Toro TurfMaster HDX 22215 Service Manual
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Toro TurfMaster HDX 22215 Service Manual

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Form No. 3432-730 Rev A
30 Inch TurfMaster® HDX WPM
Published June 2020
© 2019—The Toro® Company
Original Instructions (EN)
8111 Lyndale Avenue South
Contact us at www.Toro.com.
Bloomington, MN 55420
All Rights Reserved
CV

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Summary of Contents for Toro TurfMaster HDX 22215

  • Page 1 Form No. 3432-730 Rev A 30 Inch TurfMaster® HDX WPM Published June 2020 © 2019—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision History Page 2 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. 30 Inch TurfMaster® HDX WPM Page 3 Preface...
  • Page 4 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S. components) that may have been removed •...
  • Page 5 Table of Contents Preface ........................ 3 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–3 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Chapter 4: Engine ................... 4–1 General Information ..................
  • Page 6 Preface Page 6 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 30 Inch TurfMaster® HDX WPM Page 1–1 Safety 3432-730 Rev A...
  • Page 8 Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.
  • Page 9 Think Safety First (continued) 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…...
  • Page 10 Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish.
  • Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–3 Equivalents and Conversions......................2–8 U.S. to Metric Conversions ........................ 2–9 30 Inch TurfMaster® HDX WPM Page 2–1 Specifications and Maintenance 3432-730 Rev A...
  • Page 12 Specifications Model 22207 22215 22225 Engine Kawasaki Kohler Engine Oil Capacity 24 oz (0.70 L) with and without 22 oz (0.65 L) without filter, 29 oz (0.85 L) with filter filter Engine Oil SAE 30 or SAE 10W-30/API SJ or higher Fuel Tank 1 gallon Cut Width...
  • Page 13 Torque Specifications The 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.
  • Page 14 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–4 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 15 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 5, & 8 Studes & Sems with Studs & Sems with Regular Studs &...
  • Page 16 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Height Nuts (Class 10 or stronger Nuts) in-lb N •...
  • Page 17 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 1/2 - 13 UNC 75 ±...
  • Page 18 Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 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...
  • Page 19 U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Area Square Inches...
  • Page 20 Specifications and Maintenance: Torque Specifications Page 2–10 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 21 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 30 Inch TurfMaster® HDX WPM Page 3–1 Troubleshooting 3432-730 Rev A...
  • Page 22 GEARS The Systematic approach to defining, diagnosing and solving problems. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
  • Page 23 General Troubleshooting Problem Possible Cause Corrective Action Bent, crooked handle frame Shipping damage, improper securing Replace damaged components. while transporting Cracked or broken frame Damage from improper securing while Replace the frame. transporting the unit. Vibration from the bent crank, damaged Replace the frame.
  • Page 24 Troubleshooting: General Troubleshooting Page 3–4 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...

  • Page 25: Table Of Contents

    Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Engine Replacement.......................... 4–5 Fuel Tank Replacement ........................4–13 Throttle Control Replacement ......................4–17 30 Inch TurfMaster® HDX WPM Page 4–1 Engine 3432-730 Rev A...

  • Page 26: General Information

    General Information This unit comes with 2 different engines, model 22215 with Kawasaki FJ180V and model 22225 with Kohler CV200. These are lubricated engines with a spin on filter and use a fuel tank that is separate from the engine assembly. Engine: General Information Page 4–2 30 Inch TurfMaster®...

  • Page 27: Service And Repairs

    Service and Repairs Engine Assembly 1 g299318 Figure 3 Fuel Cap Fuel Hose Fuel Tank Throttle Mount Bracket Canister Vent Hose Control Wire Kawasaki Engine Throttle Control Tank Mount BBC Belt Fuel Hose Engine Pulley Fuel Valve Transmission Belt Fuel Filter Belt Guide Rod 30 Inch TurfMaster®...
  • Page 28 Engine Assembly 2 g299335 Figure 4 Link Wire Fuel Cap Canister Vent Hose Throttle Bracket Fuel Tank Oil Drain Hose Tank Mount Asm. BBC Belt Kohler Engine Engine Pulley Fuel Hose Transmission Belt Fuel Valve Belt Guide Rod Throttle Control Engine: Service and Repairs Page 4–4 30 Inch TurfMaster®...

  • Page 29: Engine Replacement

    Engine Replacement Engine Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3.
  • Page 30 Engine Removal (continued) 7. Rotate the belt tensioner arm by turning the 7/16 inch nut on the bottom side of the transmission clockwise. g302330 Figure 7 8. Remove the belt tension by aligning the idler pulley with the access hole on the bottom side of the transmission.
  • Page 31 Engine Removal (continued) g302331 Figure 9 10. Remove the belt from the rear of the mower. g296178 Figure 10 11. Remove the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Remove the belt guide. 30 Inch TurfMaster®...
  • Page 32 Engine Removal (continued) g296179 Figure 11 12. Loosen the ½ inch nylock nut from BBC idler arm pivot until flush with bottom bolt. Secure the topside of the bolt with a ½ inch wrench. Note: Access bottom bolt through the bottom of the deck, see image. g296180 Figure 12 13.
  • Page 33 Engine Removal (continued) g302385 Figure 13 14. Remove the BBC belt from the pulley. g296181 Figure 14 15. Remove the BBC belt from rear of mower. 16. Remove the 3 (1/2 inch) bolts securing the engine to the frame. Note: To remove the front bolt, go through the access hole in the deck with a 10 inch (3/8 inch) drive extension and a ½...
  • Page 34 Engine Installation (continued) Note: To install the front bolt, go through the access hole in the deck with a 10 inch (3/8 inch) drive extension and a ½ inch socket with a universal joint. 3. Install the BBC belt through the rear of the mower. 4.
  • Page 35 Engine Installation (continued) g305213 Figure 17 8. Install the belt guide. Install the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Torque screws to 110 ± 11 in-lbs. (12 ± 2 Nm). g296179 Figure 18 9.
  • Page 36 Engine Installation (continued) g302331 Figure 19 11. Install the transmission belt to the transmission pulley. 12. Using a 7/16 inch nut on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing idler arm to put tension on the belt.

  • Page 37: Fuel Tank Replacement

    Engine Installation (continued) g296174 Figure 21 15. Lower the rear cover. 16. Using an appropriate lifting device, lower the rear of the machine to the ground. Fuel Tank Replacement Fuel Tank Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop.
  • Page 38 Fuel Tank Removal (continued) g296195 Figure 22 6. Remove the 2 (1/4–10 inch) screws mounting the tank to the fuel tank bracket. 7. Lift fuel tank away from the machine. g296196 Figure 23 8. Remove the 3 (M6x1) screws on the Kawasaki engine securing securing the fuel tank mounting bracket to the engine assembly.
  • Page 39 Fuel Tank Removal (continued) g296197 Figure 24 9. Remove the fuel tank mounting from the engine. Fuel Tank Inspection Shake or tap the fuel tank to listen for audible rattle of the check ball in the tank vent. Fuel Tank Installation 1.
  • Page 40 Fuel Tank Installation (continued) g296197 Figure 25 3. Install the fuel tank onto the machine. g296196 Figure 26 4. Install the 2 (1/4–20 inch) taptite screws mounting the tank to the fuel tank bracket. Torque screws to 33 ± 3 in-lbs. (4 ± 1 Nm). 5.

  • Page 41: Throttle Control Replacement

    Fuel Tank Installation (continued) g296195 Figure 27 Throttle Control Replacement Throttle Control Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2.
  • Page 42 Throttle Control Removal (continued) 4. Tip the rear of the control upwards then out slightly to remove the throttle control from the engine. Note: Kawasaki engine shown. g296939 Figure 29 Throttle Control Adjustment Full forward should adjust the full throttle detent that does not apply choke. Move forward for choke to engage the choke linkage.
  • Page 43 Throttle Control Installation (continued) Note: Kawasaki engine shown. g296939 Figure 31 2. Tighten the 2 (1/4–20 inch) screws securing the throttle control to the engine shroud. Torque bolts to 55 ± 5 in-lbs. (6 ± 1 Nm). Note: Kawasaki engine shown. Kohler has different mounting locations. g296938 Figure 32 30 Inch TurfMaster®...
  • Page 44 Engine: Service and Repairs Page 4–20 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 45 Chapter 5 Controls Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 BBC Bail Replacement........................5–4 BBC Cable Replacement ........................5–6 Traction Bail Replacement ....................... 5–11 Traction Cable Replacement......................5–12 Brake Cable Replacement ....................... 5–37 Parking Brake Lever Assembly Replacement .................. 5–41 Handle Replacement ........................

  • Page 46: General Information

    General Information Controls for this unit are Blade Brake Clutch (BBC) bail, traction bail and park brake. All controls are operated by cables. All cables should be routed, not kinked or put in a bind. BBC cable is adjusted on the idler arm and the anchor point is on the frame.

  • Page 47: Service And Repairs

    Service and Repairs Controls Assembly 1 g299363 Figure 33 Parking Brake Cable Curved Washer Brake Lever Brake Lever Mount Stepped Washer BBC Lever Spring Brake Actuation Link Stepped Bushing Coated BBC Bail BBC Lever Traction Cable Handle Coated Traction Bail BBC Cable Cable Anchor Handle Support...

  • Page 48: Bbc Bail Replacement

    BBC Bail Replacement BBC Bail Removal 1. Park the machine on a level surface. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3. Loosen the 1/4–20 inch nylock nut to carriage bolt. Pull the cable housing towards the bail to release tension on the cable.

  • Page 49: Bbc Bail Removal

    BBC Bail Removal (continued) g296943 Figure 36 BBC Bail Installation 1. Install the BBC bail onto the handle assembly. g296943 Figure 37 2. Install the cable. Install the 1/4–20 shoulder bolt and nut securing the cable to the BBC bail. Torque bolt and nut to 75 ± 5 in-lbs. (8 ± 1 Nm). 30 Inch TurfMaster®...

  • Page 50: Bbc Cable Replacement

    BBC Bail Installation (continued) g302395 Figure 38 3. Tighten the 1/4–20 inch nylock nut to carriage bolt securing the cable guide clamp to the handle. Adjust the housing cable so that there is no slack in the cable. Torque nut to carriage bolt to 40 ± 7 in-lbs. (4 ± 1 Nm). g296942 Figure 39 BBC Cable Replacement...

  • Page 51: Loosen The 1/4-20 Inch Nylock Nut To Carriage Bolt. Pull The Cable Housing Towards The Bail To Release Tension On The Cable

    BBC Cable Removal (continued) 4. Loosen the 1/4–20 inch nylock nut to carriage bolt. Pull the cable housing towards the bail to release tension on the cable. g296942 Figure 40 5. Remove the 1/4–20 inch bolt and nut securing the cable to the BBC bail. Remove the cable.

  • Page 52: Figure 42

    BBC Cable Removal (continued) g302425 Figure 42 8. Remove the cable from the main frame. 9. Unhook the spring from the BBC brake arm. g305213 Figure 43 BBC Cable Installation 1. Install the cable spring to the BBC brake arm. Controls: Service and Repairs Page 5–8 30 Inch TurfMaster®...
  • Page 53 BBC Cable Installation (continued) g305213 Figure 44 2. Loosely install the 1/4–20 inch screw securing the cable to the main frame. 3. Install the cable. Install the 1/4–20 inch shoulder bolt and nut securing the cable to the BBC bail. Torque bolt and nut to 75 ± 5 in-lbs. (8 ± 1 Nm). g302395 Figure 45 4.
  • Page 54 BBC Cable Installation (continued) g296942 Figure 46 5. Install zip ties securing the cable to the handle assembly. 6. Install the cable to the main frame. 7. Install the 1/4–20 inch taptite screw securing the cable clamp to the main frame.

  • Page 55: Traction Bail Replacement

    Traction Bail Replacement Traction Bail Removal 1. Park the machine on a level surface. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3. Remove the 1/4–20 shoulder bolt and nut securing the cable to the traction bail.

  • Page 56: Traction Cable Replacement

    Traction Bail Installation (continued) g302451 Figure 50 2. Install the cable. Install the shoulder bolt and nut securing the cable to the traction bail. Torque shoulder bolt and nut to 75 ± 5 in-lbs. (8 ± 1 Nm). g302449 Figure 51 Traction Cable Replacement Traction Cable Removal 1.
  • Page 57 Traction Cable Removal (continued) g296174 Figure 52 6. Remove the 4 (1/4–20 inch) taptite screws securing the front belt cover to the frame. g296175 Figure 53 7. Remove the 1/4–20 inch shoulder bolt and nut securing the cable to the traction bail.
  • Page 58 Traction Cable Removal (continued) g302449 Figure 54 8. Open the clamp, remove the cable from the clamp lock. g302450 Figure 55 9. Rotate the belt tensioner arm clockwise from the bottom side of the transmission. Controls: Service and Repairs Page 5–14 30 Inch TurfMaster®...
  • Page 59 Traction Cable Removal (continued) g302330 Figure 56 10. To remove belt tension, align the idler pulley with the access hole on the bottom side of the transmission. Insert a quarter inch screw driver. Note: Screw driver needs to fit through access hole and the idler pulley slot securing the pulley into position.
  • Page 60 Traction Cable Removal (continued) g302331 Figure 58 12. Remove the belt from the rear of the mower. g296178 Figure 59 13. Using an appropriate lifting device, raise the rear of the machine off the ground. 14. Set the rear height-of-cut to 5 inch. 15.
  • Page 61 Traction Cable Removal (continued) g297057 Figure 60 17. Remove the mulch plug from the rear discharge. 18. Remove the 5/16–18 inch nut on carriage bolt securing the spring bracket to the frame. g297058 Figure 61 19. Using snap ring pillars, remove the snap ring retaining the pinion gear from axle shaft.
  • Page 62 Traction Cable Removal (continued) g297059 Figure 62 20. Remove the 5/16–18 inch bolt securing the axle bearing housing to the axle height-of-cut plate. g297060 Figure 63 21. While holding up the spring loaded height-of-cut handle, apply pressure to the back of the axle bearing housing assembly, separating from axle weldment. Controls: Service and Repairs Page 5–18 30 Inch TurfMaster®...
  • Page 63 Traction Cable Removal (continued) g297061 Figure 64 22. Remove the 1–4–20 taptite screw securing the transmission cable guide mounting bolt to the frame. g297062 Figure 65 23. Remove the 1/4–20 inch bolt securing the parking brake to the transmission. 30 Inch TurfMaster® HDX WPM Page 5–19 Controls: Service and Repairs 3432-730 Rev A...
  • Page 64 Traction Cable Removal (continued) g297064 Figure 66 24. Move the parking brake caliper out of the way and secure. 25. Remove the 2 Phillip head screws from the trailing shield to the main frame. g297065 Figure 67 26. Remove the 5/16–18 inch nut to carriage bolt on the LH side. Remove the RH 5/16–18 inch taptite screw to main frame securing the transmission assembly to the main housing.
  • Page 65 Traction Cable Removal (continued) g297066 Figure 68 Side g297531 Figure 69 Vertical 27. Slide transmission to the right. Line up RH side height-of-cut notch with bolt. 30 Inch TurfMaster® HDX WPM Page 5–21 Controls: Service and Repairs 3432-730 Rev A...
  • Page 66 Traction Cable Removal (continued) g297894 Figure 70 28. Remove the height-of-cut weldment from the chassis. Slide the LH side of the height-of-cut weldment first before the RH side. g297895 Figure 71 29. Center the transmission. Pinch the traction cable towards the transmission and rotate the front transmission and cable downward.
  • Page 67 Traction Cable Removal (continued) g297896 Figure 72 30. To remove the transmission from the frame, rotate the transmission upside down and slide the transmission to the right. Remove the transmission from the frame with the traction cable attached. g298181 Figure 73 31.
  • Page 68 Traction Cable Removal (continued) g298182 Figure 74 32. Using needle a nose plier, squeeze the cable anchor and remove cable anchor from the cable mount. g298183 Figure 75 33. Pull the cable and remove from the cable anchor mount. Controls: Service and Repairs Page 5–24 30 Inch TurfMaster®...
  • Page 69 Traction Cable Removal (continued) g298184 Figure 76 34. Remove the spring hook from the transmission clutch lever. g298185 Figure 77 35. Cable should now be free from the chassis. Traction Cable Installation 1. Install the spring hook to the transmission clutch lever. 30 Inch TurfMaster®...
  • Page 70 Traction Cable Installation (continued) g298185 Figure 78 2. Install the cable to the cable anchor mount. g298184 Figure 79 3. Install the cable anchor to the cable mount. Controls: Service and Repairs Page 5–26 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 71 Traction Cable Installation (continued) g298183 Figure 80 4. Install the height-of-cut spring to the RH side axle shaft. g298182 Figure 81 5. Install the transmission to the frame with the traction cable attached. 30 Inch TurfMaster® HDX WPM Page 5–27 Controls: Service and Repairs 3432-730 Rev A...
  • Page 72 Traction Cable Installation (continued) g298181 Figure 82 6. Rotate the front transmission and cable upward. Pinch the traction cable towards the transmission. Note: Cable should lay on top of the deck and not be pinched between the transmission and deck housing. g297896 Figure 83 7.
  • Page 73 Traction Cable Installation (continued) g297895 Figure 84 8. Line up the RH side height-of-cut notch with bolt. Slide the transmission to the left. g297894 Figure 85 9. Put anti-seize inside the axle bearing before sliding over the shaft. Install the axle bearing housing assembly over the axle.
  • Page 74 Traction Cable Installation (continued) g297061 Figure 86 10. Install the LH 5/16–18 inch nut to carriage bolt and the RH 1/2 inch taptite screw to the main frame securing the transmission assembly to the main housing. Torque nut to Hcarriage bolt to 140 ± 5 in-lbs. (16 ± 0.5 Nm). g297531 Figure 87 11.
  • Page 75 Traction Cable Installation (continued) g297065 Figure 88 12. Install the 3/8 inch bolt securing the parking brake to the transmission. Torque bolt to 85 ± 15 in-lbs. (9 ± 2 Nm). g297064 Figure 89 13. Install the 1/4–20 taptite screw securing the transmission cable guard to the frame.
  • Page 76 Traction Cable Installation (continued) g297062 Figure 90 14. Install the 5/16–18 inch bolt securing the axle bearing housing to the axle height-of-cut plate. Torque bolt to 160 ± 16 in-lbs. (18 ± 2 Nm). 15. Using snap ring pillars, install the snap ring retaining the pinion gear to axle shaft.
  • Page 77 Traction Cable Installation (continued) g297058 Figure 92 17. Install the mulch plug to the rear discharge. 18. Install the T-30 screw securing the dust cover to the axle assembly. Torque screw to 55 ± 5 in-lbs. (6 ± 1 Nm). g297057 Figure 93 19.
  • Page 78 Traction Cable Installation (continued) g296178 Figure 94 21. Install the transmission belt to the engine pulley. Note: Access belt from the front of the mower. g302331 Figure 95 22. Install the transmission belt to the transmission pulley. 23. Using a 7/16 inch nut on the bottom of the transmission, release pressure on the quarter inch screw driver.
  • Page 79 Traction Cable Installation (continued) g302449 Figure 96 25. Tighten the 1/4–20 inch nylock nut to carriage bolt securing the cable guide clamp to the handle. Adjust the housing cable so there is no slack in the cable. Torque nut to carriage bolt to 40 ± 7 in-lbs. (4 ± 1 Nm). g296942 Figure 97 30 Inch TurfMaster®...
  • Page 80 Traction Cable Installation (continued) 26. Install the 4 (1/4–20 inch) taptite screws securing the belt cover to the frame. Torque bolts to 110 ± 11 in-lbs. (12 ± 2 Nm). g296175 Figure 98 27. Install the 1/4–20 inch taptite screw securing the frame cover to the frame. Torque bolt to 110 ±...

  • Page 81: Brake Cable Replacement

    Brake Cable Replacement Brake Cable Removal 1. Park the machine on a level surface. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3. Cut the zip tie. 4.
  • Page 82 Brake Cable Removal (continued) g297062 Figure 102 7. Remove the 3/8 inch bolt securing the parking brake to the transmission. g297064 Figure 103 8. Remove the brake caliper from the frame. 9. Remove the 5 mm Allen head bolt securing the cable to the caliper. Controls: Service and Repairs Page 5–38 30 Inch TurfMaster®...
  • Page 83 Brake Cable Removal (continued) g302936 Figure 104 10. Remove the brake cable up through the main frame access hole. Brake Cable Installation 1. Thread brake cable through the main frame access hole. 2. Set cable length to 7–1/8 inch from cable clamp to end cable. Install the 5 mm Allen head bolt securing the cable to the caliper.
  • Page 84 Brake Cable Installation (continued) 5. Install the 1/4–20 taptite screw securing the transmission cable guide to the frame. g297062 Figure 106 6. Install the 1/4–20 inch shoulder bolt and 1/4–20 inch nylock nut securing the cable to the parking brake lever. Torque bolt and nut to 75 ± 5 in-lbs. (8 ±...

  • Page 85: Parking Brake Lever Assembly Replacement

    Brake Cable Installation (continued) g298346 Figure 108 8. Install zip ties securing the cable to the handle assembly. Parking Brake Lever Assembly Replacement Parking Brake Lever Assembly Removal 1. Park the machine on a level surface. Stop the engine and wait for all moving parts to stop.
  • Page 86 Parking Brake Lever Assembly Removal (continued) g298359 Figure 110 5. Remove the parking brake assembly from the handle. g298360 Figure 111 Parking Brake Lever Assembly Installation 1. Install the parking brake assembly to the handle. 2. Install the 5/16–18 inch bolt/nut to carriage bolt securing the parking brake assembly to the handle.

  • Page 87: Handle Replacement

    Parking Brake Lever Assembly Installation (continued) g298359 Figure 112 3. Install the 1/4–20 inch nylock nut to 1/4–20 carriage bolt securing the parking brake assembly to the handle. Torque nut to carriage bolt to 40 ± 7 in-lbs. (4 ± 1 Nm). g298358 Figure 113 Handle Replacement...
  • Page 88 Handle Removal (continued) 4. Loosen the 1/4–20 inch nylock nut to 1/4–20 inch carriage bolt securing the brake cable to the bracket. g298346 Figure 114 5. Remove the carriage bolt and 1/4–20 inch nut securing the cable to the parking brake lever. g298347 Figure 115 6.
  • Page 89 Handle Removal (continued) g298358 Figure 116 7. Remove the 5/16–18 inch nylock nut to 5/16–18 carriage bolt securing the parking brake assembly to the handle. g298359 Figure 117 8. Remove the parking brake assembly from the handle. 30 Inch TurfMaster® HDX WPM Page 5–45 Controls: Service and Repairs 3432-730 Rev A...
  • Page 90 Handle Removal (continued) g298360 Figure 118 9. Remove the 1/4–20 inch nylock nut to carriage bolt. Pull cable housing towards bail to gain slack in cable to release cable tension. Remove the cable clamp assembly from the handle. g298489 Figure 119 10.
  • Page 91 Handle Removal (continued) g302395 Figure 120 11. Remove BBC bail by pushing inward on one side and lifting away from the handle assembly. g296943 Figure 121 12. Remove traction bail by pushing inward on one side and lifting away from the handle assembly.
  • Page 92 Handle Removal (continued) g298491 Figure 122 14. Remove handle assembly from the machine. g298492 Figure 123 Handle Installation 1. Install the handle assembly to the machine. 2. Install the 5/16–18 inch bolt/nuts to carriage bolt and 4 (2 per side) bolts with captured nuts.
  • Page 93 Handle Installation (continued) g298491 Figure 124 3. Install the traction bail to the handle assembly. g302451 Figure 125 4. Install the cable. Install the bolt and nut securing the cable to the traction bail. Torque shoulder bolt and nut to 75 ± 5 in-lbs. (9 ± 1 Nm). 30 Inch TurfMaster®...
  • Page 94 Handle Installation (continued) g298490 Figure 126 5. Install the BBC bail onto the handle assembly. 6. Install the cable. Install the 1/4–20 inch shoulder bolt and nut securing the cable to the BBC bail. Torque bolt and nut to 75 ± 5 in-lbs. (9 ± 1 Nm). g302395 Figure 127 7.
  • Page 95 Handle Installation (continued) g298489 Figure 128 8. Install zip ties securing the cable to the handle assembly. 9. Install the parking brake assembly to the handle. 10. Install the 5/16–18 inch bolt/nut to carriage bolt securing the parking brake assembly to the handle. Torque bolt/nut to 80 ± 10 in-lbs. (9 ± 1 Nm). g298359 Figure 129 11.
  • Page 96 Handle Installation (continued) g298358 Figure 130 12. Install the 1/4–20 inch shoulder bolt and 1/4–20 inch nylock nut securing the cable to the parking brake lever. Torque bolt and nut to 75 ± 5 in-lbs. (8 ± 1 Nm). g298347 Figure 131 13.
  • Page 97 Handle Installation (continued) g298346 Figure 132 14. Install zip ties securing the cable to the handle assembly. 30 Inch TurfMaster® HDX WPM Page 5–53 Controls: Service and Repairs 3432-730 Rev A...
  • Page 98 Controls: Service and Repairs Page 5–54 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 99 Chapter 6 Belts Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 BBC Belt Replacement ........................6–4 Transmission Belt Replacement....................... 6–12 Engine Pulley Belt Guide Replacement.................... 6–17 30 Inch TurfMaster® HDX WPM Page 6–1 Belts 3432-730 Rev A...

  • Page 100: General Information

    General Information There are 3 belts on this unit that will need minimal maintenance for proper function, 2 belts are for the blade drive and 1 is the transmission drive belt. Blade drive has a timing belt on the cutting deck and clutching belt from the engine to the deck.

  • Page 101: Service And Repairs

    Service and Repairs Belts Assembly 1 g299420 Figure 133 BBC Belt Transmission Belt Engine Pulley Belt Guide Rod 30 Inch TurfMaster® HDX WPM Page 6–3 Belts: Service and Repairs 3432-730 Rev A...

  • Page 102: Bbc Belt Replacement

    BBC Belt Replacement BBC Belt Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3.
  • Page 103 BBC Belt Removal (continued) 7. Rotate the belt tensioner arm by turning the 7/16 inch nut on the bottom side of the transmission clockwise. g302330 Figure 136 8. Align the idler pulley with the access hole on the bottom side of the transmission to remove the belt tension.
  • Page 104 BBC Belt Removal (continued) g302331 Figure 138 10. Remove the belt from the rear of the mower. g296178 Figure 139 11. Remove the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Remove the belt guide. Belts: Service and Repairs Page 6–6 30 Inch TurfMaster®...
  • Page 105 BBC Belt Removal (continued) g296179 Figure 140 12. Loosen the ½ inch nylock nut from the BBC idler arm pivot until flush with bottom bolt. Secure the topside of the bolt with a ½ inch wrench. Note: Gain access through the front of the main frame, top side of the deck. g296180 Figure 141 13.
  • Page 106 BBC Belt Removal (continued) g302385 Figure 142 14. Remove the BBC belt from the pulley. g296181 Figure 143 15. Remove the BBC belt from rear of the mower. BBC Belt Installation 1. Install the BBC belt through the rear of the mower. 2.
  • Page 107 BBC Belt Installation (continued) g296181 Figure 144 4. Move the brake upwards to align with the pulley. g302385 Figure 145 5. Tighten the 1/2 inch nylock nut to the BBC idler arm pivot. Secure the topside of the bolt with a 1/2 inch wrench. Torque nut and bolt to 200 ± 20 in-lbs.
  • Page 108 BBC Belt Installation (continued) g305213 Figure 146 6. Install the belt guide. Install the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Torque screws to 110 ± 11 in-lbs. (12 ± 2 Nm). g296179 Figure 147 7.
  • Page 109 BBC Belt Installation (continued) g302331 Figure 148 9. Install the transmission belt to the transmission pulley. 10. Using a 7/16 inch nut on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing idler arm to put tension on the belt.

  • Page 110: Transmission Belt Replacement

    BBC Belt Installation (continued) 13. Install the 1/4–20 inch taptite screw securing the frame access cover to the frame. Torque bolt to 110 ± 11 in-lbs. (12 ± 2 Nm). g296174 Figure 150 14. Lower the rear cover. 15. Using an appropriate lifting device, lower the rear of the machine to the ground.
  • Page 111 Transmission Belt Removal (continued) g296174 Figure 151 6. Remove the 4 (1/4–20 inch) taptite screws securing the front cover to the frame. g296175 Figure 152 7. Rotate the belt tensioner arm clockwise from the bottom side of the transmission. 30 Inch TurfMaster® HDX WPM Page 6–13 Belts: Service and Repairs 3432-730 Rev A...
  • Page 112 Transmission Belt Removal (continued) g302330 Figure 153 8. To remove belt tension, align the idler pulley with the access hole on the bottom side of the transmission. Insert a quarter inch screw driver. Note: Screw driver needs to fit through access hole and the idler pulley slot securing the pulley/idler arm into position.
  • Page 113 Transmission Belt Removal (continued) g302331 Figure 155 10. Remove the belt from the rear of the mower. g296178 Figure 156 Transmission Belt Installation 1. Install the belt through the rear of the mower. 2. Install the transmission belt to the engine pulley. Note: Access belt/engine pulley from the front of the mower.
  • Page 114 Transmission Belt Installation (continued) g302331 Figure 157 3. Install the belt on the transmission pulley. 4. Using a 7/16 inch nut on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing idler arm to put tension on the belt.

  • Page 115: Engine Pulley Belt Guide Replacement

    Transmission Belt Installation (continued) g296174 Figure 159 7. Lower the rear cover. 8. Using an appropriate lifting device, lower the rear of the machine to the ground. Engine Pulley Belt Guide Replacement Engine Pulley Belt Guide Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop.
  • Page 116 Engine Pulley Belt Guide Removal (continued) g296174 Figure 160 6. Remove the 4 (1/4–20 inch) taptite screws securing the belt cover to the frame. g296175 Figure 161 7. Rotate the belt tensioner arm by turning the 7/16 inch nut on the bottom side of the transmission clockwise.
  • Page 117 Engine Pulley Belt Guide Removal (continued) g302330 Figure 162 8. To remove belt tension, align the idler pulley with the access hole on the bottom side of the transmission. Insert a quarter inch screw driver. Note: Screw driver needs to fit through access hole and the idler pulley slot securing the pulley/idler arm into position.
  • Page 118 Engine Pulley Belt Guide Removal (continued) g302331 Figure 164 10. Remove the belt through the rear of the mower. g296178 Figure 165 11. Remove the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Remove the belt guide. Belts: Service and Repairs Page 6–20 30 Inch TurfMaster®...
  • Page 119 Engine Pulley Belt Guide Removal (continued) g296179 Figure 166 12. Loosen the ½ inch nylock nut from the BBC idler arm pivot until flush with bottom bolt. Secure the topside of the bolt with a ½ inch wrench. Note: Access through the front side of the frame. g305213 Figure 167 13.
  • Page 120 Engine Pulley Belt Guide Removal (continued) g302385 Figure 168 14. Remove the BBC belt from the pulley. g296181 Figure 169 15. Remove the BBC belt from rear of the mower. 16. Remove the 2 (1/4–20 inch) taptite screws securing the guide to the frame. Note: To remove front bolt, go through the access hole in the deck with a 10 (3/8 inch) drive extension and a 3/8 inch socket with a universal joint.
  • Page 121 Engine Pulley Belt Guide Removal (continued) g296180 Figure 170 17. Remove the belt guide. 18. Replace engine pulley belt guide. Engine Pulley Belt Guide Installation 1. Using a 6 inch long, quarter inch drive extension and a 1/2 inch deep well socket, put the extension in the access hole with socket off.
  • Page 122 Engine Pulley Belt Guide Installation (continued) Note: To install the front bolt, go through the access hole in the deck with a 10 (3/8 inch) drive extension and a 3/8 inch socket with a universal joint. 3. Install the BBC belt through the rear of the mower. g296178 Figure 172 4.
  • Page 123 Engine Pulley Belt Guide Installation (continued) g302385 Figure 174 7. Tighten the ½ inch nylock nut to the BBC idler arm pivot. Secure the topside of the bolt with a ½ inch wrench. Torque nut and bolt to 200 ± 20 in-lbs. (22 ±...
  • Page 124 Engine Pulley Belt Guide Installation (continued) g302331 Figure 176 11. Install the transmission belt to the transmission pulley. 12. Using a 7/16 inch nut on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing idler arm to put tension on the belt.
  • Page 125 Engine Pulley Belt Guide Installation (continued) g296174 Figure 178 15. Lower the rear cover. 16. Using an appropriate lifting device, lower the rear of the machine to the ground. 30 Inch TurfMaster® HDX WPM Page 6–27 Belts: Service and Repairs 3432-730 Rev A...
  • Page 126 Belts: Service and Repairs Page 6–28 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 127 Chapter 7 Deck Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Deck Replacement..........................7–6 Height-of-Cut Replacement ......................7–26 Front Bumper Replacement ......................7–55 Blade Drive Assembly Replacement ....................7–63 Door and Chute Assembly Replacement ..................7–77 Blade Break Arm Replacement ......................

  • Page 128: General Information

    General Information Deck is constructed to side discharge, mulch and bag. Unit has 2 blades that utilize a sheer pin driver to protect the deck from damage in the event of the blade impacting an object. Only maintenance needed is occasional cleaning of the underside of the deck.

  • Page 129: Service And Repairs

    Service and Repairs Deck Assembly 1 g299472 Figure 179 Belt Cover Control Baffle Access Door Door Handle Chute Rear Door Asm. Mulch Plug Bumper Traction Cable Bracket Seal Clip Frame Cover Torsion Spring Button Plug Retaining Ring 30 Inch Frame Hinge Pin Trailing Shield Hinge Bracket...
  • Page 130 Deck Assembly 2 g299485 Figure 180 Synchronous Belt RH Spindle Shaft Blade Adapter Spindle Belt Guide Spindle Brake Pulley Rotary Blade Button Plug LH Spindle Shaft Sprocket Asm. Idler Pulley Flat Idler Pulley Brake Extension Spring Idler Bracket Brake Spacer Bore Adapter Brake Arm Asm.
  • Page 131 Deck Assembly 3 g299487 Figure 181 Side Discharge Chute Asm. Torsion Spring Discharge Cover Spacer Hinge 30 Inch TurfMaster® HDX WPM Page 7–5 Deck: Service and Repairs 3432-730 Rev A...

  • Page 132: Deck Replacement

    Deck Replacement Deck Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3.
  • Page 133 Deck Removal (continued) 7. Rotate the belt tensioner arm by using a 7/16 inch socket on the nut at the bottom side of the transmission, turning clockwise. g302330 Figure 184 8. To remove belt tension, align the idler pulley with the access hole on the bottom side of the transmission.
  • Page 134 Deck Removal (continued) g302331 Figure 186 10. Remove the belt from the rear of the mower. g296178 Figure 187 11. Remove the 2 (1/4–20) taptite screws securing the front BBC belt guide to the bosses on the frame. Remove the belt guide. Deck: Service and Repairs Page 7–8 30 Inch TurfMaster®...
  • Page 135 Deck Removal (continued) g296179 Figure 188 12. From the front, loosen the 5/16–18 inch nylock nut from the BBC idler arm pivot until flush with bottom bolt. Secure the topside of the bolt with a ½ inch wrench. g305213 Figure 189 13.
  • Page 136 Deck Removal (continued) g302385 Figure 190 14. Remove the BBC belt from the pulley. g296181 Figure 191 15. Remove the BBC belt from rear of the mower. 16. Remove the belt tension (5/16–18 inch) bolt and nut to relieve tension from the blade timing belt.
  • Page 137 Deck Removal (continued) g298542 Figure 192 17. Remove the 2 (1/2–20) inch nut from the BBC pulley. Pull the BBC brake pulley off the left side spindle. Note: Secure blade with a wood block. g298543 Figure 193 18. Remove both dust covers and idler pulleys from the main frame. 19.
  • Page 138 Deck Removal (continued) g298544 Figure 194 20. Remove the 5/16–18 inch bolt securing the idler pulley to the belt tension assembly. g304130 Figure 195 21. Remove the blade timing belt from the spindle pulleys. 22. Remove the 2 (1/4–20 inch) shoulder bolts securing the tension idler bracket from the frame.
  • Page 139 Deck Removal (continued) g298545 Figure 196 23. Remove the 2 sprocket pulleys and BBC pulley from the spindle assembly. 24. Remove blade and spindle shaft from spindle hub. Note: Spindle shaft and blade will drop out of the bottom side of the machine. g298546 Figure 197 25.
  • Page 140 Deck Removal (continued) g298547 Figure 198 26. Remove the 2 (1/2 inch) nuts to carriage bolts securing the deck shell to the main frame. g304131 Figure 199 27. Remove the deck shell from the main frame. Note: Image shows the front bumper removed. Deck: Service and Repairs Page 7–14 30 Inch TurfMaster®...
  • Page 141 Deck Removal (continued) g298548 Figure 200 Deck Disassembly 1. Pull up on the spring latch and remove the discharge cover. g298549 Figure 201 2. Remove the 2 (5/16–18 inch) carriage bolts securing the spring latch to the deck shell. 30 Inch TurfMaster® HDX WPM Page 7–15 Deck: Service and Repairs 3432-730 Rev A...
  • Page 142 Deck Disassembly (continued) g298613 Figure 202 3. Remove the 5/16–18 inch nut and bolt securing the spring bushing to the spring bracket. g304132 Figure 203 Deck Assembly 1. Install the 5/16–18 inch bolt and flange nut securing the spring bushing to the spring bracket.
  • Page 143 Deck Assembly (continued) g298614 Figure 204 2. Install the 2 (5/16–18 inch) bolt and nut securing the spring latch to the deck shell. Torque screw to 25 ± 3 in-lbs. (2.8 ± 0.4 Nm). g298613 Figure 205 3. Install the discharge cover. 30 Inch TurfMaster®...
  • Page 144 Deck Assembly (continued) g298549 Figure 206 Deck Installation 1. Install the deck shell to the main frame. g298548 Figure 207 2. Install the 2 (5/16–18 inch) nuts to carriage bolts securing the deck shell to the main frame. Torque bolts to 200 in-lbs. (22.6 Nm). Note: Bolt is installed from the bottom and the nut from on top.
  • Page 145 Deck Installation (continued) g304131 Figure 208 3. Install the 8 (5/16–18 inch) bolts securing spindle hub assembly to the main frame. Torque bolts to 160 ± 16 in-lbs. (18 ± 2 Nm). g298547 Figure 209 4. Install the blade and spindle shaft to the spindle hub. 30 Inch TurfMaster®...
  • Page 146 Deck Installation (continued) g298546 Figure 210 5. Install the 2 sprocket pulleys and BBC pulley to the spindle assembly. 6. Loosely install the 1/2–20 nut to spindle shaft. 7. Install the 2 (1/4–20 inch) shoulder bolts securing the tension idler bracket to the frame.
  • Page 147 Deck Installation (continued) g298544 Figure 212 10. Install the 5/16–18 inch bolt securing the fixed idler pulley to the frame. Torque bolt to 160 ± 16 in-lbs. (18 ± 2 Nm). g298544 Figure 213 11. Install both dust covers and idler pulleys to the main frame. 12.
  • Page 148 Deck Installation (continued) g298543 Figure 214 13. Install the belt tension 5/16–18 inch bolt and nut to tension the blade timing belt. Tighten bolt until there is 0.010–0.030 gap between the spring washer and frame for proper belt tension. g298542 Figure 215 14.
  • Page 149 Deck Installation (continued) g296181 Figure 216 17. Move the brake arm upwards to secure the pulley. g302385 Figure 217 18. Secure the topside of the bolt with a ½ inch wrench. Torque nut and bolt to 200 ± 20 in-lbs. (22 ± 2 Nm). Note: Access the bottom nut from the front of the machine.
  • Page 150 Deck Installation (continued) g305213 Figure 218 19. Install the belt guide. Install the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Torque bolts to 110 ± 11 in-lbs. (12 ± 2 Nm). g296179 Figure 219 20.
  • Page 151 Deck Installation (continued) g302331 Figure 220 22. Install the transmission belt to the transmission pulley. 23. Using a 7/16 inch socket on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing the idler arm to put tension on the belt.

  • Page 152: Height-Of-Cut Replacement

    Deck Installation (continued) g296174 Figure 222 26. Lower the rear cover. 27. Using an appropriate lifting device, lower the rear of the machine to the ground. Height-of-Cut Replacement Height-of-Cut Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop.
  • Page 153 Height-of-Cut Removal (continued) g296174 Figure 223 6. Remove the 4 (1/4–20 inch) taptite screws securing the front cover to the frame. g296175 Figure 224 7. Rotate the belt tensioner arm by using a 7/16 inch socket on the nut at the bottom side of the transmission, turning clockwise.
  • Page 154 Height-of-Cut Removal (continued) g302330 Figure 225 8. To remove belt tension, align the idler pulley with the access hole on the bottom side of the transmission. Insert a quarter inch screw driver. Note: Screw driver needs to fit through access hole and the idler pulley slot securing the pulley into position.
  • Page 155 Height-of-Cut Removal (continued) g302331 Figure 227 10. Remove the belt from the rear of the mower. g296178 Figure 228 11. Using an appropriate lifting device, lower the rear of the machine onto the ground. 12. Set the rear height-of-cut to 5 inch. 13.
  • Page 156 Height-of-Cut Removal (continued) g297057 Figure 229 15. Remove the 5/16–18 inch nut on carriage bolt securing the spring bracket to the frame. g297058 Figure 230 16. Using snap ring pillars, remove the snap ring retaining the pinion gear from axle shaft. Note: Inspect the pinion gear to wheel gear mesh for abnormal wear, broken teeth, and uneven wear.
  • Page 157 Height-of-Cut Removal (continued) g297059 Figure 231 17. Remove the 5/16–18 inch bolt securing the axle bearing housing to the axle height-of-cut plate. g297060 Figure 232 18. While holding up the spring loaded height-of-cut handle, apply pressure to the back of the axle bearing housing assembly, separating from axle weldment. 30 Inch TurfMaster®...
  • Page 158 Height-of-Cut Removal (continued) g297061 Figure 233 19. Using a 3/8 inch socket, remove the bolt securing the transmission cable guard and parking brake mount bolt to the frame. g297062 Figure 234 20. Remove the 1/4–20 inch bolt securing the parking brake to the transmission. Deck: Service and Repairs Page 7–32 30 Inch TurfMaster®...
  • Page 159 Height-of-Cut Removal (continued) g297064 Figure 235 21. Remove the 2 Phillip head screws from the trailing shield to the main frame. g297065 Figure 236 22. Remove the 5/16–18 inch nut to carriage bolt on LH side. Remove the RH 5/16–18 inch taptite screw to main frame securing the transmission assembly to the main housing.
  • Page 160 Height-of-Cut Removal (continued) g297066 Figure 237 g297531 Figure 238 23. Slide transmission to the right. Line up RH side height-of-cut notch with bolt. Deck: Service and Repairs Page 7–34 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 161 Height-of-Cut Removal (continued) g297894 Figure 239 24. Remove the height-of-cut weldment from the chassis. Slide the LH side of the height-of-cut weldment first before the RH side. g297895 Figure 240 25. Center the transmission. Pinch the traction cable towards the transmission and rotate the front transmission and cable downward.
  • Page 162 Height-of-Cut Removal (continued) g297896 Figure 241 26. To remove the transmission from the frame, rotate the transmission upside down and slide the transmission to the right. Remove the transmission from the frame with the traction cable attached. g298181 Figure 242 27.
  • Page 163 Height-of-Cut Removal (continued) g298182 Figure 243 28. Using needle a nose plier, squeeze the cable anchor and remove cable anchor from the cable mount. g298183 Figure 244 29. Pull the cable and remove from the cable anchor mount. 30 Inch TurfMaster® HDX WPM Page 7–37 Deck: Service and Repairs 3432-730 Rev A...
  • Page 164 Height-of-Cut Removal (continued) g298184 Figure 245 30. Remove the spring hook from the transmission clutch lever. g298185 Figure 246 31. Remove the 6 (5/16–18 inch) nuts to carriage bolts securing the engine cage to chassis. Deck: Service and Repairs Page 7–38 30 Inch TurfMaster®...
  • Page 165 Height-of-Cut Removal (continued) g298693 Figure 247 32. Remove the handle from the machine. 33. Remove the 2 (5/16–18 inch) bolts on the RH side of the height-of-cut plate. g298694 Figure 248 34. Remove the height-of-cut plate from the main frame. 35.
  • Page 166 Height-of-Cut Removal (continued) g298697 Figure 249 36. Remove the upper T-30 torx screw from the LH height adjuster handle. g298695 Figure 250 37. Remove the washer between lever and plate. 38. Remove the 2 (5/16–18 inch) bolts securing LH height-of-cut plate to the main frame.
  • Page 167 Height-of-Cut Removal (continued) g298696 Figure 251 Height-of-Cut Disassembly Remove the T-30 bolt from 5/16–18 inch nylock height lock adjustment. g298698 Figure 252 Height-of-Cut Assembly Install the T-30 bolt to the 5/16–18 inch nylock height lock adjustment. Torque bolt to 160 ± 16 in-lbs. (18 ± 2 Nm). 30 Inch TurfMaster®...
  • Page 168 Height-of-Cut Installation 1. Install the 2 (5/16–18 inch) bolts securing LH height-of-cut plate to the main frame. Torque bolts to 160 ± 16 in-lbs. (18 ± 2 Nm). g298696 Figure 253 2. Install the washer between the lever and plate. 3.
  • Page 169 Height-of-Cut Installation (continued) g298697 Figure 255 5. Install the height-of-cut plate to the main frame. Note: The spring is inside the frame. 6. Install the 2 (5/16–18 inch) bolts on the RH side of the height-of-cut plate. Torque bolts to 160 ± 16 in-lbs. (18 ± 2 Nm). g298694 Figure 256 7.
  • Page 170 Height-of-Cut Installation (continued) g298693 Figure 257 9. Install the spring hook to the transmission lever. g298185 Figure 258 10. Install the cable to the cable anchor mount. Deck: Service and Repairs Page 7–44 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 171 Height-of-Cut Installation (continued) g298184 Figure 259 11. Using needle a nose plier, install the cable anchor to the cable mount. g298183 Figure 260 12. Install the height-of-cut spring to the RH side axle shaft. 30 Inch TurfMaster® HDX WPM Page 7–45 Deck: Service and Repairs 3432-730 Rev A...
  • Page 172 Height-of-Cut Installation (continued) g298182 Figure 261 13. Install the transmission to the frame with the traction cable attached. g298181 Figure 262 14. Rotate the front transmission and cable upward. Pinch the traction cable towards the transmission. Deck: Service and Repairs Page 7–46 30 Inch TurfMaster®...
  • Page 173 Height-of-Cut Installation (continued) g297896 Figure 263 15. Slide the RH side of the height-of-cut weldment first before the LH side. Install the height-of-cut weldment to the chassis. g297895 Figure 264 16. Line up the RH side height-of-cut notch with bolt. Slide the transmission to the left.
  • Page 174 Height-of-Cut Installation (continued) g297894 Figure 265 17. Put anti-seize inside the axle bearing before sliding over the shaft. Install the axle bearing housing assembly over the axle. Line up the mounting hole on the bearing housing assembly to the weldment hole. Install the bearing retainers into the rear axle weldment and rear height-of-cut plate for alignment purposes before securing the transmission to the frame.
  • Page 175 Height-of-Cut Installation (continued) g297531 Figure 267 g297066 Figure 268 19. Install the 2 Phillip head screws securing the trailing shield to the main frame. Torque screws to 9 ± 1 in-lbs. (1 Nm). 30 Inch TurfMaster® HDX WPM Page 7–49 Deck: Service and Repairs 3432-730 Rev A...
  • Page 176 Height-of-Cut Installation (continued) g297065 Figure 269 20. Install the 1/4–20 inch bolt securing the parking brake to the transmission. Torque bolt to 85 ± 15 in-lbs. (9 ± 2 Nm). g297064 Figure 270 21. Install the 1/4–20 taptite screw securing the transmission cable guide to the frame.
  • Page 177 Height-of-Cut Installation (continued) g297062 Figure 271 22. Using snap ring pillars, Install the snap ring retaining the pinion gear to axle shaft. g297059 Figure 272 23. Install the 5/16–18 inch nut on carriage bolt securing the spring bracket to the frame.
  • Page 178 Height-of-Cut Installation (continued) g297058 Figure 273 24. Install the mulch plug to the rear discharge. 25. Install the T-30 screw securing the dust cover to the axle assembly. Torque screw to 55 ± 5 in-lbs. (6 ± 1 Nm). g297057 Figure 274 26.
  • Page 179 Height-of-Cut Installation (continued) g296178 Figure 275 28. Install the transmission belt to the engine pulley. Note: Access belt from the front of the mower. g296177 Figure 276 29. Install the transmission belt to the transmission pulley. 30. Using a 7/16 inch socket on the bottom of the transmission, release pressure on the quarter inch screw driver.
  • Page 180 Height-of-Cut Installation (continued) g296175 Figure 277 33. Install the 1/4–20 inch taptite screw securing the frame cover to the frame. Torque bolt to 110 ± 11 in-lbs. (12 ± 2 Nm). g296174 Figure 278 34. Lower the rear cover. 35. Using an appropriate lifting device, lower the rear of the machine to the ground.

  • Page 181: Front Bumper Replacement

    Front Bumper Replacement Front Bumper Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3.
  • Page 182 Front Bumper Removal (continued) g298858 Figure 281 Front Bumper Disassembly 1. Roll the front bumper assembly over. 2. Using a 9/16 inch socket and wrench, remove 3/8–16 inch nut from 3/8–16 inch bolt securing the front wheels to the axle. g298895 Figure 282 3.
  • Page 183 Front Bumper Disassembly (continued) g298896 Figure 283 g298897 Figure 284 4. Remove the 4 bushings from the axle. 5. Roll the front bumper assembly over. CAUTION The spring is loaded. 6. Depress the height-of-cut lockout lever and rotate axle forward releasing spring tension.
  • Page 184 Front Bumper Disassembly (continued) g298898 Figure 285 7. Depress the height-of-cut lockout lever and rotate axle forward releasing spring tension. 8. Apply downward pressure on the spring mandrell to remove the mandrell from the spring. g298899 Figure 286 9. Remove the 3/16 inch allen head screw securing the spring to the front bumper assembly.
  • Page 185 Front Bumper Disassembly (continued) g298900 Figure 287 11. Squeeze the height-of-cut/lockout lever and remove the 5/16–18 inch bolt from the front bumper assembly. Front Bumper Assembly 1. Place the spring onto the front bumper assembly. Loosely install the 3/16 inch allen head screw. g298901 Figure 288 2.
  • Page 186 Front Bumper Assembly (continued) g298929 Figure 289 4. Tighten the 3/16 inch Allen head screw. Torque to 140 ± 15 in-lbs. (15.8 ± 1.7 Nm). g298930 Figure 290 5. Roll the front bumper assembly over. 6. Squeeze the lever and rotate the front axle height-of-cut until aligned with the 5 inch mark.
  • Page 187 Front Bumper Assembly (continued) g298931 Figure 291 7. Slightly raise the axle weldment and install bushing on the bottom for the non-height-of-cut side of the axle weldment. Install the other bushing for the top of the non-height-of-cut side of the axle weldment. Install the (7/16 inch) bolt and nut securing the bushing to the axle weldment until finger tight, do not fully tighten fastener.
  • Page 188 Front Bumper Installation 1. Install the front axle assembly to the deck. g298858 Figure 293 2. Install the 4 (5/16–18 inch) center nuts to carriage bolts securing the front bumper assembly to the deck assembly. Torque center nuts to carriage bolts to 140 ±...

  • Page 189: Blade Drive Assembly Replacement

    Front Bumper Installation (continued) g298854 Figure 295 Blade Drive Assembly Replacement Blade Drive Assembly Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2.
  • Page 190 Blade Drive Assembly Removal (continued) 6. Remove the 4 (1/4–20 inch) taptite screws securing the front cover to the frame. g296175 Figure 297 7. Rotate the belt tensioner arm by using a 7/16 inch socket on the nut at the bottom side of the transmission, turning clockwise.
  • Page 191 Blade Drive Assembly Removal (continued) g296176 Figure 299 9. Remove the transmission belt from the engine pulley. Note: Access belt from the front of the mower. g302331 Figure 300 10. Remove the belt from the rear of the mower. 30 Inch TurfMaster® HDX WPM Page 7–65 Deck: Service and Repairs 3432-730 Rev A...
  • Page 192 Blade Drive Assembly Removal (continued) g296178 Figure 301 11. Remove the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Remove the belt guide. g296179 Figure 302 12. From the front, loosen the 5/16–18 inch nylock nut from the BBC idler arm pivot until flush with bottom bolt.
  • Page 193 Blade Drive Assembly Removal (continued) g305213 Figure 303 13. Move the brake arm downwards to release from pulley. Note: Releasing pulley pressure from the belt. g302385 Figure 304 14. Remove the BBC belt from the pulley. 30 Inch TurfMaster® HDX WPM Page 7–67 Deck: Service and Repairs 3432-730 Rev A...
  • Page 194 Blade Drive Assembly Removal (continued) g296181 Figure 305 15. Remove the BBC belt from rear of the mower. 16. Remove the belt tension (5/16–18 inch) bolt and nut to relieve tension from the blade timing belt. g298542 Figure 306 17. Remove the 2 (1/2–20 inch) nut from the BBC pulley. Pull the BBC brake pulley off the left side spindle.
  • Page 195 Blade Drive Assembly Removal (continued) g298543 Figure 307 18. Remove both dust covers and idler pulleys from the main frame. 19. Remove the 5/16–18 inch idler bolt securing the fixed idler pulley to the frame. g298544 Figure 308 20. Remove the blade timing belt from spindle pulleys. 21.
  • Page 196 Blade Drive Assembly Removal (continued) g298545 Figure 309 22. Remove the 2 sprocket pulleys and BBC pulley from the spindle assembly. 23. Remove blade and spindle shaft from spindle hub. Note: Spindle shaft and blade will drop out of the bottom side of the machine. g298546 Figure 310 24.
  • Page 197 Blade Drive Assembly Removal (continued) g298547 Figure 311 Blade Drive Assembly Installation 1. Install the 8 (5/16–18 inch) taptite screws securing spindle hub assembly to the main frame. Torque bolts to 160 ± 16 in-lbs. (18 ± 2 Nm). g298547 Figure 312 2.
  • Page 198 Blade Drive Assembly Installation (continued) g298546 Figure 313 3. Install the 2 sprocket pulleys and BBC pulley to the spindle assembly. 4. Loosely install the 1/2–20 inch nuts to spindle shaft. 5. Install the 2 (1/4–20 inch) shoulder bolts securing the tension idler bracket to the frame.
  • Page 199 Blade Drive Assembly Installation (continued) g298544 Figure 315 8. Install both dust covers and idler pulleys to the main frame. 9. Install the 2 (1/2–20 inch) nut to the BBC pulley. Pull the BBC pulley on the left side spindle. Torque nut to 60 ± 5 ft-lbs. (81.3 ± 6.7 Nm). Note: Secure the blade with a wood block.
  • Page 200 Blade Drive Assembly Installation (continued) g296181 Figure 317 14. Move the brake arm upwards to secure the pulley. g302385 Figure 318 15. Secure the topside of the bolt with a 1/2 inch wrench. Torque nut and bolt to 100 ± 15 in-lbs. (11.3 ± 1.7 Nm). Note: Access bottom nut from the front of the machine.
  • Page 201 Blade Drive Assembly Installation (continued) g305213 Figure 319 16. Install the belt guide. Install the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Torque bolts to 110 ± 11 in-lbs. (12 ± 2 Nm). g296179 Figure 320 17.
  • Page 202 Blade Drive Assembly Installation (continued) g302331 Figure 321 19. Install the transmission belt to the transmission pulley. 20. Using a 7/16 inch socket on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing idler arm to put tension on the belt.

  • Page 203: Door And Chute Assembly Replacement

    Blade Drive Assembly Installation (continued) g296174 Figure 323 23. Lower the rear cover. 24. Using an appropriate lifting device, lower the rear of the machine to the ground. Door and Chute Assembly Replacement Door and Chute Assembly Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop.
  • Page 204 Door and Chute Assembly Removal (continued) 4. Remove the 4 (1/4–20 inch) taptite screws securing the chute and door assembly to the chassis. g299115 Figure 325 5. Slide the door and chute assembly rearward and remove from the machine. 6. Remove the 2 (1/4–10 inch) taptite screws securing the door to the chute. g299116 Figure 326 7.
  • Page 205 Door Disassembly (continued) g299117 Figure 327 2. Remove the seal clip from the door assembly. g299118 Figure 328 3. Remove the push nut, rod, and spring from the hinge bracket to the rear door. 30 Inch TurfMaster® HDX WPM Page 7–79 Deck: Service and Repairs 3432-730 Rev A...
  • Page 206 Door Disassembly (continued) g299119 Figure 329 Door Assembly 1. Install the push nut, rod, and spring to the hinge bracket to the rear door. g299119 Figure 330 2. Install the seal clip to the door assembly. Deck: Service and Repairs Page 7–80 30 Inch TurfMaster®...
  • Page 207 Door Assembly (continued) g299118 Figure 331 3. Install the 2 (1/4–10 inch) taptite screws securing the handle to the rear door. Torque bolts to 17 ± 2 in-lbs. (1.9 ± 0.3 Nm). g299117 Figure 332 Door and Chute Assembly Installation 1.
  • Page 208 Door and Chute Assembly Installation (continued) 2. Install the 2 (1/4–10 inch) taptite screws securing the door to the chute. Torque bolts to 30 ± 4 in-lbs. (3.4 ± 0.5 Nm). g299116 Figure 333 3. Slide the door and chute assembly onto the machine. 4.

  • Page 209: Blade Break Arm Replacement

    Door and Chute Assembly Installation (continued) g296175 Figure 335 Blade Break Arm Replacement Blade Break Arm Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2.
  • Page 210 Blade Break Arm Removal (continued) 6. Remove the 4 (1/4–20 inch) taptite screws securing the belt cover to the frame. g296175 Figure 337 7. Rotate the belt tensioner arm by using a 7/16 inch socket on the nut at the bottom side of the transmission, turning clockwise.
  • Page 211 Blade Break Arm Removal (continued) g296176 Figure 339 9. Remove the transmission belt from the engine pulley. Note: Access belt from the front of the mower. g302331 Figure 340 10. Remove the belt from the rear of the mower. 30 Inch TurfMaster® HDX WPM Page 7–85 Deck: Service and Repairs 3432-730 Rev A...
  • Page 212 Blade Break Arm Removal (continued) g296178 Figure 341 11. Remove the 2 (1/4–20 inch) taptite screws securing the front BBC belt guide to the bosses on the frame. Remove the belt guide. g296179 Figure 342 12. From the front, loosen the 5/16–18 inch nylock nut from the BBC idler arm pivot until flush with bottom bolt.
  • Page 213 Blade Break Arm Removal (continued) g305213 Figure 343 13. Move the brake arm downwards to release from the pulley. Note: Releasing pulley pressure from the belt. g302385 Figure 344 14. Remove the BBC belt from the pulley. 30 Inch TurfMaster® HDX WPM Page 7–87 Deck: Service and Repairs 3432-730 Rev A...
  • Page 214 Blade Break Arm Removal (continued) g296181 Figure 345 15. Remove the BBC belt from rear of the mower. 16. Remove the belt tension (5/16–18 inch) bolt and nut to relieve tension from the blade timing belt. g298542 Figure 346 17. Remove both dust covers and idler pulleys from the main frame. 18.
  • Page 215 Blade Break Arm Removal (continued) g298543 Figure 347 19. Remove the 5/16–18 inch bolt securing the fixed idler pulley to the main frame. g298544 Figure 348 20. Remove fixed idler pulley from the main frame. 21. Remove the blade timing belt from the spindle pulleys. 22.
  • Page 216 Blade Break Arm Removal (continued) g302428 Figure 349 24. Remove the 5/16–18 inch nut securing the brake idler arm to the main frame. Pull the 5/16–18 inch bolt upwards and pull brake idler arm downwards to separate. g304647 Figure 350 25.
  • Page 217 Blade Break Arm Removal (continued) g302428 Figure 351 26. Remove the brake extension spring from the engine deck mount. 27. Remove the BBC cable spring from the brake idler arm. 28. Remove the brake extension spring from the brake idler arm. Blade Break Arm Disassembly Remove the 7/16 inch nut and bolt securing the idler pulley from brake idler arm.
  • Page 218 Blade Break Arm Installation 1. Install the brake extension spring to the brake idler arm. 2. Install the BBC cable spring to the brake idler arm. 3. Install the blade brake idler arm to the 5/16 inch pivot bolt and install the 5/16–18 inch nylock nut flush with the bottom of the bolt.
  • Page 219 Blade Break Arm Installation (continued) g298542 Figure 354 9. Install the BBC belt to the rear of the mower. 10. Install the BBC belt to the pulley. g296181 Figure 355 11. Move the brake arm upwards to secure the pulley. 30 Inch TurfMaster®...
  • Page 220 Blade Break Arm Installation (continued) g302385 Figure 356 12. Secure the topside of the bolt with a 1/2 inch wrench. Torque nut and bolt to 200 ± 20 in-lbs. (22 ± 2 Nm). Note: Access bottom nut from front of the machine. 13.
  • Page 221 Blade Break Arm Installation (continued) g302331 Figure 358 16. Install the transmission belt to the transmission pulley. 17. Using a 7/16 inch socket on the bottom of the transmission, release pressure on the quarter inch screw driver. Remove the quarter inch screw driver, allowing idler arm to put tension on the belt.
  • Page 222 Blade Break Arm Installation (continued) g296174 Figure 360 20. Lower the rear cover. 21. Using an appropriate lifting device, lower the rear of the machine to the ground. Deck: Service and Repairs Page 7–96 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 223 Chapter 8 Drive System Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Transmission Replacement........................ 8–6 30 Inch TurfMaster® HDX WPM Page 8–1 Drive System 3432-730 Rev A...
  • Page 224 General Information This machine uses a MV702 transmission from General Transmission and is equipped with a parking brake caliper and rotor. Transmission is a two piece axle system with a fixed mount and idler arm for increased belt life. Drive System: General Information Page 8–2 30 Inch TurfMaster®...
  • Page 225 Service and Repairs Drive System Assembly 1 g299500 Figure 361 Brace Spring Mandrell Shield Torsion Spring Height Adjustment Lock Front Axle Asm. Spacer Front Bushing Torsion Spring Wheel Cover Spacer U-Nut Wheel Front Bumper Asm. 30 Inch TurfMaster® HDX WPM Page 8–3 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 226 Drive System Assembly 2 g299501 Figure 362 RH Brace Front Block Engine Guard Wheel Axle Compression Spring 9 inch Wheel Asm. with Bearings Front Height Plate Drive System: Service and Repairs Page 8–4 30 Inch TurfMaster® HDX WPM 3432-730 Rev A...
  • Page 227 Drive System Assembly 3 g299502 Figure 363 RH HOC Plate Asm. Torsion Spring Rotor Hub LH HOC Plate Asm. Bracket Extension Spring Height Adjustment Lock Disc Brake Caliper Custom Ball Bearing Brake Rotor 15T Pinion Gear Brake Mount Bracket Wheel Cover Cable Guide Wheel Asm.
  • Page 228 Transmission Replacement Transmission Removal 1. Park the machine on a level surface and engage the parking brake. Stop the engine and wait for all moving parts to stop. Shut the fuel off. 2. Remove the grass bagger assembly if attached. 3.
  • Page 229 Transmission Removal (continued) 7. Rotate the belt tensioner arm by using a 7/16 inch socket on the nut at the bottom side of the transmisison, turning clockwise. g302330 Figure 366 8. To remove belt tension, align the idler pulley with the access hole on the bottom side of the transmission.
  • Page 230 Transmission Removal (continued) g302331 Figure 368 10. Remove the belt from the rear of the mower. g296178 Figure 369 11. Using an appropriate lifting device, lower the rear of the machine off the ground. 12. Set the rear height-of-cut to 5 inch. 13.
  • Page 231 Transmission Removal (continued) g297057 Figure 370 15. Remove the 5/16–18 inch nut on carriage bolt securing the spring bracket to the frame. g297058 Figure 371 16. Using snap ring pillars, remove the snap ring retaining the pinion gear from axle shaft. Note: Inspect the pinion gear to wheel gear mesh for abnormal wear, broken teeth, and uneven wear.
  • Page 232 Transmission Removal (continued) g297059 Figure 372 17. Remove the 5/16–18 inch bolt securing the axle bearing housing to the axle height-of-cut plate. g297060 Figure 373 18. While holding up the spring loaded height-of-cut handle, apply pressure to the back of the axle bearing housing assembly, separating from axle weldment. Drive System: Service and Repairs Page 8–10 30 Inch TurfMaster®...
  • Page 233 Transmission Removal (continued) g297061 Figure 374 19. Remove the 1/4–20 taptite screw securing the transmission cable guide to the frame. g297062 Figure 375 20. Remove the 1/4–20 inch bolt securing the parking brake to the transmission. 30 Inch TurfMaster® HDX WPM Page 8–11 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 234 Transmission Removal (continued) g297064 Figure 376 21. Remove the 2 Phillip head screws from the trailing shield to the main frame. g297065 Figure 377 22. Remove the 5/16–18 inch nut to carriage bolt on LH side. Remove the RH 5/16–18 inch taptite screw to main frame securing the transmission assembly to the main housing.
  • Page 235 Transmission Removal (continued) g297066 Figure 378 g297531 Figure 379 23. Slide transmission to the right. Line up RH side height-of-cut notch with bolt. 30 Inch TurfMaster® HDX WPM Page 8–13 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 236 Transmission Removal (continued) g297894 Figure 380 24. Remove the height-of-cut weldment from the chassis. Slide the LH side of the height-of-cut weldment first before the RH side. g297895 Figure 381 25. Center the transmission. Pinch the traction cable towards the transmission and rotate the front transmission and cable downward.
  • Page 237 Transmission Removal (continued) g297896 Figure 382 26. To remove the transmission from the frame, rotate the transmission upside down and slide the transmission to the right. Remove the transmission from the frame with the traction cable attached. g298181 Figure 383 27.
  • Page 238 Transmission Removal (continued) g298182 Figure 384 28. Using needle a nose plier, squeeze the cable anchor and remove cable anchor from the cable mount. g298183 Figure 385 29. Pull the cable and remove from the cable anchor mount. Drive System: Service and Repairs Page 8–16 30 Inch TurfMaster®...
  • Page 239 Transmission Removal (continued) g298184 Figure 386 30. Remove the spring hook from the transmission clutch lever. g298185 Figure 387 Transmission Disassembly 1. Remove the 2 (5/16–18 inch) nuts from carriage bolts securing the transmission mount plate to the transmission. 30 Inch TurfMaster® HDX WPM Page 8–17 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 240 Transmission Disassembly (continued) g299150 Figure 388 2. Support the transmission axle, drive the roll pin out using a 3/16 inch punch securing the brake hub to the transmission axle. Slide the brake hub from the transmission axle. g299143 Figure 389 3.
  • Page 241 Transmission Disassembly (continued) g299144 Figure 390 4. Secure the input shaft with a 1/8 inch drift punch inserted into the whole on the input shaft. g299145 Figure 391 5. Using a 9/16 inch socket, remove the nut securing the fan to the input shaft. 30 Inch TurfMaster®...
  • Page 242 Transmission Disassembly (continued) g304900 Figure 392 6. Using a 9/16 inch socket, remove the nut securing the input pulley to the input shaft. g304907 Figure 393 7. Remove the washer from the input shaft. Drive System: Service and Repairs Page 8–20 30 Inch TurfMaster®...
  • Page 243 Transmission Disassembly (continued) g304923 Figure 394 8. Remove the 1/4 inch nut from the idler shaft on the bottom side of the transmission. 9. Pull the idler shaft out of the pivot bearing. g304924 Figure 395 10. Remove idler shaft and spring from the spring mount. 11.
  • Page 244 Transmission Disassembly (continued) g299151 Figure 396 Transmission Assembly 1. Install the bearings to the transmission. g299151 Figure 397 2. Install the idler shaft and spring to the spring mount. 3. Install the idler shaft into the pivot bearing. Drive System: Service and Repairs Page 8–22 30 Inch TurfMaster®...
  • Page 245 Transmission Assembly (continued) g304924 Figure 398 4. Install the M8 inch nut to the idler shaft on the bottom side of the transmission. g309825 Figure 399 5. Install the washer to the input shaft. 30 Inch TurfMaster® HDX WPM Page 8–23 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 246 Transmission Assembly (continued) g304923 Figure 400 6. Using a 9/16 inch socket, install the nut securing the input pulley to the input shaft. Torque nut to 70.8 in-lbs. (8 Nm). g304907 Figure 401 Drive System: Service and Repairs Page 8–24 30 Inch TurfMaster®...
  • Page 247 Transmission Assembly (continued) 7. Using a 9/16 inch socket, install the nut securing the fan to the input shaft. Torque nut to 70.8 in-lbs. (8 Nm). g304900 Figure 402 8. Secure the input shaft with a 1/8 inch drift punch inserted into the whole on the input shaft.
  • Page 248 Transmission Assembly (continued) g299144 Figure 404 10. Slide the brake hub into the transmission axle. Support the transmission axle, drive the roll pin in using a 3/16 inch punch securing the brake hub to the transmission axle. g299143 Figure 405 11.
  • Page 249 Transmission Assembly (continued) g299150 Figure 406 Transmission Installation 1. Install the spring hook to the transmission lever. g298185 Figure 407 2. Install the cable to the cable anchor mount. 30 Inch TurfMaster® HDX WPM Page 8–27 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 250 Transmission Installation (continued) g298184 Figure 408 3. Using needle a nose plier, install the cable anchor to the cable mount. g298183 Figure 409 4. Install the height-of-cut spring to the RH side axle shaft. Drive System: Service and Repairs Page 8–28 30 Inch TurfMaster®...
  • Page 251 Transmission Installation (continued) g298182 Figure 410 5. Install the transmission to the frame with the traction cable attached. g298181 Figure 411 6. Rotate the front transmission and cable upward. Pinch the traction cable towards the transmission. 30 Inch TurfMaster® HDX WPM Page 8–29 Drive System: Service and Repairs 3432-730 Rev A...
  • Page 252 Transmission Installation (continued) g297896 Figure 412 7. Slide the RH side of the height-of-cut weldment first before the LH side. Install the height-of-cut weldment to the chassis. g297895 Figure 413 8. Line up the RH side height-of-cut notch with bolt. Slide the transmission to the left.
  • Page 253 Transmission Installation (continued) g297894 Figure 414 9. Put anti-seize inside the axle bearing before sliding over the shaft. Install the axle bearing housing assembly over the axle. Line up the mounting hole on the bearing housing assembly to the weldment hole. Install the bearing retainers into the rear axle weldment and rear height-of-cut plate for alignment purposes before securing the transmission to the frame.
  • Page 254 Transmission Installation (continued) g297531 Figure 416 g297066 Figure 417 11. Install the 2 Phillip head screws securing the trailing shield to the main frame. Torque screws to 9 ± 1 in-lbs. (1 Nm). Drive System: Service and Repairs Page 8–32 30 Inch TurfMaster®...
  • Page 255 Transmission Installation (continued) g297065 Figure 418 12. Install the 1/4–20 inch bolt securing the parking brake to the transmission. Torque bolt to 85 ± 15 in-lbs. (9 ± 2 Nm). g297064 Figure 419 13. Install the 1/4–20 taptite screw securing the transmission cable guide to the frame.
  • Page 256 Transmission Installation (continued) g297062 Figure 420 14. Using snap ring pillars, Install the snap ring retaining the pinion gear to axle shaft. g297059 Figure 421 15. Install the 5/16–18 inch nut on carriage bolt securing the spring bracket to the frame.
  • Page 257 Transmission Installation (continued) g297058 Figure 422 16. Install the T-30 screw securing the dust cover to the axle assembly. Torque screw to 55 ± 5 in-lbs. (6 ± 1 Nm). g297057 Figure 423 17. Using a socket, install the 2 (3/8–16 inch) nuts securing the wheels to the rear axles.
  • Page 258 Transmission Installation (continued) g296178 Figure 424 19. Install the transmission belt to the engine pulley. Note: Access belt from the front of the mower. g296177 Figure 425 20. Install the transmission belt to the transmission pulley. 21. Using a 7/16 inch socket on the bottom of the transmission, release pressure on the quarter inch screw driver.
  • Page 259 Transmission Installation (continued) g296175 Figure 426 24. Install the 1/4–20 inch taptite screw securing the frame cover to the frame. Torque bolt to 110 ± 11 in-lbs. (12 ± 2 Nm). g296174 Figure 427 25. Lower the rear cover. 26. Using an appropriate lifting device, lower the rear of the machine to the ground.

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Turfmaster hdx 22225

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