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

LCE Products

Mid-Size Walk Behind

Service Manual

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.

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

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

ii Mid-Size Walk Behind Service Manual

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

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

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.

THIS PAGE INTENTIONALLY LEFT BLANK

1 - 2 Mid-Size Walk Behind Service Manual

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

(C) Grade 8

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

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

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

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

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

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

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

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

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

SD

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

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 &

02

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

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

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

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

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

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

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

1

• Tires—check pressure

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

• Engine Oil—change

1

• Spark Plug(s)—check

• Electric Clutch–Adjust

• Engine—clean outside

• Paper Air Cleaner—replace

1

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

1

At Storage • Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storage

1

More often in dusty, dirty conditions.

2 - 16 Mid-Size Walk Behind Service Manual

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

XX

Storage

Service

Mid-Size Walk Behind Service Manual 2 - 17

THIS PAGE INTENTIONALLY LEFT BLANK

2 - 18 Mid-Size Walk Behind Service Manual

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

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

A

B

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

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

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