Classic 60 Deck Service Kit 902415

Deck Service Kit for
All Classics with 60” Decks

Item Number 902415
This deck service kit is designed to refurbish the deck of your mower so it cuts like new. As with all
products, proper installation is the key to obtaining all of the benefits this kit is capable of delivering.
Please take a few minutes to read through the instructions to verify the parts in your kit with the parts
list below, and learn where and how they are used.
Be sure to take all applicable safety precautions during the installation of this kit.
Parts List
Part# Description Qty.
300441 Deck Hub Assembly 2
300442 Deck Hub Assembly, Long 1
2006B130R V-Belt, 130” B Section, Raw Edge 1
30227-60X 60X Style Blade 3
67240 Short Deck Roller 2
30240-O Long Deck Roller 2
N-156 5/8”-11 Nyloc Jam Nut 4
B-255 5/8”-11x9” Carriage Bolt 2
B-278 5/8”-11x5” Carriage Bolt 2
B-136 3/8”-16x1-1/4” Carriage Bolt 12
N-108 3/8”-16 Flange Nut 12
B-121-L 5/8”-18x3” Hex Head Bolt 3
W-100 5/8” Belleville Washer 3
W-101 5/8” Fiber Washer 3
W-135 5/8” Flat Washer 2
W-182 1/4” Blade Spacer 3
30242 1/2” Blade Spacer 3
Tools Needed:
• (2) 3/4” Wrenches • Torque Wrench
• 9/16” Wrench • Blade Removal Tool
• 15/16” Wrench • Anti-seize Compound
• 1-7/8” Wrench • Putty Knife or Scraper
Disassembly
1) Park the mower on solid level ground, set the parking brake, remove the key from the ignition,
and disconnect the negative battery cable.
2) Starting at the rear of the mower, disconnect the engine to deck belt. This can easily be done
by draping a rag over the side of the belt just forward of the clutch, and pulling the rag downward
while moving around the clutch.
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3) Remove the deck from the mower. The decks on Classics are FIGURE 1
attached to the mower with a stud at the end of the deck lift chain
with 1/2” flange nuts above and below the deck hanger flange. To
remove the deck, first lower the deck to its lowest possible position.
The deck rollers should be contacting the ground. Next use (2) 3/4” REMOVE
THIS NUT
wrenches, one on each flange nut, and remove the lower flange nut
from the deck hanger stud. See Figure 1. Once all four 1/2” flange
nuts have been removed, the studs should easily pull free from the
deck hanger tabs.
4) Next, remove the (4) hairpin cotter pins from the deck stabiliz-
ers, located on the front and rear of the deck. See Figures 2 & 3. Af-
ter the pins have been removed, move the stabilizer brackets upward
and remove the deck from under the mower. DECK HANGER
5) Using the 9/16” wrench, remove the 3/8” nuts from the pul- STUD
ley guards and set the guards aside. Use a brush, vacuum, or com-
pressed air to remove any build-up or debris from the top side
of the deck. FIGURE 2
6) NOTE the routing of the deck belt and then remove
the deck belt from the pulleys using the same method in Step
1. Inspect each pulley for damage or excessive wear and re- DECK STABILIZER
place if necessary. ROD
7) Secure one of the blades with a blade removal tool.
Using the 1-7/8” wrench, remove the 1” jam nut which secures
the pulley to the spindle shaft. Now remove the pulley, or HAIRPIN
pulleys, fan, washers, and bushing from the shaft. NOTE the COTTER PIN
order in which the washers, pulleys, and bushings were
installed. Keep these components, except for the 1” jam nut,
for use later. Repeat with the remaining spindles. NOTE: If an
impact wrench is used, a blade removal tool will not be FIGURE 3
necessary.
8) CAUTION: After the 1” jam nut, pulleys, and fans
have been removed, the spindle shaft with the blade,
spacer, and washers will drop away from the deck hub.
Do this slowly so the order of spacers and washers can be
noted. NOTE the size of the spacer used on each blade.
This hardware can be discarded as new hardware has been
provided in this kit. We recommend discarding the blades if HAIRPIN
there are any large dings, nicks, or cracks on any portion of COTTER PIN
the blade.
9) Next, using a 9/16” wrench, remove the 3/8” flange
nuts from the carriage bolts which secure each deck hub to the deck, then remove the deck hub as-
semblies. Both the hardware and deck hubs can be discarded.
10) Using a putty knife or metal paint scraper, clean the underside of the deck by removing any
build-up of grass clippings or other debris.
11) Remove the 5/8” flange nuts from carriage bolts that secure the rollers to the deck using a
15/16” wrench. Discard the hardware and rollers.
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Installation FIGURE 3
12) Using a 15/16” wrench, install the new roll-

ers with the new 5/8” jam nuts and carriage bolts.
NOTE: The short rollers (67240) install with
a 5/8” flat washer between the roller and the
inside mounting flange.
13) Install the new deck hub assemblies onto
the deck using the 3/8”-16 x 1-1/4” carriage bolts
and 3/8” flange nuts.
14) Remove the 1” jam nut from the spindle
shaft but do not allow it to fall out of the hub. Place
the bushing, pulley(s), washers, and fan onto the
spindle shaft in the same order in which they we
removed in Step 7. Secure these components in
place with the 1” jam nut installed onto the spindle
shaft. See Figure 4 for the hub assemblies.
15) Install the new blades onto the hub assem-
blies using the new hardware. Place one of the
W-100 (Belleville washers) onto the B-121-L (5/8”
bolt), then insert the bolt into the hole in the blade. # Description Part Number
NOTE: Make sure the swept portion of the 1 Blade Bolt B-121-L
blade will face the deck. Next, place the W-101
2 Belleville Washer W-100
(fiber washer) onto the bolt, followed by the W-182
3 Spacer W-182 (1/4”)
(1/4” spacer) or the 30242 (1/2” spacer), which
ever size was removed in Step 8. Apply some 4 X-Blade 30227-60X
anti-seize compound to the threads of the bolt, 5 Fiber Washer W-101
then install the blade/bolt assembly into the hub. 6 Hub Assembly 300441
To tighten, place a 1-7/8” wrench on the 1” jam nut 6B Center Hub Assembly, 300442
on top of the spindle, and a 15/16” wrench on the Long
blade bolt and torque to 154 ft./lbs. Repeat with 7 Bushing (Part of 6, 6B)
the remaining blades.
8 1/8” Thick Washer (Part of 6, 6B)
16) Install the new deck belt onto the pulleys
following the same routing as the belt that was re- 9 1/4” Thick Washer (Part of 6, 6B)
moved. Refer to the belt routing decal on the deck. 10 5.25” Pulley 9907525X100S
Once the belt is started on the last pulley, turn the 11 Fan 300058
pulley while moving the belt and the belt will drop
12 1” x 2”Belleville Washer W-137
into position.
17) Reinstall the pulley guards that were re- 13 1”-14 Jam Nut N-167
moved in Step 4. 14 Top-Center Pulley 9907750X100S
18) Position the deck under the mower and 15 Spindle Hub Cap 67255
install the stabilizers onto the stabilizer pins and
reinstall the hairpin cotter pins. Insert the hanger studs into the holes in the hanger tabs on the deck
and secure in place with the 1/2” flange nuts on the bottom of the deck hanger tab. Tighten with (2)
3/4” wrenches.
19) Finally, reinstall the engine-to-deck belt.
20) Ensure all hardware it tightened, that the belts are not twisted, and that nothing is touching the
belts.
21) Reconnect the negative battery cable.
You Dixie Chopper is now ready to cut like new!
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Classic 60 Deck Service Kit 902415

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Deck Service Kit for

All Classics with 60” Decks

12) Using a 15/16” wrench, install the new roll-

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