Toro 30031, 30032, 30033, 30069, 30074 Service Manual

...
0 (0)

LCE Products

Floating Deck

Mid-Size

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 DVD (P/N 492-4757).

Interactive Hydraulic Troubleshooting DVD (P/N 492-4777).

Hydro-Gear Hydraulic Pump Service and Repair Manual (P/N 492-4749).

Ross Wheel Motor Service and Repair Manual (P/N 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.

Copyright© All Rights Reserved

©2008 The Toro Company

THIS PAGE INTENTIONALLY LEFT BLANK.

Floating Deck Mid-Size Service Manual

TABLE OF CONTENTS

SAFETY INFORMATION

 

General Information......................................................................................................................

1-1

Think Safety First..........................................................................................................................

1-1

SPECIFICATIONS

 

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

U.S. to Metric Conversions...........................................................................................................

2-6

Hydro with Pistol Grip Controls.....................................................................................................

2-7

Hydro with Pistol Grip Controls cont.............................................................................................

2-8

Hydro with Pistol Grip Controls cont.............................................................................................

2-9

Hydro with T-2 Controls ..............................................................................................................

2-10

Hydro with T-2 Controls cont. .....................................................................................................

2-11

Gear with T-Bar Controls ............................................................................................................

2-12

Gear with T-Bar Controls cont. ...................................................................................................

2-13

Gear with T-Bar Controls cont. ...................................................................................................

2-14

International Hydro with T-Bar (T2) Controls ..............................................................................

2-15

International Hydro with T-Bar (T2) Controls cont. .....................................................................

2-16

International Gear with T-Bar Controls .......................................................................................

2-17

International Gear with T-Bar Controls cont. ..............................................................................

2-18

CHASSIS

 

Electric Clutch Replacment ..........................................................................................................

3-1

Electric Clutch Removal.........................................................................................................

3-1

Clutch Burnishing Procedure .................................................................................................

3-4

Electric Clutch Installation......................................................................................................

3-4

PTO Idler Replacement ................................................................................................................

3-9

PTO Idler Removal.................................................................................................................

3-9

PTO Idler Installation............................................................................................................

3-12

Parking Brake Service - Hydro ...................................................................................................

3-14

Checking the Parking Brake ................................................................................................

3-14

Adjusting the Parking Brake.................................................................................................

3-15

Parking Brake Removal .......................................................................................................

3-16

Parking Brake Installation ....................................................................................................

3-20

Wheel Drive Belt and Wheel Hub Replacement - Gear Drive ....................................................

3-24

Wheel Drive Belt & Wheel Hub Removal.............................................................................

3-25

Wheel Drive Belt & Wheel Hub Installation..........................................................................

3-30

Brake Band Replacement...........................................................................................................

3-36

Brake Band Removal ...........................................................................................................

3-36

Brake Band Installation ........................................................................................................

3-40

Carrier Frame Replacement.......................................................................................................

3-45

Carrier Frame Removal .......................................................................................................

3-45

Carrier Frame Installation ....................................................................................................

3-48

Carrier Frame & Mower Deck Adjustments ................................................................................

3-51

Checking the Carrier Frame & Engine Deck Alignment .......................................................

3-51

Castor Wheel Replacement........................................................................................................

3-53

Castor Wheel Removal ........................................................................................................

3-53

Castor Wheel Service ..........................................................................................................

3-54

Castor Wheel Installation .....................................................................................................

3-59

Floating Deck Mid-Size Service Manual

i

TABLE OF CONTENTS

CHASSIS cont.

 

Castor Wheel Fork Bushing Replacement .................................................................................

3-60

Castor Wheel Fork Bushing Removal..................................................................................

3-60

Castor Wheel Fork Bushing Installation...............................................................................

3-61

Fuel Tank Replacement..............................................................................................................

3-62

Fuel Tank Removal ..............................................................................................................

3-62

Fuel Tank Installation ...........................................................................................................

3-67

Battery Tray Replacement..........................................................................................................

3-70

Battery Tray Removal ..........................................................................................................

3-70

Battery Tray Installation .......................................................................................................

3-72

Mid-Size Weight Replacement ...................................................................................................

3-74

Checking the Brake (T-Bar)........................................................................................................

3-75

Adjusting the Brake (T-Bar) ........................................................................................................

3-76

LINKAGE

 

Control Linkage Replacement (T-2)..............................................................................................

4-1

Control Linkage Removal.......................................................................................................

4-1

Control Linkage Installation....................................................................................................

4-5

Control Linkage & Thumb Latch Replacement (Pistol Grip Hydro) ............................................

4-10

Control Linkage & Thumb Latch Removal ...........................................................................

4-10

Control Linkage & Thumb Latch Installation ........................................................................

4-13

Lower Control Replacement (T-Bar)...........................................................................................

4-17

Lower Control Removal .......................................................................................................

4-17

Lower Control Installation ....................................................................................................

4-22

Neutral Adjustment Stud Replacement (Pistol Grip Hydro)........................................................

4-28

Neutral Adjustment Stud Removal .......................................................................................

4-28

Neutral Adjustment Stud Installation ....................................................................................

4-31

Operator Presence Control Lever Replacement (Pistol Grip Hydro)..........................................

4-35

Operator Presence Control Lever Removal.........................................................................

4-35

Operator Presence Control Lever Installation......................................................................

4-37

Speed Control Replacement (Pistol Grip Hydro)........................................................................

4-39

Speed Control Removal.......................................................................................................

4-39

Speed Control Installation....................................................................................................

4-46

Drive Lever Swivel & Bearing Replacement (Pistol Grip Hydro) ................................................

4-57

Drive Lever Swivel & Bearing Removal ...............................................................................

4-57

Drive Lever Swivel & Bearing Installation ............................................................................

4-61

Handle Assembly Replacement (T-Bar) .....................................................................................

4-66

Handle Assembly Removal (T-Bar)......................................................................................

4-66

Handle Assembly Installation (T-Bar)...................................................................................

4-73

Handle Assembly Removal (T-2) .........................................................................................

4-80

Handle Assembly Installation (T-2) ......................................................................................

4-92

Choke Cable Replacement.......................................................................................................

4-108

Choke Cable Removal .......................................................................................................

4-108

Choke Cable Installation ....................................................................................................

4-110

Throttle Cable Replacement.....................................................................................................

4-114

Throttle Cable Removal .....................................................................................................

4-114

Throttle Cable Installation ..................................................................................................

4-117

Linkage Adjustments ................................................................................................................

4-121

Speed Control Linkage Adjustment (Pistol Grip Hydro) .....................................................

4-121

Temporary Neutral Stud Adjustment ..................................................................................

4-122

Hydro Control Linkage Adjustment...........................................................................................

4-123

Adjusting the Left Side Linkage (Pistol Grip) .....................................................................

4-124

Adjusting the Right Side Linkage (Pistol Grip) ...................................................................

4-126

ii

Floating Deck Mid-Size Service Manual

 

TABLE OF CONTENTS

LINKAGE cont.

 

Neutral Stud Adjustment (Pistol Grip).......................................................................................

4-126

Adjusting the Control Rod (Pistol Grip).....................................................................................

4-128

Checking the Control Rod..................................................................................................

4-128

Adjusting the Control Rod ..................................................................................................

4-128

Tracking Adjustment (Pistol Grip) .............................................................................................

4-129

Tracking Adjustment (T-2) ........................................................................................................

4-130

Neutral Adjustment (T-2)...........................................................................................................

4-130

Control Bar Adjustment (T-Bar) ................................................................................................

4-132

ENGINE

 

Engine Removal - Pistol Grip Hydro.............................................................................................

5-1

Engine Installation - Pistol Grip Hydro..........................................................................................

5-9

Muffler Guard..............................................................................................................................

5-20

Engine Removal - Gear Drive.....................................................................................................

5-21

Engine Installation - Gear Drive..................................................................................................

5-28

HYDROSTATIC DRIVE SYSTEM

 

Hydro Drive Transmission Traction Belt Replacement .................................................................

6-1

Hydro Drive Transmission Traction Belt Removal..................................................................

6-1

Hydro Drive Transmission Traction Belt Installation...............................................................

6-4

Hydro Idler Replacement..............................................................................................................

6-7

Hydro Idler Removal ..............................................................................................................

6-7

Hydro Idler Installation ...........................................................................................................

6-9

Hydraulic Pump Replacement....................................................................................................

6-11

Hydraulic Pump Removal ....................................................................................................

6-12

Hydraulic Pump Installation .................................................................................................

6-15

Wheel Motor Replacement.........................................................................................................

6-19

Wheel Motor Removal .........................................................................................................

6-19

Wheel Motor Installation ......................................................................................................

6-22

Hydraulic Reservoir Replacement..............................................................................................

6-26

Hydraulic Reservoir Removal ..............................................................................................

6-26

Hydraulic Reservoir Installation ...........................................................................................

6-27

Hydraulic Testing ........................................................................................................................

6-29

Bleeding the Hydraulic System...................................................................................................

6-32

Checking the Hydraulic Lines.....................................................................................................

6-33

Hydraulic Schematic...................................................................................................................

6-34

GEAR DRIVE

 

Traction Drive Belt Replacement..................................................................................................

7-1

Traction Drive Belt Removal ..................................................................................................

7-1

Traction Drive Belt Installation ...............................................................................................

7-2

Gear Drive Idler Replacement......................................................................................................

7-4

Gear Drive Idler Removal ......................................................................................................

7-4

Gear Drive Idler Installation ...................................................................................................

7-6

Transmission Driven Pulley Replacement....................................................................................

7-7

Transmission Driven Pulley Removal ....................................................................................

7-7

Transmission Driven Pulley Installation ...............................................................................

7-10

Gear Drive Transmission Replacement......................................................................................

7-13

Gear Drive Transmission Removal ......................................................................................

7-13

Gear Drive Transmission Installation ...................................................................................

7-18

Floating Deck Mid-Size Service Manual

iii

TABLE OF CONTENTS

MOWER DECKS

 

Mower Spindle Drive Belt Replacement.......................................................................................

8-1

Mower Spindle Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks) ............................

8-1

Mower Spindle Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks) .........................

8-2

Mower Spindle Drive Belt Removal (36” Mower Deck)..........................................................

8-4

Mower Spindle Drive Belt Installation (36” Mower Deck).......................................................

8-5

PTO Drive Belt Replacement .......................................................................................................

8-6

PTO Drive Belt Removal (40”, 48”, 52” and 60” Mower Decks).............................................

8-6

PTO Drive Belt Installation (40”, 48”, 52” and 60” Mower Decks)..........................................

8-7

PTO Drive Belt Removal (36” Mower Decks).........................................................................

8-8

PTO Drive Belt Installation (36” Mower Decks)......................................................................

8-9

Spindle Replacement and Service .............................................................................................

8-11

Spindle Removal and Teardown ..........................................................................................

8-11

Spindle Rebuild and Installation...........................................................................................

8-14

Idler Arm Assembly Replacement...............................................................................................

8-18

Idler Arm Assembly Removal (40”, 48”, 52” and 60” Mower Decks) ....................................

8-18

Idler Arm Assembly Installation (40”, 48”, 52” and 60” Mower Decks) .................................

8-22

Idler Arm Assembly Replacement (36” Mower Deck).................................................................

8-27

Idler Arm Assembly Removal (36” Mower Deck) .................................................................

8-27

Idler Arm Assembly Installation (36” Mower Deck) ..............................................................

8-28

Adjustable Baffle Replacement ..................................................................................................

8-30

Adjustable Baffle Removal...................................................................................................

8-30

Adjustable Baffle Installation................................................................................................

8-32

Discharge Baffle Replacement...................................................................................................

8-34

Discharge Baffle Removal ...................................................................................................

8-34

Discharge Baffle Installation ................................................................................................

8-35

Fixed Baffle Replacement ..........................................................................................................

8-36

Fixed Baffle Removal (40”, 48”, 52” and 60” Mower Decks)................................................

8-36

Fixed Baffle Installation (40”, 48”, 52” and 60” Mower Decks).............................................

8-37

Fixed Baffle Replacement (36” Mower Deck).............................................................................

8-38

Fixed Baffle Removal (36” Mower Deck) .............................................................................

8-38

Fixed Baffle Installation (36” Mower Deck) ..........................................................................

8-39

Skid Plate Replacement (40”, 48”, 52” and 60” Mower Decks) ..................................................

8-39

Skid Plate Removal (40”, 48”, 52” and 60” Mower Deck) ....................................................

8-39

Skid Plate Installation (40”, 48”, 52” and 60” Mower Deck) .................................................

8-40

Skid Plate Replacement (36” Mower Deck)................................................................................

8-41

Skid Plate Removal (36” Mower Deck) ................................................................................

8-41

Skid Plate Installation (36” Mower Deck) .............................................................................

8-42

Front & Rear Deck Hanger Replacement...................................................................................

8-43

Front Deck Hanger Removal ...............................................................................................

8-43

Front Deck Hanger Installation ............................................................................................

8-45

Rear Deck Hanger Removal ................................................................................................

8-48

Rear Deck Hanger Installation .............................................................................................

8-50

Anti-Scalp Roller Replacement...................................................................................................

8-52

Single Anti-Scalp Roller Removal ........................................................................................

8-52

Single Anti-Scalp Roller Installation .....................................................................................

8-53

Double Anti-Scalp Roller Removal.......................................................................................

8-54

Double Anti-Scalp Roller Installation....................................................................................

8-54

Grass Deflector Service..............................................................................................................

8-55

Grass Deflector Removal.....................................................................................................

8-55

Grass Deflector Disassembly...............................................................................................

8-56

Grass Deflector Assembly....................................................................................................

8-56

Grass Deflector Installation..................................................................................................

8-58

iv

Floating Deck Mid-Size Service Manual

TABLE OF CONTENTS

MOWER DECKS cont.

 

Quick Latch Replacement ..........................................................................................................

8-59

Quick Latch Removal...........................................................................................................

8-59

Quick Latch Installation........................................................................................................

8-60

Mower Deck Removal..........................................................................................................

8-61

Mower Deck Installation.......................................................................................................

8-62

Checking the Engine Deck Height..............................................................................................

8-63

Checking the Carrier Frame Front-to-Rear Pitch........................................................................

8-64

Checking the Carrier Frame Side-to-Side Height.......................................................................

8-64

Checking the Mower Deck Front-to-Rear Pitch..........................................................................

8-65

Adjusting the Mower Deck Front-to-Rear Pitch ..........................................................................

8-66

Checking the Mower Deck Side-to-Side Height .........................................................................

8-66

Adjusting the Mower Deck Side-to-Side Height..........................................................................

8-67

Matching the Height-of-Cut.........................................................................................................

8-67

ELECTRICAL

 

Tools .............................................................................................................................................

9-1

Components .................................................................................................................................

9-1

Alternator ...............................................................................................................................

9-1

On/Off Switch.........................................................................................................................

9-1

Bail Switch .............................................................................................................................

9-1

Single Pole Switch .................................................................................................................

9-2

PTO Switch ............................................................................................................................

9-2

Relay, Single Pole Dual Throw...............................................................................................

9-3

Ignition Switch........................................................................................................................

9-3

Wire Harness T-Bar, Gear Drive (104-8137)..........................................................................

9-4

PTO Switch ............................................................................................................................

9-5

Delay Module .........................................................................................................................

9-5

Clutch Power Supply Test Procedure:....................................................................................

9-6

DC Mini Hour Meter ...............................................................................................................

9-8

Proximity Switch.....................................................................................................................

9-9

PTO Brake Clutch Assembly..................................................................................................

9-9

Wire Harness Pistol Grip (106-8780) ...................................................................................

9-10

PTO Switch ..........................................................................................................................

9-11

Wire Harness T-2, Hydro (114-3418) ...................................................................................

9-12

Wire Harness T-Bar, Hydro (114-3420)................................................................................

9-13

Normally Open Switch .........................................................................................................

9-14

Normally Closed Switch .......................................................................................................

9-14

Starter Solenoid ...................................................................................................................

9-14

Operator Presence Control (OPC) Switch Replacement (T-Bar) ...............................................

9-15

OPC Switch Removal (T-Bar) ..............................................................................................

9-15

OPC Switch Installation (T-Bar) ...........................................................................................

9-16

PTO Switch Replacement (T-Bar) ..............................................................................................

9-18

PTO Switch Removal (T-Bar)...............................................................................................

9-18

PTO Switch Installation (T-Bar)............................................................................................

9-19

Ignition Switch Replacement (T-Bar)..........................................................................................

9-20

Ignition Switch Removal (T-Bar) ..........................................................................................

9-20

Ignition Switch Installation (T-Bar) .......................................................................................

9-21

Delay Module Replacement (T-Bar) ...........................................................................................

9-23

Delay Module Removal (T-Bar)............................................................................................

9-23

Delay Module Installation (T-Bar).........................................................................................

9-24

Floating Deck Mid-Size Service Manual

v

TABLE OF CONTENTS

ELECTRICAL cont.

 

Parking Brake Switch Replacment (Pistol Grip & T-2)................................................................

9-26

Parking Brake Switch Removal (P.G. & T-2) ........................................................................

9-26

Parking Brake Switch Installation (P.G. & T-2) .....................................................................

9-27

Neutral Switch Replacement (Pistol Grip) ..................................................................................

9-28

Neutral Switch Removal (P.G.).............................................................................................

9-28

Neutral Switch Installation (P.G.)..........................................................................................

9-29

PTO Switch Replacement (Electric Start)...................................................................................

9-31

PTO Switch Removal (Electric Start) ...................................................................................

9-31

PTO Switch Installation (Electric Start) ................................................................................

9-33

Operator Presence Control (OPC) Switch Replacement (Pistol Grip)........................................

9-34

OPC Switch Removal (P.G.) ................................................................................................

9-34

OPC Switch Installation (P.G.) .............................................................................................

9-36

OPC Switch Position Adjustment (P.G.)...............................................................................

9-38

Hour Meter Replacement (Pistol Grip) .......................................................................................

9-39

Hour Meter Removal (P.G.)..................................................................................................

9-39

Hour Meter Installation (P.G.)...............................................................................................

9-41

Ignition Switch Replacement (Pistol Grip) ..................................................................................

9-43

Ignition Switch Removal (P.G.).............................................................................................

9-43

Ignition Switch Installation (P.G.)..........................................................................................

9-45

Kill Relay Replacement (Pistol Grip) ..........................................................................................

9-47

Kill Relay Removal (P.G.).....................................................................................................

9-47

Kill Relay Installation (P.G.)..................................................................................................

9-47

Solenoid Switch Replacement (Pistol Grip & T-2) ......................................................................

9-48

Solenoid Switch Removal (P.G. & T-2).................................................................................

9-48

Solenoid Switch Installation (P.G & T-2)...............................................................................

9-49

Operator Presence Control (OPC) Switch Replacement (T-2)...................................................

9-51

OPC Switch Removal (T-2)..................................................................................................

9-51

OPC Switch Installation (T-2)...............................................................................................

9-52

Latching Relay Replacement (T-2).............................................................................................

9-53

Latching Relay Removal (T-2) .............................................................................................

9-53

Latching Relay Installation (T-2) ..........................................................................................

9-54

Kill Relay Replacement (T-2)......................................................................................................

9-55

Kill Relay Removal (T-2) ......................................................................................................

9-55

Kill Relay Installation (T-2) ...................................................................................................

9-56

Proximity Neutral Switch Replacement (T-2)..............................................................................

9-56

Proximity Neutral Switch Removal (T-2) ..............................................................................

9-56

Proximity Neutral Switch Installation (T-2) ...........................................................................

9-57

vi

Floating Deck Mid-Size Service Manual

SAFETY

General Information

 

1

This symbol means WARNING or

Mower and attachment operator’s manuals contain

!PERSONAL SAFETY INSTRUCTION - safety information and operating tips for safe operating read the instruction because it has to do practices. Operator’s manuals are available through your with your safety. Failure to comply with Toro parts source or:

the instruction may result in personal

injury or even death.

The Toro Company

 

Publications Department

This manual is intended as a service and repair

8111 Lyndale Avenue South

manual only. The safety instructions provided herein

Bloomington, MN 55420

are for troubleshooting, service, and repair of the Mid-

 

Size Walk Behind mower. The Mid-Size Walk Behind

 

Think Safety First

Avoid unexpected starting of engine...

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

Avoid lacerations and amputations...

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

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 asphyxiation...

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

Avoid injury from batteries...

Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Battery gases can explode. Deep 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 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.

Floating Deck Mid-Size Service Manual

1-1

SAFETY

1

THIS PAGE INTENTIONALLY LEFT BLANK.

1-2

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Torque 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.

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.

Fastener Identification

2

 

Figure 1

 

 

 

 

 

Inch Series Bolts and Screws

 

 

 

 

(A) Grade 1 & 2

 

(C) Grade 8

(B) Grade 5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 2

Metric Bolts and Screws

(A) Class 8.8

(B) Class 10.9

 

 

Floating Deck Mid-Size Service Manual

2-1

SPECIFICATIONS

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

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

 

 

 

Grade 1, 5, &

SAE Grade 1 Bolts, Screws,

SAE Grade 5 Bolts, Screws,

SAE Grade 8 Bolts, Screws,

 

 

Thread Size

8 with Thin

Studs, & Sems with Regular

Studs, & Sems with Regular

Studs, & Sems with Regular

 

 

Height Nuts

Height Nuts (SAE J995

Height Nuts (SAE J995

Height Nuts (SAE J995

 

 

 

 

 

 

 

 

Grade 2 or Stronger Nuts)

Grade 2 or Stronger Nuts)

Grade 2 or Stronger Nuts)

2

 

 

In-lb

 

In-lb

 

N-cm

 

In-lb

 

N-cm

 

 

In-lb

 

N-cm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

# 6 - 32 UNC

10

± 2

13

± 2

147

± 23

15

± 2

169

±

23

23

± 2

260

± 34

 

# 6 - 40 UNF

17

± 2

190

±

20

25

± 2

280

± 20

 

 

 

 

 

 

 

 

 

 

# 8 - 32 UNC

13

± 2

25

± 5

282

± 30

29

± 3

330

±

30

41

± 4

460

± 45

 

 

# 8 - 36 UNF

31

± 3

350 ± 30

43

± 4

31

± 3

 

 

 

 

 

 

 

 

 

 

# 10 - 24 UNC

18

± 2

30

± 5

339

± 56

42

± 4

475

± 45

60

± 6

674

± 70

 

 

#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

 

 

 

ft-lb

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.

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

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.

2-2

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

StandardTorquefor Dry, Zinc and SteelelFasteners (Metric Fasteners) for Dry, Zinc, and Fasteners (Metric Fasteners)

 

Class 8.8 Bolts, Screws, and Studs with

Class 10.9 Bolts, Screws, and Studs with

 

 

Thread Size

 

Regular Height Nuts

 

Regular Height Nuts (

 

 

 

 

(Class 8 or Strong Nuts)

 

Class 10 or Strong Nuts)

 

 

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

 

2

 

 

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.

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.

Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

Floating Deck Mid-Size Service Manual

2-3

SPECIFICATIONS

OtherTorqueSpeciSpecificationsfications

SAE Grade 8 Steel Set Screws

 

 

Thread Size

Recommended Torque

2

 

 

 

 

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

 

 

 

 

 

Wheel Bolts and Lug Nuts

Thread Size

Recommended Torque**

 

 

 

7/16 - 20 UNF

65 ± 10 ft-lb

88 ± 14 N-m

Grade 5

 

 

 

 

 

1/2 - 20 UNF

80 ± 10 ft-lb

108 ± 14 N-m

Grade 5

 

 

 

 

 

M12 X 1.25

80 ± 10 ft-lb

108 ± 14 N-m

Class 8.8

 

 

 

 

 

M12 X 1.5

80 ± 10 ft-lb

108 ± 14 N-m

Class 8.8

 

 

 

 

 

** For steel wheels and non-lubricated fasteners.

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

 

 

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

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Threads per Inch

Baseline Torque*

 

 

Size

Type A

Type B

 

 

 

 

 

 

 

No. 6

18

20

20 ± 5 in-lb

 

 

 

 

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.

in-lb X 11.2985 = N-cm

N-cm X - 0.08851 = in-lb

ft-lb X 1.3558 = N-m

N-cm X 0.73776 = ft-lb

2-4

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Equivalentsand Conversions

and

Decimal and Millimeter Equivalents

Fractions

Decimals

mm

Fractions

 

Decimals

mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/64

0.015625

0.397

 

33/64

0.515625

13.097

 

 

 

2

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

Floating Deck Mid-Size Service Manual

2-5

SPECIFICATIONS

U.S. to Metric ConversionsU.S. to Metric Conversions

 

 

 

To Convert

Into

Multiply By

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Miles

Kilometers

 

1.609

 

 

 

Yards

Meters

 

0.9144

 

 

 

Feet

Meters

 

0.3048

2

 

Linear

 

 

Feet

Centimeters

 

30.48

 

Measurement

Inches

Meters

 

 

 

0.0254

 

 

Inches

Centimeters

 

 

 

 

Inches

Millimeters

 

2.54

 

 

 

 

25.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Square Miles

Square Kilometers

 

2.59

 

 

Area

Square Feet

Square Meters

 

0.0929

 

 

Square Inches

Square Centimeters

 

6.452

 

 

 

 

 

 

 

Acre

Hectare

 

0.4047

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cubic Yards

Cubic Meters

 

0.7646

 

 

Volume

Cubic Feet

Cubic Meters

 

0.02832

 

 

 

Cubic Inches

Cubic Centimeters

 

16.39

 

 

 

 

 

 

 

 

 

 

Tons (Short)

Metric Tons

 

0.9078

 

 

Weight

Pounds

Kilograms

 

0.4536

 

 

 

Ounces

Grams

 

28.3495

 

 

 

 

 

 

 

 

 

Pressure

Pounds/Sq. In.

Kilopascal

 

6.895

 

 

 

 

 

 

 

 

 

 

Foot-pounds

Newton-Meters

 

1.356

 

 

Work

Foot-pounds

Kilogram-Meters

 

0.1383

 

 

 

Inch-pounds

Kilogram-Centimeters

 

1.152144

 

 

 

 

 

 

 

 

 

Liquid Volume

Quarts

Liters

 

0.9463

 

 

Gallons

Liters

 

3.785

 

 

 

 

 

 

 

 

 

 

 

 

 

Liquid Flows

Gallons/Minute

Liters/Minute

 

3.785

 

 

 

 

 

 

 

 

 

Temperature

Fahrenheit

Celsius

1.

Subtract 32°

 

 

 

 

2.

Multiply by 5/9

 

 

 

 

 

 

 

 

 

 

 

 

2-6

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Hydro with Pistol Grip Controls

Models:

 

 

 

 

 

 

 

 

 

 

Model

 

Engine

 

Deck

 

 

 

 

 

 

30284

 

17 hp Kawasaki

 

 

36”

 

 

 

 

 

 

30286

 

17 hp Kawasaki

 

 

40”

 

2

 

 

 

 

 

 

 

 

 

30288

 

19 hp Kawasaki

 

 

48”

 

 

 

 

 

 

30289

 

19 hp Kawasaki

 

 

52”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30280

 

23 hp Kawasaki

 

 

60”

 

 

 

 

 

 

Engines:

 

 

 

 

 

 

 

 

 

 

 

 

Output (Max. @ 3600 RPM)

 

 

 

 

 

17 hp (12.7 kW)

 

19 hp (14.2 kW)

23 hp (17.2 kW)

 

 

 

Make

Kawasaki

 

Kawasaki

Kawasaki

 

 

 

Model

FH541V

 

FH580V

FH680V

 

 

 

Hi-Idle

3600 rpm

 

3600 rpm

3600 rpm

 

 

 

Starter

Electric

 

Electric

Electric

 

 

 

Oil Capacity

3.8 pint (1.8L)

 

3.8 pint (1.8L)

4.0 pint (1.9L)

 

 

 

Fuel System:

 

 

 

 

 

 

 

 

 

 

4.8 gallons (18 liters) fuel tank capacity

 

 

 

 

 

Traction Drives:

 

 

 

 

 

 

 

 

 

Traction Control:

 

 

Toro Pistol Grip Control System

 

 

Hydraulic Pump:

 

 

Two Hydro-Gear Model PG

 

 

Hydraulic Wheel Motor:

 

 

Two Parker TEO-195 / Model 30280: Parker TEO-230

 

 

Hydraulic Oil Filter:

 

 

10 Micron Automotive Spin-On Type

 

 

Hydraulic Fluid:

 

 

Synthetic, 15w50

 

 

Hydraulic Fluid Capacity:

 

 

2.1 quarts (1.9 liters)

 

 

Parking Brake:

 

 

Standard equipment

 

 

Ground Speed: (MPH/kmh)

 

 

Variable, 0 to 6.35 MPH (10kmh) Fwd / 0 to 2.5 (4kmh) Rev

 

 

Hourmeter with Service Indicator

Standard equipment

 

 

Floating Deck Mid-Size Service Manual

2-7

SPECIFICATIONS

Hydro with Pistol Grip Controls cont.

 

 

Wheels and Tires:

 

 

 

 

 

Front Castor Tires:

9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease fittings /

 

 

 

Model 30280: 11x4.0-5 smooth tread, semi-pneumatic with tapered roller bearings

 

 

Front Castor Fork:

Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs

2

 

 

have grease fitting for lubrication. Model 30280: 1” (2.5cm) diameter pivot shaft. The pivot

 

 

hubs have tapered roller bearings and access for lubrication.

 

 

Rear Traction Tires:

17 hp - 16x6.50-8, 4 ply with Turf Traction Tread

 

 

 

23 hp - 16x7.50-8, 4 ply with Turf Traction Tread

 

 

 

19 hp - 18x8.50-10, 4 ply with Turf Traction Tread

 

 

Mower Drive:

 

 

 

 

 

Mower Engagement:

 

Engine mounted electric clutch

 

 

Clutch Adjustment:

 

Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm)

 

 

PTO Drive Belt:

 

HB section with Aramid (Kevlar) cords and dry clutching envelope

 

 

PTO Idler:

 

Spring loaded pivot hub with grease fitting for lubrication / 36” deck includes additional

 

 

 

 

fixed idler.

 

 

Deck Drive Belt:

 

HA section with Aramid (Kevlar) cords and standard (non-clutching) envelope

 

 

Deck Drive Idler:

 

Spring loaded / 36” decks have non-greaseable pivot hub

 

 

 

 

40”, 48” and 52” have pivot hub with grease fitting for lubrication

 

 

Mower Decks:

 

 

 

 

 

HOC Range:

 

 

1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

 

 

Blades:

 

 

36” - two .250” (6.3mm) thick heat treated steel blades

 

 

 

 

 

40”, 48” and 52” - three .250” (6.3mm) thick heat treated steel blades

 

 

Spindles:

 

 

Machined steel 1.00” (25mm) diameter shaft

 

 

Spindle Housing:

 

 

Ductile cast iron 9-3/8” (24cm) diameter mounted with six bolts

 

 

Bearings:

 

 

Sealed ball bearings permanently lubricated with high temperature grease

 

 

Construction:

 

 

7 gauge (.179 inch (4.5mm)) steel welded construction.

 

 

Blade Tip Speed: (Domestic)

36” - 18,420 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

40” - 18,278 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

48” - 18,503 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

52” - 18,420 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

60” - 18,271 ft/m calculated @ 3600 engine rpm

 

 

Anti-Scalp Rollers:

 

 

36” - 2 front mounted

 

 

 

 

 

40” - 3 front mounted

 

 

 

 

 

48” - 3 front mounted (optional 2 rear mounted)

 

 

 

 

 

52” & 60” - 3 front mounted, 2 rear mounted

 

 

Skid Plate:

 

 

Standard

 

 

Adjustable Discharge Baffle:

Standard

 

 

Rubber Discharge Chute:

Standard

2-8

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Hydro with Pistol Grip Controls cont.

Unit Dimensions:

 

 

 

 

 

 

 

 

 

Width Deflector

Width Deflector

 

 

 

 

Model No.

Height*

Down

Raised

Length*

Weight**

 

 

30284

41.5” (105cm)

51.1” (130cm)

37.2” (94cm)

84.5” (214cm)

677 lbs. (302kg)

 

 

2

30286

41.5” (105cm)

55.5” (141cm)

41.6” (105cm)

81.3” (206cm)

677 lbs. (302kg)

 

30288

41.5” (105cm)

63.5” (161cm)

49.6” (126cm)

83.8” (213cm)

692 lbs. (314kg)

 

 

30289

41.5” (105cm)

67.6” (171cm)

53.7” (136cm)

83.8” (213cm)

731 lbs. (331kg)

 

 

30280

41.5” (105cm)

75.6” (192cm)

61.8” (157cm)

85.7” (217cm)

780 lbs. (354kg)

 

 

*With handle height in lowest position **Estimated operating weight

Floating Deck Mid-Size Service Manual

2-9

SPECIFICATIONS

Hydro with T-2 Controls

 

 

Models:

 

 

 

 

 

 

 

 

 

 

 

Model

Engine

 

Deck

 

 

 

 

 

 

30494

17 HP Kawasaki

 

36”

 

 

 

 

2

 

30496

17 HP Kawasaki

 

40”

 

 

 

 

 

 

 

 

 

 

 

 

 

30498

19 HP Kawasaki

 

48”

 

 

 

 

 

 

30499

19 HP Kawasaki

 

52”

 

 

 

 

 

 

 

Engines:

 

 

 

 

 

 

 

 

 

 

 

 

Output (Max. @ 3600 RPM)

 

 

 

 

 

 

17 HP (12.7 kW)

19 HP (14.2 kW)

 

 

 

 

 

Make

Kawasaki

Kawasaki

 

 

 

 

 

Model

FH541V

 

FH580V

 

 

 

 

 

Hi-Idle

3600 rpm

3600 rpm

 

 

 

 

 

Starter

Electric

 

Electric

 

 

 

 

 

Oil Capacity

3.8 pint (1.8L)

3.8 pint (1.8L)

 

 

 

 

 

Fuel System:

 

 

 

 

 

 

 

 

 

 

 

4.8 gallons (18 liters) fuel tank capacity

 

 

 

 

Traction Drives:

 

 

 

 

 

 

 

 

 

Traction Control:

 

 

Toro T2 Control System

 

 

 

Hydraulic Pump:

 

 

Two Hydro-Gear Model PG

 

 

 

Hydraulic Wheel Motor:

 

Two Parker TEO-195

 

 

 

Hydraulic Oil Filter:

 

 

10 micron automotive spin-on type

 

 

 

Hydraulic Fluid:

 

 

Synthetic, 15w50

 

 

 

Hydraulic Fluid Capacity:

 

2.1 quarts (1.9 liters)

 

 

 

Parking Brake:

 

 

Standard equipment

 

 

 

Ground Speed: (MPH/kmh)

 

Variable, 0 to 6.1 mph (9.8kmh) Fwd / 0 to 2.5 mph (4kmh) Rev

 

 

 

Hourmeter with Service Indicator

Standard equipment

 

 

 

Wheels and Tires:

 

 

 

 

 

 

 

 

 

Front Castors Tires:

 

9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease fittings

 

 

Front Castors Fork:

 

Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs

 

 

 

 

 

have grease fitting for lubrication.

 

 

Rear Traction Tires:

 

17 hp - 16x6.50-8, 4 ply with turf traction tread.

 

 

 

 

 

19 hp - 16x7.50-8, 4 ply with turf traction tread.

2-10

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Hydro with T-2 Controls cont.

Mower Drive:

 

 

 

 

 

 

 

 

 

 

 

Mower Engagement:

 

Engine mounted electric clutch

 

 

 

 

 

 

 

Clutch Adjustment:

 

Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm)

 

 

 

PTO Drive Belt:

 

HB section with Aramid (Kevlar) cords and dry clutching envelope

 

 

 

 

 

2

PTO Idler:

 

Spring loaded pivot hub with grease fitting for lubrication / 36” deck includes additional

 

 

 

 

fixed idler

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Deck Drive Belt:

 

HA section with Aramid (Kevlar) cords and standard (non-clutching) envelope

 

 

Deck Drive Idler:

 

Spring loaded / 36” decks have non-greaseable pivot hub

 

 

 

 

 

 

40”, 48” and 52” have pivot hub with grease fitting for lubrication

 

 

 

Mower Decks:

 

 

 

 

 

 

 

 

 

 

 

HOC Range:

 

 

1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

 

 

 

Blades:

 

 

36” - two .250” (6.3mm) thick heat treated steel blades

 

 

 

 

 

 

 

40”, 48” and 52” - three .250” (6.3mm) thick heat treated steel blades

 

 

Spindles:

 

 

Machined steel 1.00” (25mm) diameter shaft

 

 

 

 

 

Spindle Housing:

 

 

Ductile cast iron, 9-3/8” (24cm) diameter mounted with six bolts

 

 

 

Bearings:

 

 

Sealed ball bearings permanently lubricated with high temperature grease

 

 

Construction:

 

 

7 gauge (.179 inch (4.5mm)) steel welded construction

 

 

 

Blade Tip Speed: (Domestic)

36” - 18,420 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

 

 

40” - 18,278 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

 

 

48” - 18,503 ft/m calculated @ 3600 engine rpm

 

 

 

 

 

 

 

52” - 18,420 ft/m calculated @ 3600 engine rpm

 

 

 

Anti-Scalp Rollers:

 

 

36” - 2 front mounted

 

 

 

 

 

 

 

 

 

 

 

40” - 3 front mounted

 

 

 

 

 

 

 

 

 

 

 

48” - 3 front mounted (optional 2 rear mounted)

 

 

 

 

 

 

 

52” - 3 front mounted, 2 rear mounted

 

 

 

 

 

Skid Plate:

 

 

Standard

 

 

 

 

 

 

 

Adjustable Discharge Baffle:

Standard

 

 

 

 

 

 

 

Rubber Discharge Chute:

Standard

 

 

 

 

 

 

 

Unit Dimensions:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Width Deflector

Width Deflector

 

 

 

 

 

 

Model No.

 

 

Height

 

Down

Raised

 

Length

 

Weight*

 

 

30494

 

46” (117cm)

51.1” (130cm)

37.2” (94cm)

 

78.5” (199cm)

 

667 lbs. (302kg)

 

 

30496

 

46” (117cm)

55.5” (141cm)

41.6” (105cm)

 

75.3” (191cm)

 

667 lbs. (302kg)

 

 

30498

 

46” (117cm)

63.5” (161cm)

49.6” (126cm)

 

77.8” (198cm)

 

682 lbs. (309kg)

 

 

30499

 

46” (117cm)

67.6” (171cm)

53.7” (136cm)

 

77.8” (198cm)

 

721 lbs. (327kg)

 

 

* Estimated operating weight

Floating Deck Mid-Size Service Manual

2-11

SPECIFICATIONS

Gear with T-Bar Controls

 

 

Models:

 

 

 

 

 

 

 

 

 

 

Model

 

 

Engine

 

 

Deck

 

 

 

 

 

30092

 

 

15 hp Kawasaki

 

 

32”

 

 

 

 

 

30094

 

 

15 hp Kawasaki

 

 

36”

 

 

 

2

 

30096

 

 

15 hp Kawasaki

 

 

40”

 

 

 

 

 

30098

 

 

17 hp Kawasaki

 

 

48”

 

 

 

 

 

 

30099

 

 

17 hp Kawasaki

 

 

52”

 

 

 

 

 

Engines:

 

 

 

 

 

 

 

 

 

 

 

 

 

Output (Max. @ 3600 RPM)

 

 

 

 

 

 

15 HP (11.2 kW)

 

 

17 HP (12.7 kW)

 

 

 

Make

 

Kawasaki

 

 

Kawasaki

 

 

 

Model

 

FH430V

 

 

FH541V

 

 

 

Hi-Idle

 

3600 rpm

 

 

3600 rpm

 

 

 

 

 

 

3200 rpm (30092)

 

 

 

 

 

 

 

 

Starter

 

Recoil

 

 

Recoil

 

 

 

Oil Capacity

 

3.8 pint (1.8L)

 

 

3.8 pint (1.8L)

 

 

 

Fuel System:

 

 

 

 

 

 

 

 

 

 

4.8 gallons (18 liters) fuel tank capacity

 

 

 

Traction Drives:

 

 

 

 

 

 

 

 

Traction Control:

 

Toro T-Bar Control System

 

 

Transmission:

 

 

Peerless 700-070A, 5 speed forward / 1 reverse

 

 

Transmission Output Shaft:

 

Heavy-duty with 9 tooth spline

 

 

Axle:

 

 

1” (2.5cm) heavy-duty axle

 

 

Traction Drive Belt:

 

Two “A” section banded design

 

 

Wheel Hub Bearing:

 

Tapered roller bearings

 

 

Ground Speed: (mph/kmh)

 

(36” 40” 48” 52”) 1st - 2 mph (3.2kmh) / 2nd - 2.6 mph (4.1kmh) / 3rd - 3.4 mph

 

 

 

 

 

 

 

(5.4kmh) / 4th - 4.1 mph (6.5kmh) / 5th - 6.1 mph (9.8kmh) forward / 3 mph

 

 

 

 

 

 

 

(4.8kmh) reverse

 

 

 

 

 

 

 

(32”) 1st - 0.9 mph (1.4kmh) / 2nd - 2.1 mph (3.3kmh) / 3rd - 3.4 mph (5.4kmh) /

 

 

 

 

 

 

 

4th - 4.3 mph (6.9kmh) / 5th - 5 mph (8kmh) forward / 2.5 mph (4kmh) reverse

 

 

Parking Brake:

 

Two wheel band type standard

2-12

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

Gear with T-Bar Controls cont.

Wheels and Tires:

 

 

 

 

Front Castor Tires:

9x3.5-4, 4 ply smooth tread, semi-pneumatic with needle bearings and grease fittings

 

 

Front Castor Fork:

Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs

 

 

 

have grease fitting for lubrication.

 

 

 

2

Rear Traction Tires:

15 hp - 16x6.50-8, 4 ply with turf traction tread

 

 

17 hp - 16x6.50-8, 4 ply with turf traction tread

 

 

 

 

 

 

Mower Drive:

 

 

 

 

Mower Engagement:

Engine mounted electric clutch

 

 

Clutch Adjustment:

Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm)

 

 

PTO Drive Belt:

HB section with Aramid (Kevlar) cords and dry clutching envelope

 

 

PTO Idler:

Spring loaded pivot hub with grease fitting for lubrication / 36” deck includes additional

 

 

 

fixed idler

 

 

Deck Drive Belt:

HA section with Aramid (Kevlar) cords and standard (non-clutching) envelope

 

 

Deck Drive Idler:

Spring loaded / 36” decks have non-greaseable pivot hub

 

 

 

40”, 48” and 52” have pivot hub with grease fitting for lubrication

 

 

Mower Decks:

 

 

 

 

HOC Range:

 

(32”) 2” (5cm) to 5” (13cm) in 1/2” (1.27cm) increments

 

 

 

 

(36”, 40”, 48”, 52”) 1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

 

 

Blades:

 

32” - One .188” (4.7mm) thick heat treated steel blade

 

 

 

 

36” - Two .250” (6.3mm) thick heat treated steel blades

 

 

 

 

40”, 48” and 52” - Three .250” (6.3mm) thick heat treated steel blades

 

 

Spindles:

 

Machined steel 1.00” (25mm) diameter shaft

 

 

Spindle Housing:

 

Ductile cast iron 9-3/8” (24cm) diameter mounted with six bolts

 

 

Bearings:

 

Sealed ball bearings permanently lubricated with high temperature grease

 

 

Construction:

 

(32”) 12 gauge (.104” (2.77mm)) stamped steel

 

 

 

 

(36”, 40”, 48”, 52”) 7 gauge (.179” (4.5mm)) steel welded construction

 

 

Blade Tip Speed: (Domestic)

32” - 17,942 ft/m calculated @ 3300 engine rpm

 

 

 

 

36” - 18,420 ft/m calculated @ 3600 engine rpm

 

 

 

 

40” - 18,278 ft/m calculated @ 3600 engine rpm

 

 

 

 

48” - 18,503 ft/m calculated @ 3600 engine rpm

 

 

 

 

52” - 18,420 ft/m calculated @ 3600 engine rpm

 

 

Anti-Scalp Rollers:

 

32” - None

 

 

 

 

36” - 2 front mounted

 

 

 

 

40” - 3 front mounted

 

 

 

 

48” - 3 front mounted (optional 2 rear mounted)

 

 

 

 

52” - 3 front mounted, 2 rear mounted

 

 

Skid Plate:

 

(36”, 40”, 48”, 52”) Standard

 

 

Adjustable Discharge Baffle:

(36”, 40”, 48” ,52”) Standard

 

 

Rubber Discharge Chute:

(36”, 40”, 48”, 52”) Standard

 

 

Floating Deck Mid-Size Service Manual

2-13

SPECIFICATIONS

Gear with T-Bar Controls cont.

 

 

Unit Dimensions:

 

 

 

 

 

 

 

 

 

Width Deflector

Width Deflector

 

 

 

 

Model No.

Height*

Down

Raised

Length*

Weight**

 

 

30092

43.5” (110cm)

42” (107cm)

32” (81cm)

73” (185cm)

388 lbs. (176kg)

2

 

30094

41.2” (105cm)

51.1” (130cm)

37.2” (94cm)

82.7” (210cm)

588 lbs. (267kg)

 

30096

41.2” (105cm)

55.5” (141cm)

41.6” (106cm)

79.5” (202cm)

596 lbs. (270kg)

 

 

 

30098

41.2” (105cm)

63.5” (161cm)

49.6” (126cm)

82” (208cm)

649 lbs. (294kg)

 

 

30099

41.2” (105cm)

67.6” (172cm)

53.7” (136cm)

82” (208cm)

684 lbs. (310kg)

*With handle height in lowest position

**Estimated operating weight

2-14

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

International Hydro with T-Bar (T2) Controls

Models:

 

 

 

 

 

 

 

 

 

 

 

Model

 

Engine

 

Deck

 

 

 

 

 

30032 (CE)

 

15 hp Kawasaki

 

91cm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine:

 

 

 

 

 

 

 

 

 

 

2

 

 

Output (Max. @ 3600 rpm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15 HP (11.2 kW)

 

 

 

 

 

 

Make

 

Kawasaki

 

 

 

 

 

 

 

 

Model

 

FH430Y

 

 

 

 

 

 

 

 

 

Hi-Idle

 

2900 RPM

 

 

 

 

 

 

 

 

Starter

 

Recoil

 

 

 

 

 

 

 

 

 

Oil Capacity

 

3.8 Pint (1.8L)

 

 

 

 

 

 

 

 

Fuel System:

 

 

 

 

 

 

 

 

 

 

 

4.8 Gallons (18 liters) fuel tank capacity

 

 

 

 

Traction Drives:

 

 

 

 

 

 

 

 

 

 

 

Traction Control:

 

 

Toro “T2” Control System

 

 

 

Hydraulic Pump:

 

 

Two Hydro-Gear Model PG

 

 

 

Hydraulic Wheel Motor:

 

 

Two Parker TEO-195

 

 

 

Hydraulic Oil Filter:

 

 

10 micron automotive spin-on type

 

 

 

Hydraulic Fluid:

 

 

Synthetic, 15w50

 

 

 

Hydraulic Fluid Capacity:

 

2.1 quarts (1.9 liters)

 

 

 

Parking Brake:

 

 

 

 

Standard equipment

 

 

 

Ground Speed: (kmh)

 

 

Variable, 0 to 9.8kmh fwd / 0 to 4kmh rev

 

 

 

Hourmeter with Service Indicator

 

Standard equipment

 

 

 

Wheels and Tires:

 

 

 

 

 

 

 

 

 

Front Castors Tires:

 

9x3.5-4, 4 ply, smooth tread, semi-pneumatic with needle bearings and grease fittings

 

 

Front Castors Fork:

 

Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs

 

 

 

 

 

 

have grease fitting for lubrication.

 

 

Rear Traction Tires:

 

15 hp - 16x6.50-8, 4 ply with turf traction tread

 

 

Floating Deck Mid-Size Service Manual

2-15

SPECIFICATIONS

International Hydro with T-Bar (T2) Controls cont.

 

 

Mower Drive:

 

 

 

 

Mower Engagement:

Engine mounted electric clutch

 

 

Clutch Adjustment:

Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm)

 

 

PTO Drive Belt:

HB section with Aramid (Kevlar) cords and dry clutching envelope

2

 

PTO Idler:

Spring loaded pivot hub with grease fitting for lubrication / 91cm (36”) deck includes

 

 

additional fixed idler.

 

 

 

 

 

Deck Drive Belt:

HA section with Aramid (Kevlar) cords and standard (non-clutching) envelope

 

 

Deck Drive Idler:

Spring loaded / 91cm (36”) decks have non-greaseable pivot hub

 

 

Mower Decks:

 

 

 

 

HOC Range:

 

1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

 

 

Blades:

 

Two .250” (6.3mm) thick heat treated steel blades

 

 

Spindles:

 

Machined steel 1.00” (25mm) diameter shaft

 

 

Spindle Housing:

 

Ductile cast iron, 9-3/8” (24cm) diameter mounted with six bolts

 

 

Bearings:

 

Sealed ball bearings permanently lubricated with high temperature grease

 

 

Construction:

 

7 gauge (.179” (4.5mm)) steel welded construction

 

 

Blade Tip Speed:

 

21,070 ft/m calculated @ 2900 engine rpm

 

 

Anti-Scalp Rollers:

 

2 front mounted

 

 

Skid Plate:

 

Standard

 

 

Adjustable Discharge Baffle:

Standard

 

 

Rubber Discharge Chute:

Standard

Unit Dimensions:

 

 

Width Deflector

Width Deflector

 

 

Model No.

Height

Down

Raised

Length

Weight*

30032

46” (117cm)

51.1” (130cm)

37.2” (94cm)

78.5” (199cm)

667 lbs. (302kg)

*Estimated operating weight

2-16

Floating Deck Mid-Size Service Manual

SPECIFICATIONS

International Gear with T-Bar Controls

Models:

 

 

 

 

 

 

 

 

 

Model

 

Engine

 

Deck

 

 

 

 

30031 (CE)

 

15 hp Kawasaki

 

91cm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engines:

 

 

 

 

 

 

 

 

2

 

 

Output (Max. @ 2900 RPM)

 

 

 

 

 

 

 

 

 

 

 

 

 

15 HP (11.2 kW)

 

 

 

 

 

Make

 

Kawasaki

 

 

 

 

 

 

 

Model

 

FV430V

 

 

 

 

 

 

 

Hi-Idle

 

2900 RPM

 

 

 

 

 

 

 

Starter

 

Recoil

 

 

 

 

 

 

 

Oil Capacity

 

3.8 pints (1.8L)

 

 

 

 

 

 

 

Fuel System:

 

 

 

 

 

 

 

 

 

4.8 gallons (18 liters) fuel tank capacity

 

 

 

Traction Drives:

 

 

 

 

 

 

 

Traction Control:

 

Toro T-Bar Control System

 

 

Transmission:

 

 

Peerless 700-070A, 5 speed forward / 1 reverse

 

 

Transmission Output Shaft:

 

Heavy duty with 9 tooth spline

 

 

Axle:

 

 

1” heavy-duty axle

 

 

Traction Drive Belt:

 

Two “A” section banded design

 

 

Wheel Hub Bearing:

 

Tapered roller bearings

 

 

Ground Speed: (kmh)

 

1st - 3.2kmh / 2nd - 4.1kmh / 3rd - 5.4kmh / 4th - 6.5kmh / 5th - 9.8kmh fwd

 

 

 

 

 

 

4.8kmh rev

 

 

Parking Brake:

 

 

Two wheel band type standard

 

 

Wheels and Tires:

Front Castors Tires:

9x3.5-4, 4 ply, smooth tread, semi pneumatic with needle bearings and grease fittings

Front Castors Fork:

Heavy-duty commercial design with 1-1/8” (2.8cm) diameter pivot shaft. The pivot hubs

 

have grease fitting for lubrication.

Rear Traction Tires:

15 hp - 16x6.50-8, 4 ply with turf traction tread

Floating Deck Mid-Size Service Manual

2-17

SPECIFICATIONS

International Gear with T-Bar Controls cont.

 

 

Mower Drive:

 

 

 

 

Mower Engagement:

Engine mounted electric clutch

 

 

Clutch Adjustment:

Periodic air gap adjustment required - .018” + .003” (0.45 + 0.0762mm)

 

 

PTO Drive Belt:

HB section with Aramid (Kevlar) cords and dry clutching envelope

2

 

PTO Idler:

Spring loaded pivot hub with grease fitting for lubrication / 91cm deck includes additional

 

 

fixed idler

 

 

 

 

 

Deck Drive Belt:

HA section with Aramid (Kevlar) cords and standard (non-clutching) envelope

 

 

Deck Drive Idler:

Spring loaded / 91cm decks have non-greaseable pivot hub

 

 

Mower Decks:

 

 

 

 

HOC Range:

 

1” (2.5cm) to 4.50” (11cm) in 1/4” (0.6cm) increments

 

 

Blades:

 

Two .250” (6.3mm) thick heat treated steel blades

 

 

Spindles:

 

Machined steel 1.00” (2.5cm) diameter shaft

 

 

Spindle Housing:

 

Ductile cast iron, 9-3/8” (24cm) diameter mounted with six bolts

 

 

Bearings:

 

Sealed ball bearings permanently lubricated with high temperature grease

 

 

Construction:

 

7 gauge (.179” (4.5mm)) steel welded construction

 

 

Blade Tip Speed: (Domestic)

91cm - 12,070 ft/m calculated @ 2900 engine rpm

 

 

Anti-Scalp Rollers:

 

91cm - 2 front mounted

 

 

Skid Plate:

 

Standard

 

 

Adjustable Discharge Baffle:

Standard

 

 

Rubber Discharge Chute:

Standard

 

 

Rubber Discharge Chute:

Standard

Unit Dimensions:

 

 

Width Deflector

Width Deflector

 

 

Model No.

Height*

Down

Raised

Length*

Weight**

30031 (CE)

41.2” (105cm)

51.1” (130cm)

37.2” (94cm)

82.7” (210cm)

598 lbs. (271kg)

*With handle height in lowest position **Estimated operating weight

2-18

Floating Deck Mid-Size Service Manual

Toro 30031, 30032, 30033, 30069, 30074 Service Manual

CHASSIS

Electric Clutch Replacment

5.Unplug the clutch lead from the harness connector (Fig. 0002).

Electric Clutch Removal

1.

Park the machine on a level surface.

 

 

 

2.

Turn the engine off and remove the key.

 

 

 

3.

Set the parking brake.

 

 

 

4.

Move the negative battery terminal boot and dis-

 

 

 

 

connect the negative (black) battery cable from the

 

 

 

 

3

 

battery (Fig. 0001).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig 0002

PICT-0548a

6.Push the grommet and clutch plug through the frame to the underside of the machine (Fig. 0003).

Fig 0001

PICT-0250

Fig 0003

PICT-0277

Floating Deck Mid-Size Service Manual

3-1

Loading...
+ 436 hidden pages