again, refer to ”Checking the Brake" on page 4 - 5.

Figure 33

(1) Yoke (2) Parking brake lever

(released position) (3) Clevis pin (4) Hair pin cotter

(5) Jam nut (6) Brake rod (7) Lower brake lever (8) 1 o’clock position

T-Bar - Gear Drive - Fixed Deck

Checking the Brake

m-6614

1. Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake.

2. Rear wheels must lock when you try to push the machine forward or backward. Adjustment is required if the wheels turn and do not lock; refer to ”Adjusting the Brake" on page 4 - 7.

3. Release the brake and press the upper control bar very lightly, approximately 1/2 inch (13mm), wheels should rotate freely.

4. If both conditions are met, no adjustment is required.

4 - 6 Mid-Size Walk Behind Service Manual

Page 39

CHASSIS

Adjusting the Brake

The brake lever is on the upper control bar (Figure 34). If the parking brake does not hold securely, an adjustment is required.

Figure 34

(1) Upper control bar (2) Parking brake lock

1. Check the brake before you adjust it; refer to ”Checking the Brake" on page 4 - 6.

4. Check the brake operation again; refer to ”Checking the Brake" on page 4 - 6.

Important

wheels must rotate freely when you push the mower. If the brake action and free wheel cannot be achieved, examine the brake system components for wear or damage.

(1) Brake rod (2) Wing nut

With the parking brake released, the rear

Figure 35

m-3773

2. Release the parking brake; refer to ”Releasing the Parking Brake" on page 4 - 4.

3. To adjust the brake, set the parking brake latch, and rotate the wing nuts on the brake rods (Figure

35). Clockwise to tighten the brake and counterclockwise to loosen the brake.

Note: The control bar should be parallel with reference bar when properly adjusted.

T-Bar - Gear Drive - Floating Deck

Checking the Brake

1. Park the machine on a level surface, disengage the PTO.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Apply the parking brake. The wheels must lock when you try to push the machine forward.

4. If the wheels do not lock, adjust the brakes. Refer to ”Adjusting the Brake" on page 4 - 8.

5. Release the brake and press upper control bar very lightly, approximately 1/2 inch (13mm). The wheels should rotate freely. If not; refer to ”Adjusting the Brake" on page 4 - 8.

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Page 40

CHASSIS

Adjusting the Brake

The brake lever is on the upper control bar (Figure 36). If the parking brake does not hold securely, adjustment is required.

Note: For the initial adjustment, adjust the wing nut until it is 1-1/4 inches (32mm) from the top of the rod (Figure 37).

8. Install the trunnion into hole F (Figure 37). Tighten the wing nut.

9. Secure trunnion to brake lever with washer and hair pin cotter (Figure 37).

10. Check the brake operation again; refer to ”Checking the Brake" on page 4 - 7.

Important

wheels must rotate freely when you push the mower. If brake action and free wheel rotation cannot be achieved, examine the brake system components for wear or damage.

With the parking brake released, the rear

Figure 36

(1) Upper control bar (2) Parking brake lever (set

position)

1. Park the machine on a level surface, disengage the PTO, and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Check the brake before you adjust it; refer to ”Checking the Brake" on page 4 - 7.

4. Release the parking brake; refer to ”Releasing the Parking Brake" on page 4 - 4.

5. To adjust the brake, remove the hair pin cotter and washer from the brake lever and trunnion (Figure

37).

6. Rotate the wing nut clockwise to increase the braking pressure.

m-5233

(1) Hair pin cotter and

washer (2) Trunnion (3) Brake lever (4) Wing nut

Figure 37

(5) Hole F (6) Initial adjustment - 1-1/4

inch (32 mm)

(7) Rod

m-6512

Brake Band (T-Bar - Gear Drive)

Removal

1. Turn the engine off and remove the high tension wire(s) from the spark plug(s).

2. Jack up the machine until the tire is off the floor. Support the machine with jack stands or blocks to prevent it from falling.

7. Rotate the wing nut counterclockwise to decrease the braking pressure.

4 - 8 Mid-Size Walk Behind Service Manual

3. Remove rear wheel and tire from the wheel hub.

4. Remove the wheel hub from the axle.

Page 41

CHASSIS

5. Remove the drive belt from the pulleys.

6. Remove the dust cover, cotter pin, nut, and washer from the axle (Figure 38).

Figure 38

0819-03

7. Slide the hub with the pulleys and brake drum off the axle (Figure 39).

8. Inspect the brake drum. Replace it if is severely scored.

9. Remove the hairpin cotter and disconnect the brake rod from the brake arm (Figure 40).

Figure 40

0819-02

10. Pry off the push nut securing the brake arm to the pivot (Figure 41).

Figure 39

0819-05

Figure 41

0819-01

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Page 42

CHASSIS

11. Remove the 3 push nuts securing the brake band to the brake link (Figure 42). Note: Use all new push nuts when reassembling the brakes.

Figure 42

Installation

Follow the removal procedures in reverse and check the brakes, ”Checking the Brake" on page 4 - 7.

Important

brake arm pivot with anti-seize compound during assembly.

Lubricate the brake link pivot pins and

0819-06

4 - 10 Mid-Size Walk Behind Service Manual

Page 43

Wheel Drive and Brake Assembly

CHASSIS

Ref Qty. Description Ref Qty. Description

1 2 3 4 6 7 8 9 10 12 13 14 15 16 16:1 16:2 16:3 17 18 19 19:2 19:3 19:4 20

4 2 2 2 2 2 2 2 2 8 4 2 2 2 1 1 1 8 2 2 2 1 4 2

Ring-Retaining Ring-Retaining, External Plate-Link, Brake Brake Arm ASM Pin-Hair Rod-Brake Ring-Retaining Brake Link ASM V-Belt Nut-Lock, NI Bearing-Cone, Tapered Washer-Spacer Nut-SHH Wheel And Tire ASM Tire Wheel Stem-Valve Nut-Lug Cap-Dust Hub/wheel ASM Bearing-Cup, Tapered Fitting-Grease Stud-Wheel Pulley-Wheel

22 23 24 25 26 27 28 29

2 8 2 2 1 2 6 6

Band-Brake Screw-HH Seal-Grease Spacer-W heel Axle ASM Pin-Cotter Nut-HF Screw-HHF

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Page 44

CHASSIS

Drum Brake / Pulley Assembly Removal (Gear Drive)

1. Raise the rear of machine so wheels are off the ground and support with jack stands.

Figure 43

2. Remove the 4 wheel lug nuts from wheel hub.

mvc-899

Figure 45

5. Remove the dust cap.

Figure 46

mvc-003

mvc-901

Figure 44

3. Remove the rear wheel and tire from the wheel hub.

4. Remove belt from drum/pulley assembly.

4 - 12 Mid-Size Walk Behind Service Manual

mvc-900

Page 45

CHASSIS

6. Remove cotter pin securing axle nut and discard cotter pin.

Figure 47

mvc-902

7. Remove the axle nut.

8. Remove the retaining ring holding the brake lever to chassis and discard.

Figure 49

mvc-013

9. Remove hair pin holding brake rod to brake lever.

Figure 48

mvc-904

Figure 50

mvc-015

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Page 46

CHASSIS

10. Disconnect brake rod from brake lever.

Figure 51

mvc-002

11. Remove hub, drum/pulley assembly with the brake band assembly from axle.

12. Slide brake band from drum and inspect for wear or damage. Replace if needed.

Figure 53

mvc-011

13. While using a 1/2" socket with extension to hold the bolt, use a 1/2" wrench and loosen lock nut and remove.

Figure 52

mvc-004

Figure 54

mvc-005

4 - 14 Mid-Size Walk Behind Service Manual

Page 47

Figure 55 nvc-007

CHASSIS

15. Inspect axle shaft, bearings and bearing races for wear, damage or dirt (Figure 57).

14. Separate drum/pulley assembly from wheel hub (Figure 56).

Figure 56

mvc-008

Figure 57

16. Reassemble brake drum/pulley assembly onto hub - torque nuts to 200 in. lbs. (22.6 N-m).

17. If you have the split pulley assembly - fasten the 2 split pulleys to the brake drum and fasten to wheel hub.

Figure 58

mvc-010

mvc-012

Note: Reassemble in reverse order.

18. Torque wheel lug nuts to 85 ft. lbs. (115 N-m).

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Page 48

CHASSIS

Parking Brake Linkage (Pistol Grip Hydro)

Removal

1. Remove the hairpin cotter retaining the lower link to the brake shaft (Figure 59).

Figure 59

0602-36

4. Remove the bellcrank assembly.

5. Remove the hairpin clip from the upper linkage rod and remove the rod from the bellcrank (Figure

61).

Figure 61

6. Remove the 2 bolts securing the bellcrank to the rear frame (Figure 62).

0602-39

2. To remove the idler spring, remove the nut and bolt assembly from the brake mounting flange end of the spring. Slip the opposite end of the spring off the brake return lever (Figure 60).

Figure 60

3. Remove the remaining bolts securing the parking brake assembly to the rear frame.

0602-44

Figure 62

0602-46

4 - 16 Mid-Size Walk Behind Service Manual

Page 49

7. To remove the parking brake lever assembly, remove the pivot bolt and bushing from the lever bracket (Figure 63).

CHASSIS

Figure 63

Installation

Follow the removal procedures in reverse.

0602-37

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Page 50

CHASSIS

Linkage Assembly (Pistol Grip Hydro)

Ref. No. Qty. Description Ref. No. Qty. Description

1 1 Switch - Open, Normally 14 2 Screw - HH 2 2 Nut - SQH 15 1 Bushing - Plastic 3 1 Nut - Lock, NI 16 1 Bellcrank ASM 4 1 Lever - Park Brake 17 1 Pin - Cotter 5 1 Grip - Lever 18 1 Yoke - Linkage, Brake 6 1 Bracket ASM 19 1 Linkage - Lower 6:2 2 Sleeve - Bushing 20 1 Brake 7 1 Bushing - Pivot 21 1 Nut - Jam 8 2 Washer - Flat 22 1 Screw - HH 9 1 Screw - HH 23 1 Spring - Idler 10 2 Screw 24 2 Nut - Whizlock 11 1 Linkage - Upper 25 1 Pin - Clevis 12 5 Nut - HHF 26 1 Nut - HF 13 3Pin - Hair 27 3Screw - HH

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CHASSIS

Fuel Tank Service

Draining The Fuel Tank

DANGER

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.

1. Park the machine on a level surface, to

tank drains completely. Then disengage the power

take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Close fuel shut-off valve at fuel tank.

Note: Remove fuel line from fuel valve that is closest to the engine.

assure fuel

Fuel Tank Removal

1. Place shutoff valve in the “off” position.

2. Disconnect the fuel line at the filter (Figure 64).

Figure 64

3. Remove the 4 bolts securing the fuel tank to the frame.

Installation

Follow the removal procedures in reverse. Note: DO NOT overtighten the sprung mounting bolts (Figure

65).

0602-06

3. Squeeze the ends of the hose clamp together and slide it up the fuel line away from valve.

4. Pull the fuel line off the valve. Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.

Figure 65

0602-14

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CHASSIS

Electric (PTO) Clutch (Floating Deck Models)

Removal

1. Stop the engine, remove the key, and disconnect the spark plug wires.

2. Raise the rear of the unit and place on safety stands.

3. Remove the deck covers.

4. Using a large channel lock pliers, move the idler pulley against spring tension until the PTO drive belt can be slipped off the idler pulley (Figure 66).

11. Lift the engine and insert 3/4” (19mm) wooden blocks between the engine and frame (Figure 67). This will provide clearance between the axle and clutch pulley to permit removing the clutch from the crankshaft.

Figure 67

12. Remove the nut, bolt, and spacer securing the clutch arm to the frame (Figure 68).

0820-04

Figure 66

5. Slip the PTO drive belt off the deck pulley and PTO clutch.

6. Disconnect the spring from the traction belt tensioning arm.

7. Separate the clutch wiring and push the clutch plug and grommet through the frame.

8. Remove the traction drive belt.

9. Remove the 2 rear engine mounting bolts and replace with 3” (76mm) long 5/16” bolts to maintain the engine to frame positioning.

10. Remove the 2 front engine mounting bolts and nuts.

0819-21

Figure 68

(A) Clutch arm bolt (B) Clutch retaining bolt

13. Remove the clutch retaining bolt and washer.

14. Slide the electric clutch off the crankshaft.

Installation

Follow the removal procedures in reverse. Apply antiseize compound on the crankshaft to prevent rust.

0820-06

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Page 53

CHASSIS

Replacing the Drive Belt (Gear Drive - Floating Deck)

Service Interval/Specification

Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks and signs of overheating.

1. Remove top capscrew securing idler support and idler bracket to rear frame (Figure 69).

2. Loosen bottom two mounting screws enough to allow belt to pass between drive pulley and idler support (Figure 69).

3. Raise wheel off ground enough to allow belt removal.

Replacing the Drive Belt (Fixed Deck Pistol Grip)

Service Interval/Specification

Check all belts after every 50 operating hours or monthly, whichever occurs first. Look for dirt, wear, cracks, and signs of overheating.

1. Disengage the blade control (PTO) lever and set the parking brake.

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

3. Remove the drive spring from the adjustment bolt (Figure 70).

Figure 70

Figure 69

(1) Top capscrew (2) Idler bracket

Mid-Size Walk Behind Service Manual 4 - 21

(3) Idler support (4) Bottom capscrew

m-1722

(1) Drive belt (2) Drive spring

4. Remove the drive belt from the pulleys and over the tire.

5. Install the new belt and the drive spring.

(3) Tire (4) Adjustment bolt

m-5372-2

Page 54

CHASSIS

Replacing the Traction Belt (Floating Deck)

1. Raise the front of the machine and support with jack stands.

2. Disconnect clutch wire connector from wire harness (Figure 71).

3. Remove PTO drive belt. Refer to ”Replacing the Drive Belt (Gear Drive - Floating Deck)" on page 4

- 21.

4. Remove clutch retainer from the engine deck (Figure 71).

5. Unhook tension spring from side of frame (Figure

71).

6. Loosen pivot bolt enough to remove traction belt from the drive pulley and clutch (Figure 71).

7. Install new belt around clutch and drive pulley.

11. Install PTO drive belt.

Figure 71

(1) Traction belt (2) Idler pulley (3) Clutch retainer (4) Tension spring

m-5321

(5) Clutch wire connector (6) Pivot bolt (7) Drive pulley (8) Engine deck

8. Torque pivot bolt to 35 - 40 ft. lb. (47 - 54 N•m). Install tension spring between idler arm and frame bracket (Figure 71).

9. Install clutch retainer to the engine deck (Figure

71).

10. Connect clutch wire connector to wire harness.

Replacing the Traction Belt (Fixed Deck)

1. Disengage the blade control (PTO) lever and set the parking brake.

2. Stop the engine and wait for all moving parts to stop before leaving the operating position.

3. Raise the rear of the machine and hold it up with jack stands.

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Page 55

CHASSIS

4. Remove the mower belt (Figure 72).

Figure 72

(1) Idler pulley in slot (2) Traction belt (3) Mower belt

5. Loosen the mounting bolt enough to slide the idler pulley in the slot and remove the traction belt from the engine and drive pulleys (Figure 72).

(4) Belt guide (5) 1-1/4 in. (32mm) (6) Mower belt

m-4726

Adjusting Grass/Mud Scraper

1. Loosen the locknut holding scraper to the engine frame (Figure 73).

2. Rotate scraper until aligned with center of pulley grooves (Figure 73).

3. Tighten the locknut (Figure 73).

Note: The scraper must not contact the pulley on the sides or bottom of grooves. Re-adjust if necessary.

6. Install the new traction belt around the engine and the drive pulleys (Figure 72).

7. Slide the idler pulley in the engine frame to tension the traction belt and tighten mounting bolt (Figure

72).

8. Install the mower belt (Figure 72).

9. Check the belt guide under the engine frame for the proper adjustment (Figure 72).

Note: The distance between the belt guide and mower belt should be 1-1/4 in. (32mm) when the mower belt is engaged. Adjust the belt if necessary. The disengaged belt should not drag or fall off the pulley when the guides are properly adjusted.

(1) Scraper (2) Locknut

Figure 73

(3) Pulley

m-3776

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THIS PAGE INTENTIONALLY LEFT BLANK

4 - 24 Mid-Size Walk Behind Service Manual

Page 57

HYDRAULIC DRIVE SYSTEMS

Hydraulic Drive System Overview

The hydrostatic drive system consists of two bidirectional high-pressure loops, one for each drive wheel. Each loop is made up of a pump, motor, and the high-pressure hoses connecting them together. Both high-pressure loops share a common low-pressure supply system. The components of the low-pressure supply system are the reservoir, filter, and lowpressure hoses.

The pump is driven by an internal combustion engine through a belt and pulley system.

The speed and direction of each drive wheel is controlled independently by varying the output of the pump. The output of the pump is varied by moving the speed control handle and drive lever.

Hydraulic System

The charge pump portion of the pump circulates fluid through the low-pressure system.

Oil is drawn through each pump’s case drain line to the reservoir for cooling, then through the filter for cleaning and finally pumped back into the high pressure loop by the charge pump.

On fixed deck models only, a cold start ring is used, which when engaged, removes tension from the pump drive belt. This reduces the effort required to pull the recoil starter when in cold temperatures.

More detailed information about each component can be found on the Toro Hydraulic Troubleshooting CD (PN# 492-4777), Ross Wheel Motor Service and Repair Manual (492-4753), and the Hydro-Gear Service and Repair Manual, PN# 492-4749.

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HYDRAULIC DRIVE SYSTEMS

Hydraulic Drive System Assembly

Ref. No. Qty. Description Ref. No. Qty. Description

1 4 Nut - HHF 15 4 Fitting - Straight 2 2 Fitting - 90° 15:1 1 “O” Ring 2:1 1 “O” Ring 15:2 1 “O” Ring 3 4 Hose - Pressure, High 16 2 Motor - Wheel 4 2 Screw 17 1 Filter Head ASM 5 2 Pump 18 2 Screw - HH 6 2 Fitting 19 1 Filter - HYD 6:1 1 “O” Ring 20 2 Washer - Lock 7 4 Fitting - Straight 23 1 Hose - Charge 7:1 1 “O” Ring 24 1 Clamp - Hose 7:2 1 “O” Ring 25 2 Nut - HF 10 2 Screw - HH 26 2 Spacer 11 1 Reservoir - HYD 27 2 Washer - Flat 11:1 1 Cap - Reservoir, HYD 28 4 Screw - HH 11:2 1 Gasket - Cap 29 1 HYD Hose ASM 12 1 Adapter - Straight 30 1 HYD Hose ASM 12:1 1 “O” Ring 31 8 Washer - Flat 13 1 Elbow - 45° 32 2 Grip - Valve, Dump 13:1 1 “O” Ring 33 2 Nut - Lock, NI 14 4 Clamp - Hose 34 1 Decal - Tank, HYD

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HYDRAULIC DRIVE SYSTEMS

Servicing the Hydraulic System

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 8 operating hours.

• After every 200 operating hours.

1. Disengage the PTO, turn the ignition key to off, and remove the key.

2. Wait for all moving parts to stop before leaving the operating position and then chock or block tires.

Important

or severe hydraulic system damage may result.

3. Remove hydraulic reservoir cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out.

4. Locate filter under engine base and place drain pan under filter (Figure 74).

Do not substitute an automotive oil filter

7. Install replacement hydraulic filter onto the filter adapter. Do not tighten.

8. Remove plastic bag from reservoir opening and allow filter to fill with hydro fluid.

9. When fluid overflows filter, turn the oil filter clockwise until the rubber gasket contacts the filter adapter. Then tighten the filter an additional 1/2 turn (Figure 74).

10. Clean up any spilled fluid.

11. Add Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil to approximately 1/4 in. (6mm) below the top of reservoir baffle.

Important

fluids could cause system damage.

12. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer to "Bleeding Hydraulic System (Floating Deck Models)" on page 5 - 4.

Use oil specified or equivalent. Other

5. Remove the old filter and wipe the filter adapter gasket surface clean (Figure 74).

Figure 74

(1) Hydraulic filter (2) Gasket

6. Apply a thin coat of hydro fluid to the rubber gasket on the replacement filter.

(3) Adapter

m-1256

13. Recheck level and add fluid, if required. Do not overfill.

Checking the Hydraulic Fluid

Check the hydraulic fluid level:

• Before engine is first started.

• After first

• After 40 operating hours.

Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.

Important

fluids could cause system damage.

Hydraulic System Oil Capacity: 67 oz. (2.0 l).

1. Position machine on a level surface, stop the

8 operating hours.

Use oil specified or equivalent. Other

engine and chock or block tires.

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HYDRAULIC DRIVE SYSTEMS

2. Clean area around filler neck of hydraulic tank

(Figure 75).

WARNING

3. Remove cap from filler neck. Look inside to check if there is fluid in the reservoir. (Figure 75).

4. If there is no fluid, add fluid to reservoir approximately a 1/4 in. (6mm) below the top of baffle.

5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid.

6. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required.

Note: Fluid level should be to the top of the baffle when fluid is

7. Install cap on filler neck.

warm (Figure 75).

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

Bleeding Hydraulic System (Floating Deck Models)

The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is

performed on the system.

(1) Cap (2) Baffle

Figure 75

m-4280

(3) Fluid level - full

1. Raise rear of the machine so wheels are off the ground and support with jack stands.

2. Start the engine and run at idle speed. Engage traction on one side and spin the wheel by hand.

3. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly (minimum 2 minutes).

4. Check hydraulic fluid level as it drops and add as required to maintain proper level.

5. Repeat procedure on opposite wheel.

5 - 4 Mid-Size Walk Behind Service Manual

Page 61

Bleeding Hydraulic System (Fixed Deck Models)

The traction system is self-bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system.

Air must be purged from the hydraulic system when any hydraulic components, including oil filter, are removed or any of the hydraulic lines are disconnected. The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump. Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is “primed”.

HYDRAULIC DRIVE SYSTEMS

1. Disengage the PTO, turn the ignition key to off, and remove the key. Wait for all moving parts to stop before leaving the operating position.

2. Raise the rear of machine so wheels are off the ground and support with jack stands.

3. Check hydraulic fluid level.

4. Start engine and move throttle control to full throttle position. Move the speed control lever to the middle speed position and place the drive levers into the “drive” position.

If either drive wheel does not rotate, it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward direction.

Note: It is necessary to lightly touch the charge pump cap (Figure 76) with your hand to check the pump temperature. If the cap is too hot to touch, turn off engine. The pumps may be damaged if the pump becomes too hot. If either drive wheel still does not rotate, continue to next step.

Figure 76

(1) Charge pump cap (2) Socket head screw

m-5955

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HYDRAULIC DRIVE SYSTEMS

5. Thoroughly clean the area around each of the charge pump housings.

6. To “prime” charge pump, loosen two hex socket head capscrews (Figure 76) 1-1/2 turns only. Make sure engine is not running. Lift charge pump housing upward and wait for a steady flow of oil to flow out from under housing. Retighten capscrews. Do this for both pumps.

Note: Hydraulic reservoir can be pressurized to up to 5 psi to speed this process.

7. If either drive wheel still does not rotate, stop and repeat steps 4, 5, and 6 on the respective pump. If wheels rotate slowly, the system may prime after additional running. Recheck hydraulic fluid level.

8. Allow unit to run several minutes after the charge pumps are “primed” with drive system in the full speed position.

9. Check hydro control linkage adjustment. Refer to "Hydro Control Linkage Adjustment (Pistol Grip Floating Deck)" on page 5 - 12.

5. Quickly push the upper control bar against the reference bar. The front caster wheels should almost lift off the ground. If front caster wheels lift the off the ground, the machine is too aggressive and adjustment is required.

6. Move the engine throttle to the “FAST” position.

7. Quickly push the upper control bar against the reference bar. The front caster wheels should lift approximately 1 inch (25mm) off the ground. If front caster wheels lift the off the ground more than 2 inches (50mm), the machine is too aggressive. Adjustment is required.

8. If the machine accelerates slowly, and the front caster wheels do not lift off the ground, the machine is too un-responsive. Adjustment is required.

Adjustment Procedure

The by-pass valve should be adjusted to deliver best performance for the size (weight) mower you have. The by-pass valve factory setting is 1/2 turn out.

By-Pass Valve (T-Bar)

The by-pass valve is adjustable to ensure easy operation with a variety of deck sizes. If the front of the deck lifts off the ground when the upper control bar is quickly pushed forward or the machine is unable to drive up hills, an adjustment may be needed.

Test Procedure

1. Start engine and run for 5 minutes at 3/4 throttle, to warm hydraulic fluid.

2. Drive the machine to a clear and level open area such as a driveway.

Important

area in front of the machine.

3. Loosen the quick release levers and push the reference bar forward to the “FAST” position. Lock the quick release levers to secure the reference bar.

4. Move throttle control to 3/4 throttle.

There should be at least 10 feet of clear

The following values can be used as initial settings for different size mowers:

52 in. (132cm) 1/2 turn out

44 in. (112cm) 1 turn out

36 in. (91cm) 1-1/6 turn out

1. Loosen large jam nut several turns (Figure 77).

2. Gently close by-pass valve (Figure 77).

Important

seat may be damaged. Do not exceed 50 inch pounds (6 N-m) to close valve.

3. Open by-pass valve 1/2 turn (Figure 77).

4. Tighten jam nut to lock the adjustment (Figure 77).

5. Repeat “Test Procedure” to check for proper operation.

Important

sensitive, do not adjust more than 1/6 turn (one flat) at a time.

Do not over-tighten valve or needle and

By-pass valve adjustment is very

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HYDRAULIC DRIVE SYSTEMS

6. If the machine is too aggressive or tends to jump forward, the valve needs to be opened further.

7. If the machine is slow to respond, the valve needs to be closed further.

8. Repeat “Test Procedure” to check for proper operation. Re-adjust the by-pass valves until proper performance is achieved.

3. Move control bar rearward and forward then release. If wheels rotate when control bar is in neutral, adjustment is required.

4. Loosen top and bottom jam nuts at pump arm neutral

5. Push down on pump arm until sleeve contacts bottom nut (Figure 78). Wheel should now be rotating slowly

6. Turn bottom nut up slowly, moving sleeve and pump arm up, until wheel stops rotating (Figure

78).

7. Turn top nut the adjustment (Figure 78).

8. Repeat step 3 above to check adjustment. Repeat adjustment procedure if necessary.

9. Repeat on other wheel, if necessary.

adjustment sleeve (Figure 78).

in reverse.

down against sleeve and tighten to lock

Figure 77

(1) By-pass valve (2) Jam nut

m-5209

Neutral Adjustment (T-Bar Floating Deck)

If wheels turn when control bar is in neutral, adjustment is required.

1. Raise rear of the machine so wheels are off the ground and support with jack stands.

CAUTION

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the Ignition and chock or block tires when leaving the machine unattended, even if just for a few minutes.

(1) Top jam nut (2) Sleeve

Figure 78

(3) Bottom jam nut (4) Pump arm

m-5204

Handle and Control Rods (T-Bar Floating Deck)

1. Align upper handle with upper mounting holes in rear frame (Figure 79).

2. Start engine and run for 5 minutes at 3/4 throttle, to warm hydraulic fluid.

Mid-Size Walk Behind Service Manual 5 - 7

2. Secure each upper mounting hole with a flange bolt (3/8 x 1 in. (26mm) and flange nut (Figure 79). Torque bolts to 25 ft. lbs. (34 N-m).

Page 64

HYDRAULIC DRIVE SYSTEMS

3. Select high, medium or low position for the lower mounting hole (Figure 79). This allows the upper handle to be adjusted to the user’s height preference.

4. Secure each lower mounting hole with a flange bolt (3/8 x 1 in. (26mm) and flange nut (Figure 79). Torque bolts to 25 ft. lbs. (34 N-m).

Figure 79

(1) Upper handle (2) Rear frame (3) Flange bolt, 3/8 x 1 in.

(26mm)

(4) Flange nut, 3/8 in.

(5) Upper mounting hole (6) Lower mounting hole (7) Low position (8) High position

m-5336

Install Control Rods

3. Press and hold upper control bars against reference bar, so stop hits (Figure 80).

Figure 80

(1) Upper control bars (2) Hairpin cotter

4. Push rod full forward until bearing is against control bracket stop. Thread rod in or out of fitting on control bracket until rod aligns with holes in upper control bars (Figure 81).

5. When rod and holes in upper control bars line up, turn rod one additional turn, so rod is shorter.

Note: Upper control bar stop must hit reference bar before roller bearing hits control bracket stop.

(3) Reference bar (4) Stop

m-5264

Before installing and adjusting control rods, loosen quick release levers and move reference control bar all the way forward.

Left Control Rod

1. Slide clevis pin through rod fitting and mounting hole in control bracket (from outside). Secure with washer and hairpin cotter (Figure 81).

2. Remove hairpin cotter and rod from upper control bars (Figure 80).

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HYDRAULIC DRIVE SYSTEMS

6. Connect rod to upper control bars with previously removed hairpin cotter (Figure 80).

Figure 81

(1) Control rod-left (2) Control bracket (3) Rod fitting (4) Clevis pin

Right Control Rod

1. Slide rod into control bracket and secure with hairpin cotter (Figure 82).

2. Remove hairpin cotter and rod from upper control bars (Figure 80).

(5) Washer (6) Hairpin cotter (7) Control bracket stop (8) Roller bearing

m-5263

6. Connect rod to upper control bars with previously removed hairpin cotter, tighten wing nut and turnbuckle (Figure 80).

Figure 82

(1) Control rod-right (2) Control bracket (3) Hairpin cotter (4) Wing nut

Adjust Tracking

1. After completing assembly, check machine tracking. Operate machine by holding upper control bar against reference bar with wheel drive engaged.

(5) Turnbuckle (6) Control bracket stop (7) Roller bearing

m-5262

3. Press and hold upper control bars against reference bar, so stop hits (Figure 80).

4. Push rod full forward until bearing is against control bracket stop. Loosen wing nut and thread turnbuckle in or out until rod aligns with holes in upper control bars (Figure 82).

5. When rod and holes in upper control bars line up, rotate turnbuckle one additional turn, so rod is shorter.

Note: Upper control bar stop must hit reference bar before roller bearing hits control bracket stop.

Mid-Size Walk Behind Service Manual 5 - 9

2. If machine does not track straight, moves more right or left, adjustment is required.

3. Loosen wing nut on right control rod and rotate turnbuckle in or out to change tracking. Secure turnbuckle in position with wing nut (Figure 82).

4. Check for proper tracking.

Note: Control rods must be adjusted if handle height position is changed.

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HYDRAULIC DRIVE SYSTEMS

Hydro Linkage Adjustments (Pistol Grip Floating Deck)

Perform the following linkage adjustments when the machine needs maintenance. If adjustment is needed, do them in the order that they are listed

• Adjust speed control linkage.

• Adjust neutral control linkage.

• Adjust hydro control linkage.

• Adjust control rods.

• Tracking adjustment.

Speed Control Linkage (Pistol Grip Floating Deck)

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

2. Move the speed control lever (located on the console) to the full forward position.

3. Check the orientation of the tabs on the ends of the speed control crank. These tabs should be pointing straight down at the 6 o’clock position approximately (Figure 83).

4. Adjust the threaded yoke at the bottom of the speed control linkage until the tabs are at the 6 o’clock position (Figure 83).

5. Pull the speed control lever back to neutral.

6. Check to make sure the safety switch is depressed and there is a 5/16 in. (8mm) space between the actuating tab and the switch. (Figure

84).

7. If needed, adjust switch location to create the 5/16 in. (8mm) space (Figure 84).

Figure 84

(1) Actuating tab (2) 5/16 in (8mm) space

(3) Safety switch

m-5394-1

Figure 85 0610-03

Figure 83

(1) Speed control rod (2) Yoke (3) Speed control crank

5 - 10 Mid-Size Walk Behind Service Manual

(4) Tabs, 6 o’clock position (5) Jam nut

m-5398-1

(A) Tab at 6 o’clock

Page 67

Figure 86 0610-01

HYDRAULIC DRIVE SYSTEMS

Neutral Control Linkage Adjustment (Pistol Grip Floating Deck)

WARNING

Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.

WARNING

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

Figure 87 0610-02

Important

adjustments in the order that they are listed.

Perform the following linkage

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

1. Raise the rear of the machine onto jack stands to raise the drive wheels off the ground.

2. Start the engine and move the throttle to the full throttle position.

3. Place the neutral locks in the full forward position and move the speed control lever to the medium speed position.

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HYDRAULIC DRIVE SYSTEMS

4. Hold OPC levers down.

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

WARNING

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.

• Never operate this unit with Operator Presence Control (OPC) levers held in place.

5. Squeeze one drive lever until an increased resistance is felt. This is where neutral should be.

Note: Make sure you have not reached the end of the neutral lock slot. If you have, shorten the control lever linkage. Refer to "Control Rod Adjustment (Pistol Grip Floating Deck)" on page 5 - 14.

12. Repeat this procedure for the opposite side.

Figure 88

(1) Neutral control linkage (2) Yoke

(3) Adjusting bolt (4) Nut

m-5394-2

Hydro Control Linkage Adjustment (Pistol Grip Floating Deck)

6. If the wheel turns while holding the drive lever in neutral, the neutral control linkages need to be adjusted (Figure 88). If wheel stops, then go to step 12.

7. Loosen the nut against the neutral control linkage yoke (Figure 88).

8. Adjust the neutral control linkage until the respective drive wheel stops while the drive lever is pulled against the neutral spring (neutral position) (Figure 88).

9. Turn the adjusting bolt approximately 1/4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counterclockwise if the wheel is turning forward (Figure 88).

10. Release the drive lever to the forward drive position and squeeze back into the neutral position. Check to see if the wheel stops. If not, repeat the above adjustment procedure.

11. After adjustments are made, tighten the nuts against the yokes.

WARNING

Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.

WARNING

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

Left Side Linkage Adjustment

1. Raise the rear of the machine and place on jack stands.

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HYDRAULIC DRIVE SYSTEMS

2. Place the speed control lever in the neutral position.

3. Place the left drive lever in the full forward position.

4. Hold OPC levers down.

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

WARNING

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.

• Never operate this unit with Operator Presence Control (OPC) levers held in place.

5. Loosen the front nut on left hydro control linkage as shown in Figure 89.

7. Turn the rear adjusting nut clockwise 1/4 of a turn at a time. Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Figure 89).

8. Turn the rear nut an additional 1/2 turn and tighten the front nut.

Note: Make sure flat part of linkage is perpendicular to pin part of swivel.

9. After adjusting the left hydro control linkage, move the speed control lever forward and then back to the neutral position.

10. Make sure the speed control lever is in the neutral position and the tire does not rotate.

11. Repeat adjustment if needed.

Note: If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console, especially the rear pivot spring so the speed control lever is held firmly in place and does not slide, but not too tight where the speed control lever binds. Repeat above adjustments if necessary (Figure 90).

Figure 89

(A) Hydro control linkage (B) Front nut

6. Turn the left rear adjusting nut counterclockwise until wheel rotates forward (Figure 89).

Mid-Size Walk Behind Service Manual 5 - 13

0610-17

(A) Rear pivot spring (B) Spring

Right Side Linkage Adjustment

1. Place the speed control lever in the neutral position.

2. Place the right drive lever in the full forward position.

Figure 90

0602-28

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HYDRAULIC DRIVE SYSTEMS

3. Hold OPC levers down.

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

4. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Figure 91).

5. Turn the knob clockwise 1/4 of a turn at a time. Then move the speed control forward and back to neutral. Repeat this until right wheel stops rotating forward (Figure 91).

6. The

7. Adjust spring length by turning nut at front of

spring that keeps tension on the knob should

normally not need adjustment. However if adjustment is needed, adjust the length of spring to 1 in. (26mm) between the washers (Figure 91).

spring (Figure 91).

Control Rod Adjustment (Pistol Grip Floating Deck)

Checking Control Rod

1. With rear of machine supported on jack stands and engine running at full throttle, move the speed control lever to the medium speed position.

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

2. Move the respective drive lever upward until it reaches the neutral position and engage neutral locks.

3. If the tire rotates in either direction, the length of the control rod will need to be adjusted.

Adjusting Control Rods

1. Adjust the rod length by releasing the drive lever and removing clevis pin. Rotate the rod in the rod fitting (Figure 92).

2. Lengthen the rod if the tire is turning in reverse and shorten the rod if the tire is turning forward.

Figure 91

(A) Spring (B) Hydro control linkage

3. Rotate the rod several turns if the tire is rotating fast. Then, adjust the rod in 1/2 turn increments.

4. Release and engage neutral lock checking that the tire does not rotate. Continue this process until the tire does not rotate.

5. Place the hairpin back into clevis pin (Figure 92).

0610-19

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HYDRAULIC DRIVE SYSTEMS

6. Repeat this adjustment for opposite side.

Figure 92

(A) Handle (B) Neutral lock (C) Neutral position

(D) Drive lever (E) Full speed forward (F) Control rod

Tracking Adjustment

0610-14

4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Figure 93).

Figure 93

(1) Quick track knob

m-5398-2

Motion Control Linkage Removal

1. Remove machine from any jack stands.

2. Adjust rear and front tire pressure to specification. Check that front castors pivot freely

3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt.

(Pistol Grip Floating Deck)

1. Turn the ignition switch to off and disconnect the spark plug wire(s).

2. Remove the operator’s manual tube from the handle bar assembly.

3. Remove the knob from the speed control lever.

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HYDRAULIC DRIVE SYSTEMS

4. Remove the hairpin cotter at each end of the upper control link (Figure 94).

Figure 94

5. To remove the speed control bellcrank, remove the hairpin cotters securing the hydro control link and tracking adjustment link to the bellcrank (Figure 95).

0618-02

6. Remove the 2 Allen head shoulder bolts from the ends of the bellcrank (Figure 96), and remove the bellcrank.

Figure 96

7. Remove the nut securing the hydro control link (left side) and tracking control link (right side) to the pump control bellcrank (Figure 97).

0602-27

Figure 95

5 - 16 Mid-Size Walk Behind Service Manual

0602-32

Figure 97

0602-26

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HYDRAULIC DRIVE SYSTEMS

8. Remove the return spring from the upper bracket (Figure 98).

Figure 98

0610-16

9. Remove the nuts from the 4 bolts securing the shield from the frame (Figure 99).

10. Carefully pull the shield with the control shaft bearing, spacers, and through bolts from the frame (Figure 100).

Figure 100

0602-22

11. Remove the hydro control shaft.

12. Remove the pin from the clevis on the neutral control link (Figure 101).

Figure 99

0602-33

Figure 101

0602-23

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HYDRAULIC DRIVE SYSTEMS

13. Remove the “E” clip from the pivot on the pump control bellcrank (Figure 102).

Figure 102

0602-24

14. Remove the hairpin clip from the reverse rod on the hand lever (Figure 103).

15. Using a 5/16 8 point socket, loosen the set screw securing the hydro control shaft to the pump (Figure 104).

Figure 104

0602-21

16. Remove the shaft from the pump (Figure 105).

Figure 103

0602-29

Figure 105

0602-31

Removal

Follow the removal procedures in reverse.

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Page 75

Upper Handle Assembly - Pistol Grip

HYDRAULIC DRIVE SYSTEMS

Ref. No. Qty. Description Ref. No. Qty. Description

1 1 Handle ASM 24 2 Screw - HH 1:2 2 Decal - Lock, Neutral 25 2 Pin - Clevis 1:3 1 Decal - Warning 26 4 Screw - HH 1:4 1 Decal - Throttle 27 4 Washer - Belleville 1:5 1 Decal - Proline 28 4 Nut - HHF 1:6 1 Decal - Engage, Deck 29 2 Nut - Lock, NI 1:7 1 Decal - Caution, Brake 30 4 Nut - HF 2 1 Switch - Key 31 2 Washer - Flat 3 1 Key - Ignition 32 6 Washer - Spring 4 1 Knob - Push/Pull 33 1 Latch - Lever, LH Drive 5 1 Nut - Jam 34 1 Latch - Lever, RH Drive 6 1 Bearing - Nylon 35 2 Screw - HH 7 1 Lever - LH 36 1 Tube - Manual 8 2 Screw - Set 37 2 R - Clamp 9 2 Bushing - Nylon 38 2 Screw 10 1 Spring - Extension 39 2 Grip - Latch 11 1 Operator Presence Control Rod ASM 40 2 Screw - HH 12 1 Lever - RH 41 1 Washer - Friction 13 1 Nut - Push 42 2 Washer - Friction 14 1 Knob - Ball 43 1 Plate - Lever, Shifter 15 1 Cable - Throttle 44 1 Lever - Shift 16 2 Bolt - CARR 45 1 Knob - Ball 17 2 Nut - Lock 46 2 Nut - Lock, NI 18 1 Linkage - Blade 47 2 Spring - Compression 19 3 Pin - Hair 48 1 Washer - Flat 21 1 LH Drive Lever ASM 49 2 Screw - HH 21:2 2 Sleeve - Bushing 50 1 Rod - Control, Speed 22 1 RH Drive Lever ASM 51 1 Nut 22:2 2 Sleeve - Bushing 52 1 Yoke - Adjustable 23 2 Bushing - Lever, Drive 53 1 Pin - Clevis

54 2 Grip - Handle

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HYDRAULIC DRIVE SYSTEMS

Lower Control Assembly - Pistol Grip

Ref. No. Qty. Description Ref. No. Qty. Description

1 12 Nut - HF 22 2 Screw - HH 2 8 Nut - HHF 23 4 Nut - Lock, NI 3 4 Spacer - Shield 24 1 Shaft - Control, LH 4 7 Screw - HH 25 2 Screw - HH 5 6 Washer - Flat 26 2 Spring - Extension 6 4 Washer - Lock 27 2 Swivel - Lever, Drive 7 4 Screw - HH 28 2 Tab - Spring, Extension 8 2 Fitting - Grease 29 2 Bolt - TAP HH 9 2 Shield - Controls, Hydro 32 2 Rod - Lever, Drive 10 4 Spacer - Shield 34 7 Washer - Flat 11 2 Screw 37 1 Crank - Control, Speed 12 2 Washer - Flat 38 1 Knob - Tracking 13 2 Bearing - Flange, Side 39 1 Spacer 14 2 Pin - Hair 40 1 Spring - Compression 15 7 Nut - Hex 41 2 Nut 16 2 Bushing - Flanged 42 2 Yoke - Adjustable 17 2 Spring - Return, Neutral 43 2 Pin - Clevis 18 2 Bolt - Return, Neutral 44 2 Pin - Cotter 19 2 Link - Control, Speed 45 2 Swivel - Adjustable, Short 20 1 Shaft - Control, RH 46 1 Decal - Tracking 21 2 Screw 47 2 Ring - Retaining

5 - 20 Mid-Size Walk Behind Service Manual

Page 77

Upper Handles Assembly - T-Bar

HYDRAULIC DRIVE SYSTEMS

Ref. No. Qty. Description Ref. No. Qty. Description

1 1 Control Bar ASM 18 1 Fitting–Rod 2 1 Nut–Lock 19 1 Washer–Flat 3 1 Bail ASM 20 1 Handle – Upper 4 1 Decal–T Bar 21 4 Screw–HHF 5 1 Decal–Drive, Traction 22 4 Nut–HF 6 1 Screw–SHH 23 2 Sleeve 7 3 Tie–Cable 24 2 Washer–Belleville 8 1 Pivot ASM 25 2 Nut–Lock 9 2 Pin–Cotter 26 1 Handle ASM 10 1 Decal – Warning 27 1 Decal–Protection, Ear 11 4 Pin–Hair 28 1 Rod–Control, Lower 12 1 Rod – Control 29 1 Nut–Wing 13 1 Decal–Lock, Speed 30 1 Turnbuckle 14 2 Pin–Clevis 31 1 Rod–Control, Upper 15 2 Quick Release Lock ASM 32 1 Connector–Body 16 2 Spacer 33 1 Switch–Bail 17 1 Pin–Clevis

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HYDRAULIC DRIVE SYSTEMS

Lower Controls Assembly - T-Bar

Ref. No. Qty. Description Ref. No. Qty. Description

1 1 Lever–Pivot, RH 19 2 Screw–HSBH 2 4 Side Flange Bearing ASM 20 2 Spring–Detent 3 6 Nut–Lock 21 2 Stop–Reverse 4 2 Arm–Pump 22 2 Screw–HH 5 4 Screw–HH 23 1 Bracket–Pivot, Left 6 4 Ring–Grip, Ex *24 1 Bracket–Pivot, Right 7 1 Lever–Pivot, LH 25 2 Decal–Hydro 8 2 Rod–Link 26 6 Screw–HH 9 8 Screw–HH 27 2 Screw–HH 10 2 Sleeve 28 2 Spacer – Tubular 11 4 Nut–Jam 29 2 Locknut–Flange 12 4 Washer–Flat 30 8 Nut–Lock, NI 13 2 Nut–Lock, NI 31 1 Arm–Pivot, LH 14 1 Arm–Detent, LH *32 1 Arm–Pivot, RH *15 1 Arm–Detent, RH 33 2 Pin–Roll 16 2 Bushing–Arm, Detent 34 2 Washer–Thrust 17 2 Spacer–Bearing 35 6 Nut–Lock, NI 18 2 Bearing

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Page 79

HYDRAULIC DRIVE SYSTEMS

Hydraulic Testing

Tools Needed:

• Hydro-Gear manual 492-4749

• Hydraulic flow tester - BDP Flow Test Kit 70661, or equivalent

• Jack

• Jack stands

• 15/16" open end wrench

• 7/16" open end wrench

• 13/16" Socket or Air Impact

• Ratchet

• Oil Pan

• Torque wrench

• Toro Hydraulic Troubleshooting CD P/N 492-4777 CD # 2

Installation And Testing Procedures:

Using the Bi-Directional Flow Test Kit, determination of directional flow is not necessary. The flow meter may be connected in either direction into the forward and reverse high pressure system lines.

1. Jack up rear axle - support unit with jack stands (Figure 106).

Figure 106

2. Remove wheel on the side to be tested and place oil pan under wheel motor (Figure 107).

mvc-017

Caution: Ensure all fittings and hoses are attached securely. This test is being completed on the vehicle's high pressure system lines. Failure to perform this properly could result in bodily injury.

Figure 107

mvc-889

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Page 80

HYDRAULIC DRIVE SYSTEMS

3. Remove upper hydraulic line from wheel motor and attach to flow test gauge (Figure 108).

Figure 108

mvc-893

4. Remove lower hydraulic line from wheel motor and attach to the other side of the flow test gauge(Figure 109).

Note: When using a flow test gauge that is NOT bi-directional and it is connected in this manner, it is important not to operate the machine in reverse or you could damage the flow test gauge.

Figure 110

5. Open the restriction valve all the way (counterclockwise) (Figure 111).

mvc-890

Figure 109

5 - 24 Mid-Size Walk Behind Service Manual

mvc-890

Figure 111

mvc-894

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HYDRAULIC DRIVE SYSTEMS

6. Run the machine for 2 minutes in forward (no load) to purge air from the system.

7. Run engine at full throttle (no load) - verify RPM with a tachometer - 3200 + or - 150 RPM's. Do

not exceed 3600 RPM.

8. With the drive control fully forward (Pistol Grip, Figure 112, T-Bar, Figure 113) slowly tighten the restriction valve until the gauge indicates 300 PSI (21 bar).

Example:

1st Reading 300 psi (21 bar) reading 7 gpm

(26l/min).

2nd Reading 1100 psi (76 bar) reading

3 gpm (11l/min).

300 psi (21 bar) reading

7gpm (26l/min) (1st reading)

- 3gpm (11l/min) (2nd reading) 4 gpm (15l/min) (the difference)

Subtract 1st reading from the 2nd. (In this example, 4gpm difference would indicate a defective pump).

An acceptable “flow droop” or difference is: 1.5 gpm (5.6 liter/min).

9. When test is complete and if necessary repairs have been made - reassemble hydraulic lines to wheel motor and reassemble wheel to hub and torque wheel nuts to 85 ft. lbs. (115 N-m) + or - 8 ft. lbs.

Figure 112

Record the flow reading from the bi-directional flow meter. Refer to the Hydro-Gear manual for acceptable GPM. Make a second flow reading at 1100 PSI and record. Subtract the first reading from the second reading and determine if this is an acceptable GPM.

mvc-896

10. Test operate machine and purge air from hydraulic system.

Wheel Motor Removal and Installation - Floating Deck

1. Identify hydraulic lines.

2. Remove hydraulic lines from wheel motor.

3. Unbolt 4 screws holding wheel motor to chassis. Note: If wheel hub is to be removed, see step 5 on page 5 - 26, Figure 115.

Figure 113

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mvc-898

Page 82

HYDRAULIC DRIVE SYSTEMS

Wheel Motor Removal - Fixed Deck

1. Apply the parking brake and loosen the 4 lug nuts.

2. Remove the cotter key and remove the hub nut, then release the parking brake (Figure 114).

Figure 114

3. Raise the unit until the drive wheels are off the ground, then place the unit on jack stands.

0602-59

7. Thoroughly clean area round hydraulic fittings to prevent dirt from entering the system.

8. Mark the hose locations (Figure 116). Then remove the hoses at the wheel motor fittings.

Figure 116

9. Cap the pump and hose end fittings (Figure 117) and tie the hose ends out of the way.

0602-57

4. Remove the drive wheel.

5. Install the hub puller (P/N TOR4097) on the wheel studs (Figure 115). Tighten the forcing screw to remove the hub from the tapered wheel motor shaft.

Figure 115

6. Drain the hydraulic oil reservoir by removing the return and supply lines.

0662-58

Figure 117

10. Remove the 4 mounting bolts and remove the wheel motor from the unit (Figure 117).

0602-56

Wheel Motor Installation

1. Slide the wheel motor into position from under the unit. Secure it to the frame with the 4 mounting bolts. Torque to 30 ft. lbs. (41 N-m).

5 - 26 Mid-Size Walk Behind Service Manual

Page 83

HYDRAULIC DRIVE SYSTEMS

2. Install new ‘O’ rings on the motor fittings. Install the hose fittings.

3. Align the wheel hub to the woodruff key on the motor shaft. Slide hub into position and thread the nut onto the shaft to hold the hub in position. Slide the wheel onto the hub and snug up the lug nuts. Apply the parking brake and tighten the hub nut to 165 ft. lbs. (224 N-m) and install the cotter key.

4. Reconnect the return and supply lines to the reservoir and refill with fresh oil until the level is 1/4” (6mm) below the top baffle (Figure 123).

Pump Removal

1. Thoroughly clean the area around the pump and hydraulic fittings to prevent dirt from entering the system.

2. Remove the drive pulley.

3. Use the cold start ring to remove tension from the pump drive belt.

4. Loosen the two set screws and slide the pulley off the pump shaft. Remove the woodruff key from the shaft (Figure 119).

Figure 118

(1) Cap (2) Baffle

5. Bleed air from the system:

6. Start the engine and run at idle speed. Engage traction on one side and spin the wheel by hand.

7. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly (minimum 2 minutes).

8. Check hydraulic fluid level as it drops and add as required to maintain proper level.

9. Repeat procedure on opposite wheel.

10. Lower unit to the ground and tighten lug nuts to 85 ft. lbs. (115 N-m). Tighten lug nuts in a crisscross pattern from top to bottom - left to right.

(3) Fluid level - full

m-4280

Figure 119

Note: When installing the pulley, slide it onto the shaft

until the end of the shaft is flush with the bottom of the counter bore in the pulley.

5. Drain the fluid reservoir by removing the return and supply lines.

0602-50

Mid-Size Walk Behind Service Manual 5 - 27

Page 84

HYDRAULIC DRIVE SYSTEMS

6. Mark the fittings to prevent reversing them when they are reinstalled. Hold the pump fitting stationary while removing the hose fittings from the pump. Cap the fittings to prevent dirt from entering the system (Figure 120).

Figure 120

Note: Fuel tank removed for clarity.

0602-51

8. To remove the supply line, slide the hose clamp at least 2” (50mm) down the supply hose to clear the barbed fitting (Figure 121). Pull the hose off the fitting and cap both the supply hose and fitting.

9. Use a 5/16 8 point socket to loosen the set screw on the control linkage. Remove the pump mounting bolts and slide the control shaft out of the linkage (Figure 122).

7. Remove the return line from the 90° fitting located on the side of the pump (Figure 121).

Figure 121

(A) Return line (B) Supply line

0602-49

Figure 122

10. To replace the pump, reverse the above steps.

11. Reconnect the return and supply lines to the reservoir and refill with fresh oil until the level is 1/4” (6mm) below the top baffle (Figure 123).

Figure 123

0602-21

m-4280

(1) Cap (2) Baffle

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(3) Fluid level - full

Page 85

12. Raise the rear of the machine and support on jack stands so the wheels are off the ground.

13. Bleed air from the system:

14. Start the engine and run at idle speed. Engage traction on one side and spin the wheel by hand.

15. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly (minimum 2 minutes).

16. Check hydraulic fluid level as it drops and add as required to maintain proper level.

17. Repeat procedure on opposite wheel.

HYDRAULIC DRIVE SYSTEMS

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THIS PAGE INTENTIONALLY LEFT BLANK

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Page 87

GEAR DRIVE TRANSMISSION

Transmission Removal - Gear Drive

1. Raise the rear of the unit and place on safety stands.

2. Remove the spring from the belt tensioning arm (Figure 124).

3. Remove the pivot bolt and tensioning arm assembly (Figure 124).

5. Slide the pulley off the transmission input shaft.

6. Remove the hairpin cotter and washer securing the control rod to the idler bracket. Remove the control rod from the bracket (Figure 126).

Figure 126

7. Remove the hairpin cotter and washer from the brake rod and remove the brake rod from the idler bracket (Figure 127).

0819-16

Figure 124

4. Remove the external snap ring and loosen the transmission pulley set screw (Figure 125).

0819-35

Figure 125

(A) Set screw (B) Snap ring

0820-01

Figure 127

0820-07

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Page 88

GEAR DRIVE TRANSMISSION

8. Remove the 3 nuts and bolts securing the idler support to the frame (Figure 128). Remove the idler support, idler bracket and torsion spring from the frame.

Figure 128

0819-38

9. Remove the 2 nuts and bolts securing the bearing to the frame (Figure 129).

10. Pull the extension shafts out of the splined couplers and through the frame (Figure 130).

Figure 130

0819-40

11. Remove the nut securing the shift lever to the transmission (Figure 131).

Figure 129

Figure 131

0819-39

0819-36

6 - 2 Mid-Size Walk Behind Service Manual

Page 89

12. Remove the 4 transmission mounting bolts and remove the transmission (Figure 132).

GEAR DRIVE TRANSMISSION

Figure 132

Installation

Follow the removal procedures in reverse. NOTE: For transmission service procedures, refer to the appropriate Peerless Service Manual.

0819-37

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Page 90

GEAR DRIVE TRANSMISSION

Transmission Drive Assembly

Ref. No. Qty. Description Ref. No. Qty. Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20

21 22

1 1 2 1 1 1 2 2 2 2 4 3 2 2 2 2 2 1

1 1

Grip Lever - Shift Nut - Lock, NI Washer - Belleville Washer Transmission Fitting - Grease Coupler Guard - Coupler Flange - Output Screw - HH Key - Woodruff Screw - Set Ring - Retaining Pulley - Transmission Shaft - Output Bearing - Shaft Rod - Shield

Shield - Trailing Pulley - Driven

Screw - Set, HSH Ring - Snap, External

23 24 25 26 27 27:1 28 29 30 31 32

1 1 1 1 1 2 1 1 4 4 4

V - Belt Spring Bolt - Wheel Screw - HH Lever - Idler Bushing - Flange Pulley Nut - Lock, NI Screw - HH Washer - Lock Nut - Lock, NI

6 - 4 Mid-Size Walk Behind Service Manual

Page 91

GEAR DRIVE TRANSMISSION

Control Linkage Removal (T-Bar)

1. Disconnect wiring for operator presence control (OPC) switch from T-Bar.

2. Disconnect the plug from the OPC switch (Figure

133).

Figure 133

0819-28

4. Pull the wire harness from the tube in the T-Bar (Figure 135).

Figure 135

5. Remove the cotter pins connecting the link to the T-Bar. This will also allow removal of the OPC handle (Figure 136).

0819-15

3. Remove the spade connectors from the plastic plug by depressing the connector lock with a paper clip or special tool (Figure 134). NOTE: When assembled, the orange wire should be on the operator’s right.

Figure 134

0819-11

Figure 136

0819-10

Mid-Size Walk Behind Service Manual 6 - 5

Page 92

GEAR DRIVE TRANSMISSION

6. Remove the hairpin cotters and washers securing the trunnions to the idler brackets (Figure 137).

Figure 137

7. Remove the cotter pins from the T-Bar.

8. Remove the pivot pins securing the T-Bar to the handle (Figure 138).

0819-16

Control Linkage Adjustment (T-Bar Gear Drive)

1. Check the initial adjustment of the control rods. The control rods should be threaded through the rod fittings approximately 3” (76mm) (Figure 139).

)

(

”

Figure 139

0819-17

Figure 138

Installation

Follow the removal procedures in reverse.

0819-12

2. Check the parking brake engagement. The parking brake lever should swing into a snug position against the upper handle while pulling back on the upper control bar (Figure 140).

Figure 140

0819-09

6 - 6 Mid-Size Walk Behind Service Manual

Page 93

GEAR DRIVE TRANSMISSION

3. Check operation. If adjustment is required, remove the hairpin cotter and washer and adjust the rod fittings up or down on the control rod, as needed.

NOTE: The control bar and upper handle must be parallel when in the relaxed drive and brake positions.

4. Check pulley travel. The idler pulleys should move approximately 3/4” (19mm) to properly tension the wheel belts (Figure 141).

)

(

”

Procedure

1. Install control rods into the bell cranks and secure them with the hairpin cotters (Figure 142).

Note: Install rod fittings so the clevis pin is above the control rod, as shown in Figure 142.

Figure 142

m-6592

Figure 141

5. If pulley travel is more than 3/4” (19mm), the brakes must be adjusted. Refer to Checking and Adjusting the Brake, page 4 - 6 through 4 - 8.

Linkage Adjustment (Pistol Grip Gear Drive)

Parts needed for this step:

Qty. Part

2 Control rods

2 Cotter pin

2 Clevis Pin

2 Washer

2 Hairpin cotter pin

0820-08

(1) Control rod (2) Bell crank

2. Place the clevis pin into the upper part of the control rods, drive lever and neutral/parking brake locks (Figure 143).

(3) Hairpin cotter

Mid-Size Walk Behind Service Manual 6 - 7

Page 94

GEAR DRIVE TRANSMISSION

3. Install the hairpin cotter pins between the drive levers and neutral/parking brake locks and into the clevis pins (Figure 143).

m-7669

(1) Control rod (2) Drive lever (3) Hairpin cotter

Figure 143

(4) Clevis pin (5) Handle (6) Neutral/parking brake lock

6. Tighten the wing nut to prevent the turnbuckle from turning (Figure 144).

7. Check the drive adjustment by squeezing the drive levers firmly and then releasing. If the 3/16 to 1/4 inch (5 to 6mm) adjustment has changed, adjust as necessary.

8. Check the parking brake. Refer to ”Brake Service" on page 4 - 3.

4. Loosen the turn buckle wing nut (Figure 144).

Figure 144

(1) Turnbuckle (2) Wing nut

5. Adjust the control rod length by rotating the turnbuckle until there is 3/16 to 1/4 inch (5 to 6mm) clearance between the control rod end and the bottom of the neutral/parking brake lock slot with the drive lever in the drive position (Figure

145).

(3) Control rod

m-6592-2

Figure 145

(1) Handle (2) Neutral/Parking brake lock (3) 3/16 inch to 1/4 inch (5mm

to 6mm clearance)

(4) Drive lever (5) Drive position (6) Control rod

6 - 8 Mid-Size Walk Behind Service Manual

Page 95

MOWER DECKS

Setting Up the Frame (Floating Deck)

Checking Carrier Frame and Deck Alignment

1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Place a long straight edge on top of the engine deck as shown in Figure 146.

3. At the carrier frame cross tube, measure location A height (Figure 146). This measurement must be 2-13/16 in. (71mm), plus or minus 1/4 in. (6mm).

4. If the height at location A is not correct, adjustment is needed.

5. Loosen the carrier frame mounting bolts on both sides of the machine (Figure 146).

6. Align the carrier frame and engine deck to obtain 2-13/16 in. (71mm), plus or minus 1/4 in. (6mm) at location A (Figure 146).

Checking Engine Deck Height (Floating Deck)

1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Adjust the tire pressure in all tires to specifications.

3. Measure engine deck height at location A (Figure

147).

4. Measure engine deck height at location B (Figure

147).

5. If the height at location A and B are not the same, change tire pressure slightly to make them the same.

7. Tighten the carrier frame mounting bolts on both sides of the machine (Figure 146).

Figure 146

(1) Carrier frame (2) Top of engine deck (3) Carrier frame mounting

bolts

(4) Location A, 2-13/16 in.

(71mm)± 1/4 in. (6mm) (5) Straight edge (6) Carrier frame cross tube

M-5315

Figure 147

(1) Back view of machine (2) Top of engine deck (3) Tires

Checking Carrier Frame Side-to-Side

1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Adjust the tire pressure in all tires to specifications.

3. Measure carrier frame height at location A (Figure

148).

(4) Same height at locations

A and B

m-5237

4. Measure carrier frame height at location B (Figure

148).

Mid-Size Walk Behind Service Manual 7 - 1

Page 96

MOWER DECKS

5. If the carrier frame height is not the same, move spacers from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level.

Figure 148

(1) Caster wheel (2) Carrier frame (3) Front height-of-cut pins

Checking Carrier Frame Front-to-Rear Pitch (Floating Deck)

The carrier frame must have a pitch of 1/4 in. (6mm) over the length of 24 inches (6.1cm) on the carrier frame.

1. Measure out 24 inches (6.1cm) on the carrier frame (Figure 149).

2. Measure carrier frame height at location A (Figure

149).

3. Measure carrier frame height at location B (Figure

149).

(4) Same height at

locations A and B

(5) Caster spacers

m-5231

5. If the carrier frame is not correct, move caster spacers from top or bottom to make the correct pitch.

6. The tire pressure may also be adjusted slightly to achieve the correct pitch.

Figure 149

(1) Caster wheel (2) Carrier frame (3) 1/4-3/8 in. (6mm - 10mm)

pitch over 24 in. (6.1 cm) length

(4) Height at locations

A and B

(5) Caster spacers

m-5242

Checking the Deck Level Side-toSide (Floating Deck)

1. Adjust the tire pressure in all tires to specifications.

2. Position the blades side-to-side (Figure 150). Measure at A and B locations (Figure 150) from a level surface to the cutting edge of blade tips (Figure 151).

4. The height at location A must be 1/4-3/8 in. (6mm

- 10mm) lower than location B (Figure 149).

7 - 2 Mid-Size Walk Behind Service Manual

Page 97

MOWER DECKS

3. The difference between measurements A and B should be no more than 1/4 in. (6mm).

Figure 150

m-1078-3

3. The mower blade should be 1/4 in. (6mm) lower in front C than in the rear D. Rotate blades and repeat for other blades. If it is not correct, proceed to "Adjusting the Deck Front-toRear Blade Slope" on page 7 - 3.

Figure 152

m-1078-2

Figure 151 m-2550

Checking the Deck Front-to-Rear

Figure 153 m-2539

Blade Slope (Floating Deck)

1. Adjust the tire pressure in all tires to specifications.

2. Position one blade front-to-rear (Figure 152). Measure at C and D locations (Figure 152) from a level surface to the cutting edge of the blade tips (Figure 153).

Mid-Size Walk Behind Service Manual 7 - 3

Adjusting the Deck Front-to-Rear Blade Slope

1. Change the front-to-rear pitch by adjusting the front height-of-cut posts (Figure 154).

2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Figure 154).

Page 98

MOWER DECKS

3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Figure 154).

Figure 154

(1) Caster wheel (2) Carrier frame (3) Front height-of-cut pins

4. Position the blades front-to-rear (Figure 152). Measure at C and D locations (Figure 152) from a level surface to the cutting edge of the blades (Figure 153).

(4) Jam nut (5) Ball joint

m-6371

3. With the machine on level surface, position one blade front-to-rear (Figure 155). Measure at A and from level surface to the cutting edge of the blade tips (Figure 156).

4. The measurement should be 4 in. (102mm).

Figure 155

m-1078-4

5. Check the side-to-side leveling of the cutting unit.

Adjusting the Side-to-Side Level (Fixed Deck)

1. Changing the side-to-side level is done by adjusting tire pressure.

2. After leveling side-to-side, check front-to-rear pitch.

Matching Height-of-Cut (Fixed Deck)

1. Make this adjustment after the mower has been leveled side-to-side and the pitch has been set.

2. Set the height-of-cut to the 4 in. (102mm) position following the height-of-cut decal.

Figure 156 m-2550

5. If it does not measure correctly, add or remove air pressure equally in all tires to adjust height-of-cut.

7 - 4 Mid-Size Walk Behind Service Manual

Page 99

MOWER DECKS

Replacing the Mower Belt (Floating Deck) 36 in. (91cm)

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the knobs/rubber washers holding the carrier frame cover and remove the carrier frame cover.

4. Remove the knobs/rubber washers holding the belt cover to the cutting unit and remove the belt cover.

5. Remove the PTO drive belt. Refer to "Replacing the PTO Drive Belt (Floating Deck) 36 in. (91cm)" on page 7 - 5.

6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Figure 157).

7. Install the new mower belt around the outward spindle pulley, the idler pulley, and in the lower groove of the double spindle pulley (Figure 157).

11. Install the carrier frame cover onto the cutting unit, then install and tighten the knobs/rubber washers.

(1) Mower belt (2) Idler arm spring (3) Outward pulley

Figure 157

(4) PTO drive belt (5) Double spindle pulley

m-5247

Replacing the PTO Drive Belt (Floating Deck) 36 in. (91cm)

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt. Replace the drive belt if any of these conditions are evident.

1. Disengage the PTO and set the parking brake.

8. Reconnect the idler arm spring (Figure 157).

9. Install the PTO drive belt. Refer to "Replacing the PTO Drive Belt (Floating Deck) 36 in. (91cm)" on page 7 - 5.

10. Reinstall the belt cover onto the cutting unit, then reinstall and tighten the knobs/rubber washers.

Mid-Size Walk Behind Service Manual 7 - 5

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the knobs/rubber washers holding the carrier frame cover and remove the carrier frame cover.

4. Remove the knobs/rubber washers holding the belt covers to the top of the cutting unit and remove the belt covers.

5. Remove the heat shield from the engine deck and carrier frame.

6. Remove the idler spring from idler arm. Remove the drive belt from the PTO clutch pulley, idler pulleys and the left spindle pulley (Figure 158).

Page 100

MOWER DECKS

7. Install the new drive belt onto the PTO engagement pulley and the top groove of the center spindle pulley (Figure 158).

8. Install belt onto idler pulleys and then install idler spring (Figure 158).

9. Install the heat shield to the engine deck and carrier frame.

10. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs/rubber washers.

11. Reinstall the carrier frame cover onto the cutting unit, then reinstall and tighten the knobs/rubber washers.

3. Remove the knobs holding the belt covers to the cutting unit and remove the belt covers.

4. Remove the PTO drive belt. Refer to "Replacing the PTO Drive Belt (Floating Deck) 44 & 52 in. (111 & 132cm)" on page 7 - 7.

5. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn deck belt (Figure 159).

6. Install the new deck belt around the two outside spindle pulleys, the idler pulley, and in the lower groove of the center spindle pulley (Figure 159).

7. Connect the idler arm spring (Figure 159).

8. Reinstall the PTO drive belt. Refer to "Replacing the PTO Drive Belt (Floating Deck) 44 & 52 in. (111 & 132cm)" on page 7 - 7.

9. Adjust deck belt guide to 1/8 in. (3mm) from belt (Figure 159).

10. Reinstall the deck covers onto the cutting unit, then reinstall and tighten the knobs.

Figure 158

(1) PTO clutch pulley (2) Drive belt idler

(3) Drive belt (4) Double spindle pulley

Replacing the Deck Belt (Floating Deck) 44 & 52 in. (111 & 132cm)

1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove the knobs holding the carrier frame cover and remove the carrier frame cover.

11. Install the carrier frame cover onto the cutting unit, then install and tighten the hand knobs.

(1) Deck belt (2) Idler arm spring (3) Outward pulley

Figure 159

(4) PTO drive belt (5) Center spindle pulley (6) Deck belt guide

m-5194-2

7 - 6 Mid-Size Walk Behind Service Manual

Toro 30140, 30150, 30161, 30164, 30167 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual