BIGDOG MOWER CO. ALPHA · cb carriage bolt mb machine bushing ce clevis pin ms machine screw cn...

200 South Ridge RoadHesston, Kansas

67062

BIGDOG® MOWER CO. ALPHA®

Parts Manual

124973EX_0119 c-1

Table of Contents

General InformationService Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Options Available From Your Dealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Hardware Description Codes & Abbreviations . . . . . . . . . . . . . . . . . . . . 1-2Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Fenders & Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Section 3Transmission Assembly—42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Transmission Assembly—52" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Transmission Service Parts—42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Transmission Service Parts—52" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Steering & Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Steering Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Section 4Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Section 5Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Engine Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Section 642" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-242" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-442" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-652" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-852" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1052" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14Spindle Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Section 7Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

c-2 124973EX_0119

124973EX_0119 1-1

General Information

This manual covers BIGDOG® ALPHA® models: 939124EX, & 939140EX.

Service Literature

Options Available From Your Dealer

Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative.

Note: Items sold in bulk such as seals and hoses are sold by the foot.

Using This Manual

This manual is part of a service package for the BigDog® mowers. Use of this manual in conjunction with other Big-Dog® mower and component manuals will provide the information necessary to service and maintain BigDog® mowers.

This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without noti-fication. If a change has been made to your machine which is not reflected in this parts manual, see your authorized dealer for current information and parts.

The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units.

The Operator's Manual provides fundamental operational information and operational safety that is needed when oper-ating the mower.

The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products.

PART NO. DESCRIPTION607233 OPERATOR’S MANUAL119552 WARRANTY STATEMENT119293 GENERAL SERVICE MANUAL

PART NO. DESCRIPTION933010 2-BAG CATCHER KIT124448 MULCH KIT (42")124443 MULCH KIT (52")799288 FLEX FORKS121472 STRIPE KIT (52")122760 STEERING EXTENSION KIT

1-2 124973EX_0119

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

Standard Torques

The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTIONCB CARRIAGE BOLT MB MACHINE BUSHINGCE CLEVIS PIN MS MACHINE SCREWCN CLIP NUT NT NUTCP COTTER PIN SC SELF TAPPING CAP SCREWCS CAP SCREW SH SOCKET HEADCW CUP WASHER SB SHOULDER BOLT

FDRW FENDER WASHER SS SET SCREWFW FLAT WASHER OD OUTSIDE DIAMETERHX HEX HEAD ID INSIDE DIAMETERLW LOCK WASHER WN WELD NUT

SIZE FT-LBS N•M SIZE FT-LBS N•M.250 8.2 11.1 M3 1 1.3.312 17 23 M4 2.2 3.375 30 40 M5 4.5 6.1.438 48 65 M6 7.7 10.4.500 73 99 M8 18.5 25.562 105 143 M10 37 50.625 145 200 M12 64 87.750 260 350 M14 80 108.5.875 420 565 M16 160 2151.00 625 850 M20 320 435

M24 555 750

124973EX_0119 2-1

Section 2

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Fenders & Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-2 124973EX_0119

Frame

21

24

41

4

17

4

7

4

4

4

20

1113

14

5

1

2

8

3

7

221

12

410

7

15

19

5

6

22

7

84

4

8

7

28

4

28

27

7

29

7

7

18

27

28

27

15

4

3

9

4

7

7

4

16

23

7

17

25

26

124973EX_0119 2-3

Frame

NOTES:

1. Serial number decal. In the event the serial number decal becomes damaged or illegible, please contact your dealer to order a replacement.

2. EPA compliance decal.3. Torque all hardware to a minimum of 33 ft-lbs.

INDEX NO. PART NO. QTY. DESCRIPTION

1 123637-2 1 SEAT SUPPORT2 123636-2 1 SPRING SUPPORT3 029629 10 CS .375-16 X .75 HX FLK4 604176 30 CS .375-16 X .75 HX FLK PLN5 190186 2 HYDRO BRACKET6 552424 1 RS FRAME CHANNEL (WITH DECAL)7 604177 30 NT .375-16 HX FLK PLN8 601982 5 CN .250-20 X .15 MAX THK9 552421 1 ENGINE PLATE (WITH DECAL)

10 190183 1 RS REAR BRACKET11 553643 1 BUMPER (WITH DECALS)12 605073 1 BUMPER DECAL13 602041 1 HOT DECAL14 190184 1 LS REAR BRACKET15 016899 10 NT .375-16 FLK G516 600899 1 PUMP BELT WARNING DECAL17 116125 2 CROSS SUPPORT18 190185 1 RS FRONT BRACKET19 116124-2 1 LS FRONT BRACKET20 552423 1 LS FRAME CHANNEL (WITH DECALS)21 N/A 2 SERIAL NUMBER / SPEC DECAL22 601967 1 ENGINE COMPARTMENT DECAL23 124803-2 1 FRONT CROSS FRAME24 552422 1 FOOT PAN (WITH DECAL)25 601981 1 SAFE OPERATION DECAL26 605782 1 LEVEL FUEL FILL DECAL27 000331 6 WIRE TIE28 604307 6 PUSH BUTTON MOUNT29 190187 1 BATTERY TRAY

2-4 124973EX_0119

Fenders & Instrument Panel

1

8

9

5

4

2

67

12

13

14

1011

15

18

19

20

21

5

13

1316

24

22233

17

124973EX_0119 2-5

Fenders & Instrument Panel

NOTES:


1 601097 1 CHOKE CABLE2 776476 1 PTO SWITCH3 769166 1 HOUR METER4 605808 1 KEY ASSEMBLY5 045898 1 IGNITION SWITCH6 551898 1 INSTRUMENT PANEL (WITH DECAL)7 604889 1 INSTRUMENT PANEL DECAL8 601098 2 CB 10-24 X .500 ZYNC9 055947 1 CS .250-20 X .50 HX G510 601096 1 THROTTLE CABLE11 704932 2 FW .219 X .50 X .04812 059832 2 NT #10-24 HX NL ZN13 604324 8 CS .250-20 X .75 HX FLG14 601982 1 CN .250-20 X .15 MAX THK15 605083 1 RS FENDER16 605082 1 LS FENDER17 000331 2 WIRE TIE18 554781 1 FOOTREST (WITH DECAL)19 605072 1 BIG DOG DECAL20 029629 2 CS .375-16 X .75 HX FLK21 016899 2 NT .375-16 HX G5 FLK22 601053 2 SEALED RELAY (WITH BRACKET)23 604876 1 WIRE HARNESS 24 114052 1 CLUTCH CONNECTOR REPAIR KIT

2-6 124973EX_0119

Battery

12

7

5

6

6

3

5 4

BATTERY

6

POSITIVE BATTERYCABLE

7

6

NEGATIVE BATTERYCABLE

9

124973EX_0119 2-7

Battery

NOTES:

1. When performing service on the mower, disconnect the negative battery cable (black) and do not reconnect it to the battery until ready to start the engine.


1 604178 1 TIE DOWN STRAP2 604465 2 CS .250-20 X 7.50 HX G53 768515 2 FW .281 X .625 X .0664 771428 1 RED BATTERY CABLE BOOT5 024927 2 NT .250-20 HX G56 029868 4 LW .250 INT-EXT TOOTH Z7 055939 2 CS .250-20 X .75 HX G58 000331 2 WIRE TIE (NOT SHOWN)9 601982 2 CN .250-20 X .15 MAX THK

2-8 124973EX_0119

Engine Guard

NOTES:

INDEX NO. PART NO. QTY DESCRIPTION

1 119236 1 ENGINE GUARD SCREEN2 190327 1 ENGINE GUARD3 016832 6 NT .312-18 HX FLK4 016899 4 NT .375-16 HX G5 FLK5 016253 6 CB .312-18 X .75 FUL ZN6 029629 4 CS .375-16 X .75 HX FLK

1

23

5

6

5

4

124973EX_0119 2-9

This page intentionally left blank.

2-10 124973EX_0119

Lights

1

1

1

3

3

5

6

4

2

5

124973EX_0119 2-11

Lights

NOTES:

1. Part of the Fender & Instrument Panel Assembly.


1 190246 1 LIGHT ANGLE2 605209 4 CS #8-32 X .500 PH TRX3 605208 4 NT #8-32 HX NL ZN4 605003 2 LIGHT5 604307 2 PUSH BUTTON MOUNT6 000331 4 WIRE TIE7 000430 1 WIRE TIE (NOT SHOWN)8 605010 1 LIGHT WIRE HARNESS (NOT SHOWN)

2-12 124973EX_0119

124973EX_0119 3-1

Section 3

Transmission Assembly—42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Transmission Assembly—52" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Transmission Service Parts—42" . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Transmission Service Parts—52" . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Steering & Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Steering Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-2 124973EX_0119

Transmission Assembly—42"

1

3

1

4

7

9

13

17

18

810

11 12

101915

16

1516

2

6 1

14

4

5

6

21

2

6 1

2

2

2

5

2

2

124973EX_0119 3-3


NOTES:

1. Torque to 17 ft-lbs.2. Do not torque; the idler arm must pivot freely.


1 710087 4 CS .312-18 X 2.50 HX G52 768523 16 FW .343 X .687 X .051/.080H3 604343 1 CB .375-16 X 2.25 STD ZN4 043067 4 CS .312-18 X 3.00 HX G5 Z5 016899 2 NT .375-16 HX G5 FLK6 058776 8 NT .312-18 HX G5 ZY NL7 603907 1 DRIVE BELT8 080655 1 CS .375-16 X 1.50 HX G59 116289 1 IDLER SPACER10 767954 10 FW .379 X .813 X .06311 604491 1 PULLEY 2.0" IDLER12 604490 1 SPRING13 116287 1 IDLER ARM14 005108 1 CS .375-16 X 3.50 HX G5 Z15 706549 2 HP .080D X 1.1916 116218 2 TOW VALVE LINK17 712893 1 FW .406 X 1.25 X .12 HRD Z18 086660 1 NT .375-16 G5 NL19 054502 5 NT .375-16 HX G5

3-4 124973EX_0119


24

10

28

10

23

2120

21

22

27

21

28

26

21

FRONT OFMOWER

25

10

1910

LEFT SIDE SHOWNRIGHT SIDE SIMILAR

124973EX_0119 3-5


NOTES:


20 068551 2 NT .250-20 HX ZY NL21 768515 8 FW .281 X .625 X .06622 601051 2 OVERTRAVEL SPRING23 601131 2 SPRING24 116143 2 ACTUATOR25 606765 1 LS TRANSMISSION26 606766 1 RS TRANSMISSION27 123634-2 1 HYDROSTAT CROSS BRACE28 056036 4 CS .375-16 X 2.25 HX G5

3-6 124973EX_0119


1

3

1

4

7

9

13

17

18

8

1011 12

101915

16

1516

2

6 1

14

4

5

6

2 1

2

6 1

2

2

2

5

2

2

124973EX_0119 3-7


NOTES:

1. Torque to 17 ft-lbs.2. Do not torque; the idler arm must pivot freely.


1 710087 4 CS .312-18 X 2.50 HX G52 768523 16 FW .343 X .687 X .051/.080H3 604343 1 CB .375-16 X 2.25 STD ZN4 043067 4 CS .312-18 X 3.00 HX G5 Z5 016899 2 NT .375-16 HX G5 FLK6 058776 8 NT .312-18 HX G5 ZY NL7 603907 1 DRIVE BELT8 080655 1 CS .375-16 X 1.50 HX G59 116289 1 IDLER SPACER10 767954 10 FW .379 X .813 X .06311 604491 1 PULLEY 2.0" IDLER12 604490 1 SPRING13 116287 1 IDLER ARM14 005108 1 CS .375-16 X 3.50 HX G5 Z15 706549 2 HP .080D X 1.1916 116218 2 TOW VALVE LINK17 712893 1 FW .406 X 1.25 X .12 HRD Z18 086660 1 NT .375-16 G5 NL19 054502 5 NT .375-16 HX G5

3-8 124973EX_0119


24

1028

10

23

2120

21

22

27

21

28

26

21LEFT SIDE SHOWNRIGHT SIDE SIMILAR

FRONT OFMOWER

25

10

19

10

124973EX_0119 3-9


NOTES:


20 068551 2 NT .250-20 HX ZY NL21 768515 8 FW .281 X .625 X .06622 601051 2 OVERTRAVEL SPRING23 601131 2 SPRING24 116143 2 ACTUATOR25 604128 1 RS TRANSMISSION26 604127 1 RS TRANSMISSION27 123634-2 1 HYDROSTAT CROSS BRACE28 056036 4 CS .375-16 X 2.25 HX G5

3-10 124973EX_0119

Transmission Service Parts—42"

606765 LEFT SIDE TRANSMISSION


1 795047 1 PARKING PAWL KIT2 798371 1 RETAINING RING3 798363 1 PARK BRAKE GEAR4 602094 1 FAN/PULLEY KIT5 607237 1 END CAP6 788877 1 HUB NUT7 607236 1 4-LUG HUB KIT (WITH NUT)8 604902 1 HG RTN CCW9 604903 1 HG RTN SPRING

606766 RIGHT SIDE TRANSMISSION


1 795047 1 PARKING PAWL KIT2 798371 1 RETAINING RING3 798363 1 PARK BRAKE GEAR4 602094 1 FAN/PULLEY KIT5 607237 1 END CAP6 788877 1 HUB NUT7 607236 1 4-LUG HUB KIT (WITH NUT)8 604901 1 HG RTN CW9 604903 1 HG RTN SPRING

423

7

1

6

8

9

LEFT SIDE TRANSMISSION SHOWNRIGHT SIDE SIMILAR

5

124973EX_0119 3-11

Transmission Service Parts—52"

604127 RIGHT SIDE TRANSMISSION


1 795047 1 PARKING PAWL KIT2 798371 1 RETAINING RING3 798363 1 PARK BRAKE GEAR4 602094 1 FAN/PULLEY KIT5 601433 1 4 BOLT HUB KIT (WITH NUT)6 788877 1 HUB NUT7 604903 1 HG RTN SPRING8 604901 1 HG RTN CW

604128 LEFT SIDE TRANSMISSION


1 795047 1 PARKING PAWL KIT2 798371 1 RETAINING RING3 798363 1 PARK BRAKE GEAR4 602094 1 FAN/PULLEY KIT5 601433 1 4 BOLT HUB KIT (WITH NUT)6 788877 1 HUB NUT7 604903 1 HG RTN SPRING8 604902 1 HG RTN CCW

3

4

5

2

1

6

8

7

RS TRANSMISSIONSHOWNLS SIMILAR

3-12 124973EX_0119

Steering & Brake


14

2

16

3

12

2

3

14

19

6

8

FRONT OF MOWER

4

11

7

5

11

1

FRONT OF MOWER

5

9

20

21

22 21

23

3

10

2

2

18

159

13

VIEWED FROMUNDERNEATH

RIGHT SIDE SHOWNLEFT SIDE SIMILAR

17

18

124973EX_0119 3-13

Steering & Brake

NOTES:

1. Part of the Transmission Assembly.2. Torque to 14 ft-lbs.


1 603983 2 DAMPER2 781922 4 BALL STUD3 768523 6 FW .343 X .687 X .051/.080H4 601069 2 CN .312-18 X .20 MAX THK5 768515 4 FW .281 X .625 X .0666 048553 2 CP .062D X 1.00 LG HML Z7 068551 2 NT .250-20 HX ZY NL8 772483 2 SB .312 X .75 SH .250-209 605273 2 STEERING ROD ASSEMBLY10 023655 2 NT .312-24 HX G5 NL11 606575 2 CLIP12 110370 2 STEERING HANDLE (WITH GRIP)

781260 1 STEERING BAR GRIP13 N/A 1 STEERING COVER ASSEMBLY14 029629 5 CS .375-16 X .75 HX FLK15 767954 4 FW .379 X .813 X .06316 036244 4 CS .375-16 X 1.00 HX G517 029751 2 CS .375-16 X 1.00 HX FLK18 016899 7 NT .375-16 HX G5 FLK19 034272 2 NT .312-18 HX G520 604173 2 YOKE, 5/16-2421 041152 6 NT .312-24 HX ZNYC22 603905 2 STEERING ROD23 116144 2 STEERING BUSHING

3-14 124973EX_0119

Steering Cover Assembly

5

8

11

1

2

36

7

12

9

5

6 20

14

9

13 17

1517

11

1816

19

1

2

322

8

10

10

13

14

14

14

15

15

15

1621

17

17

47

14

4

14

1

1

22

124973EX_0119 3-15


NOTES:

1. Do not torque; the brake bell crank must pivot freely.


1 604452 2 CS .250-20 X 2.00 HX FLTHD2 768515 4 FW .281 X .625 X .0663 605529 2 DRIVE STRAIGHT STOP4 055939 2 CS .250-20 X .75 HX G55 601822 2 NUT PLATE .420 CENTERS6 781211 2 PUSH BUTTON SWITCH7 086660 2 NT .375-16 HX G5 ZY NL8 781708 2 CS .500-13 X 4.25 HX G59 781567 2 NT .500-13 HX G8 ZY NL10 063198 4 CS 10-24 X .75 HX FLK ZN11 005108 2 CS .375-16 X 3.50 HX G5 Z12 606106 1 LS STEERING BOX13 604288 2 STEERING SPACER14 768523 8 FW .343 X .687 X .051/.080H15 058776 4 NT .312-18 HX NL G516 604179 2 BRAKE ROD17 765339 4 BUSHING18 116142 1 LS BRAKE BELLCRANK19 785139 1 LS STEERING DECAL20 606105 1 RS STEERING BOX21 116141 1 RS BRAKE BELLCRANK22 785220 1 RS STEERING DECAL

3-16 124973EX_0119


24

22

2526

23

27

28

29

29

124973EX_0119 3-17


NOTES:


23 016899 1 NT .375-16 HX FLK G524 552456 1 STEERING COVER (WITH DECALS)25 605074 1 KICK PAN DECAL26 554780 1 DECK HEIGHT ASSEMBLY (WITH DECAL)27 029629 1 CS .375-16 X .75 HX FLK28 607109 1 DECK HEIGHT DECAL29 781153 4 BUSHING

3-18 124973EX_0119

124973EX_0119 4-1

Section 4

Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-2 124973EX_0119

Wheel & Tire

12

3

456

6

7

8

1

124973EX_0119 4-3

Wheel & Tire

NOTES:

1. Torque to 65–75 ft-lbs.


1 604963 2 TIRE/WHEEL ASSEMBLY 18 X 8.5-82 061077 8 WHEEL NUT3 705954 2 CS .500-13 X 1.25 HX G54 344267 2 FW .510 X 2.15 X .187 SPL5 712976 2 FW .531 X 1.375 X .1256 784223 4 BEARING7 784603 2 SPACER8 N/A 2 FRONT WHEEL ASSEMBLY

4-4 124973EX_0119

Front Wheel Breakdown

2

5

6

4

1

7

78

6

3

3


124973EX_0119 4-5

Front Wheel Breakdown

NOTES:


1 190026 1 FORK2 707398 1 NT .500-13 JAM NY LK3 767962 2 FW .531 X 1.063 X .1754 604718 1 CS .500-13 X 6.50 HX G55 306969 1 GAUGE WHEEL SPACER6 604962 1 TIRE/WHEEL 11 X 4-57 772806 2 BEARING CAP8 772814 1 3/4" ROLLER BEARING

4-6 124973EX_0119

Drive Wheel Breakdown

NOTES:

604963 TIRE & WHEEL ASSEMBLY


1 605433 1 TIRE, 18 X 7.0-82 605264 1 WHEEL ASSEMBLY, 8 X 5.3753 019521 1 VALVE STEM

1

2

3

124973EX_0119 5-1

Section 5

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Engine Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-2 124973EX_0119

Engine

14

9

15

2

1

1

3

38

4

6

7

16

5

11 10

2

5

14

5

5

8

12

13

3

124973EX_0119 5-3

Engine

NOTES:

1. Supplied with the engine.2. Torque to 45–48 ft-lbs. Replace (do not reuse) the cap screw if it is

removed or loosened. Use only hand tools to install this fastener.3. Torque to 30–35 ft-lbs. Replace (do not reuse) the cap screw if it is

removed or loosened. Use only hand tools to install this fastener.4. Torque to 17 ft-lbs.


1 N/A 1 KAWASAKI FR691V & FR651V ENGINES2 604463 12" OIL DRAIN HOSE3 604016 1 MUFFLER4 016899 1 NT .375-16 HX G5 FLK5 767954 5 FW .379 X .813 X .0636 121625 1 CLUTCH ANCHOR7 036244 1 CS .375-16 X 1.00 HX G58 602580 4 CS .375-16 X 1.25 HX G8 P859 605574 1 PULLEY

10 712372 1 KEY 1/4 SQ X .66 LG11 000331 3 WIRE TIE12 791251 1 CLUTCH HARNESS PIGTAIL13 605595 1 CLUTCH BUSHING14 605827K 1 CLUTCH KIT15 602680 1 FW .453 X 1.12 X .119 HRD16 785048 1 CS .437-20 X 3.00 HX G5 P85

5-4 124973EX_0119

Engine

25

15A FUSE

BLK

RED

2223

20

1817

19

RED

BLK

26

2424

A

115

6

6

6

6

6

18

21

6

1

SEAT SUPPORTWITH GROMMET

6

124973EX_0119 5-5

Engine

NOTES:

5. Part of the fuel system.6. Part of the wire harness.


17 055939 2 CS .250-20 X .75 HX G518 768515 4 FW .281 X .625 X .06619 044255 1 NT #10-32 HX ZN20 030817 1 STARTER SOLENOID21 024927 2 NT .250-20 HX G522 029876 1 LW .312 INT-EXT TOOTH23 720516 1 CS M8 X 1.25 X 16 HX FL 10.924 000323 2 HOSE CLAMP25 015818 18" 1/4" FUEL LINE26 604274 1 3/16" FORMED VAPOR LINE

FUEL & VAPOR LINE LENGTHS

18" TANK TO FUEL FILTER (FUEL)A

5-6 124973EX_0119

Engine Service Parts

NOTES:


1 604240 1 AIR FILTER2 068478 1 IN-LINE FUEL FILTER3 602581 1 OIL FILTER4 604350 1 OIL DRAIN VALVE5 604369 1 O-RING

2

3

4

1

5

124973EX_0119 5-7


5-8 124973EX_0119

Fuel System

8

9

10

6

7 3

4

6

7 6

7

2

11

12

13

14

1

15

15B

B

14

15 C

16

FRONT OFMOWER

5

5A

A

124973EX_0119 5-9

Fuel System

NOTES:


1 606432 1 FUEL TANK ASSEMBLY2 603807 1 RATCHETING GAS CAP, 3.5"3 117059 1 LEFT TANK MOUNT4 117060 1 RIGHT TANK MOUNT5 713198 18.5" SEAL 3/8 X 3/46 055939 3 CS .250-20 X .75 HX G57 768515 3 FW .281 X .625 X .0668 604279 1 3/16" FORMED VAPOR LINE9 604322 1 1/4" HOSE BARB CROSS10 604273 1 3/16" FORMED VAPOR LINE11 604292 1 BOOT, 3/16" TO 1/4" BARB12 604323 1 VAPOR SYSTEM FILTER13 000331 2 WIRE TIE14 604307 2 PUSH BUTTON MOUNT15 033035 22" WEATHERSTRIP16 601400 1 GM .63 X 1.13 X .88 X .13

SEAL & WEATHERSTRIP LENGTH

9.25"

5"

12"

ABC

5-10 124973EX_0119

124973EX_0119 6-1

Section 6

42" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

42" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

42" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

52" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

52" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

52" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Deck Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Spindle Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-2 124973EX_0119

42" Service Deck

NOTES:


1 554656 1 42" DECK (WITH DECALS)2 604221 1 DANGER/CHUTE DECAL3 604222 1 DANGER/OBJECTS DECAL4 793521 1 42" DECK ID DECAL

1

2

3

4

124973EX_0119 6-3


6-4 124973EX_0119

42" Deck Pulleys & Spindles

14

22

17

13

4

2

1

15

1

23

2

11

16

21

5

5

6

2

127

8

3

18

19

1

3

3

4

9

10

20

124973EX_0119 6-5


NOTES:

1. Torque to 18 ft-lbs.2. Torque to 75 ft-lbs.3. Torque to 73 ft-lbs.4. Torque to 30 ft-lbs. The idler arm must pivot freely.


1 781567 2 NT .500-13 NL2 767962 2 FW .531 X 1.063 X .1753 603986 1 IDLER PULLEY, 4.00" FLAT4 086660 1 NT .375-16 G5 NL5 712893 2 FW .406 X 1.25 X .12 HRD Z6 117512 1 IDLER ARM7 122388 1 IDLER SPRING8 604110 1 SPRING TENSIONER ANCHOR9 601839 1 PIVOT SPACER BUSHING

10 117539 1 SPACER11 604253 1 CB .50-13 X 2.00 STD ZN12 604219 1 IDLER PULLEY, 4.00" FLAT13 606943 2 NT .562-18 HX G5 NL14 603987 2 PULLEY15 604123 2 PULLEY SPACER16 036236 8 CS .312-18 X 1.00 HX G517 768523 8 FW .343 X .687 X .051/.080H18 604251 1 NT .312-18 HX NL JAM G2 ZN19 122398 1 TENSIONING PULLEY STOP20 037887 1 CB .312-18 X 1.00 FULL ZN21 080655 1 CS .375-16 X 1.50 HX G522 604254 1 CB .50-13 X 2.50 STD ZN23 604214 2 SPINDLE ASSEMBLY

6-6 124973EX_0119

42" Deck

2

7

4

16

14

3

5

2

610

98

1

15

17

19

9

9 18

10

22

1

11

12

13

811

124973EX_0119 6-7

42" Deck

NOTES:

1. Torque to 48 ft-lbs.2. Torque to 2–5 ft-lbs on these 4 self-tapping screws.


1 604403 2 PULLEY COVER2 604324 4 CS .250-20 X .75 HX FLG3 600726 1 BELT, A 114.3" EL4 606931 1 DISCHARGE CHUTE5 606981 1 DISCHARGE CHUTE PIN6 604331 1 CHUTE SPRING7 603332 1 CLIP E .66 X .303 X .0358 781567 3 NT .500-13 NL9 767962 FW .531 X 1.063 X .13710 788166 1 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)11 074252 2 CS .500-13 X 1.50 HX G512 124837-2 1 PULLER13 606250 2 PIVOT SPACER BUSHING14 603992 2 BLADE, 20.50"-M-F-CW15 602680 2 FW .453 X 1.12 X .119 HRD16 754101 2 CS .437-20 X 1.25 HX G5 ZNY

794685 2 BLADE, F20.50"-H-F-CW793935 2 BLADE, 20.50"-CAT-F-CW794230 2 BLADE, 20.50"-GAT-F-CW

17 781708 1 CS .500-13 X 4.25 HX G518 031997 1 PLASTIC WHEEL19 053199 1 NT .500-13 HX JAM ZNYC

6-8 124973EX_0119

52" Service Deck

NOTES:

INDEX NO. PART NO. QTY DESCRIPTION

1 554658 1 52" DECK (WITH DECALS)2 601624 1 DISCHARGE CHUTE DECAL3 601837 1 DECK DANGERS DECAL 4 785535 1 52 DECK ID DECAL5 604222 1 DANGER / OBJECTS DECAL

1

2

3

4

5

124973EX_0119 6-9


6-10 124973EX_0119


3 1

2

3

4

1

2 16

17

9

15

12

13

11

10

6 5

78

1

2

18

19

20

8

262523

24

22

42

1

3

314

19

21

124973EX_0119 6-11


NOTES:

1. Torque to 18 ft-lbs. 2. Torque to 75 ft-lbs. 3. Torque to 73 ft-lbs.4. Torque to 30 ft-lbs. The idler arm must pivot freely.


1 781567 3 NT .500-13 NL2 767962 3 FW .531 X 1.063 X .1373 603986 1 IDLER PULLEY, 4.00" FLAT4 124942-4 1 IDLER ARM5 122388 1 IDLER SPRING6 604110 1 SPRING TENSIONER ANCHOR7 086660 1 NT .375-16 G8 NL8 712893 2 FW .406 X 1.25 X .12 HRD Z9 604253 1 CB .50-13 X 2.00 STD ZN10 606943 3 NT .562-18 HX G5 NL11 603988 3 DRIVE PULLEY "B-SEC"12 036236 12 CS .312-18 X 1.00 HX G513 768523 12 FW .343 X .687 X .051/.080H14 604123 3 PULLEY SPACER15 604231 1 IDLER PULLEY, 5.00" O.D.16 601839 1 PIVOT SPACER BUSHING17 117539 1 SPACER18 604219 1 IDLER PULLEY, 4.00" FLAT19 604251 2 NT .312-18 HX NL JAM G2 ZN20 122398 1 TENSIONING PULLEY STOP21 017129 1 FW .440 X 1.00 X .083 ZNY22 604214 3 SPINDLE ASSEMBLY23 604254 2 CB .50-13 X 2.50 STD ZN24 037887 1 CB .312-18 X 1.00 FULL ZN25 083147 1 CB .312-18 X .620 G5 ZN26 080655 1 CS .375-16 X 1.50 HX G5

6-12 124973EX_0119

52" Deck1

4

8

5

14

17

15

3

6

2

7

9

18

20

13

13 19

14

1

16

1210

2 22

11

9 1213

124973EX_0119 6-13

52" Deck

NOTES:

1. Torque to 48 ft-lbs.2. Torque to 2–5 ft-lbs on these 4 self-tapping screws.


1 604337 1 RS PULLEY COVER2 604324 4 CS .250-20 X .75 HX FLG3 604338 1 LS PULLEY COVER4 607162 1 BELT, B-SEC 138.00"5 606931 1 DISCHARGE CHUTE6 606981 1 DISCHARGE CHUTE PIN7 604331 1 CHUTE SPRING8 603332 1 CLIP E .66 X .303 X .0359 074252 2 CS .500-13 X 1.50 HX G510 124837-2 1 PULLER11 606250 2 PIVOT SPACER BUSHING12 781567 4 NT .500-13 NL13 767962 6 FW .531 X 1.063 X .13714 788166 2 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)15 603995 3 BLADE, 17.86"-M-F-CW

783753 3 BLADE, 17.86"-L-F-CW787721 3 BLADE, 17.86"-H-F-CW603848 3 BLADE, 17.86"-CAT-F-CW794198 3 BLADE, 17.86"-MUL-F-CW785436 3 BLADE, 17.86"-GAT-F-CW

16 602680 3 FW .453 X 1.12 X .119 HRD17 754101 3 CS .437-20 X 1.25 HX G5 ZNY18 781708 1 CS .500-13 X 4.25 HX G519 031997 1 PLASTIC WHEEL20 053199 1 NT .500-13 HX JAM ZNYC

6-14 124973EX_0119

Deck Lift1

2

34 5

6

7

410

9

8

3

4

56

7

1114

8

154

1617

18

4 10

14

1920

1920

1722

23

RIGHT SIDE

11

2

11

12

13

2

124973EX_0119 6-15

Deck Lift

NOTES:


1 607039 1 MAGNETIC PIN .375 X 1.62 2 016899 10 NT .375-16 HX G5 FLK3 086660 4 NT .375-16 G8 NL4 767954 8 FW .379 X .813 X .0635 605114 4 FW .41 X .94 X .25 UHMW6 118018 4 PIVOT7 607017 4 DECK HANGER8 791673 8 E CLIP .625 X .480 X .042 Z9 124792-2 1 REAR DECK LIFT BAR10 054502 2 NT .375-16 HX G511 029629 10 CS .375-16 X .75 HX FLK12 722199 8" WEAR TAPE13 125224-4 1 DECK HEIGHT SPACER BRACKET14 116151 4 PIVOT BLOCK15 005132 2 CS .375-16 X 1.12 HX G5 Z16 601839 2 PIVOT SPACER BUSHING17 607119-4 1 DECK LIFT LINK18 190167 1 FRONT DECK LIFT BAR19 607093 4 CP RUE RING .054 X .39220 768523 4 FW .343 SAE21 074252 2 CS .500-13 X 1.50 HX G522 606250 2 PIVOT SPACER BUSHING23 781567 2 NT .500-13 NL

6-16 124973EX_0119

Deck Lift

2

2

3

45

8

6

7

9

1114

3

4

5 8

6

7

18

1114

1920

21

2223

1920

LEFT SIDE

11

124973EX_0119 6-17

Spindle Breakdown

NOTES:


1 604019 1 TOP BEARING2 604218 1 SPINDLE HOUSING3 607274 1 SPINDLE SHAFT ASSEMBLY

1

2

3

6-18 124973EX_0119

124973EX_0119 7-1

Section 7

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-2 124973EX_0119

Seat

1

2

5

8

12

4

1

6

3

2

9

10

11

1314

4

4

4

12

BOTTOM VIEW

7

124973EX_0119 7-3

Seat

NOTES:

1. Do not torque; the seat pan must pivot freely.2. Torque to 7 ft-lbs.


1 605009 1 SEAT2 554782 1 SEAT PAN (WITH DECALS)3 604307 1 PUSH BUTTON MOUNT4 767954 4 FW .379 X .813 X .0635 086660 2 NT .375-16 G5 NL6 000331 1 WIRE TIE7 768523 4 FW .343 X .687 X .051/.080H8 036236 4 CS .312-18 X 1.00 HX G59 029629 2 CS .375-16 X .75 HX FLK

10 793851 2 COMPRESSION SPRING 1.25 X 4.00 X .18811 016899 2 NT .375-16 HX G5 FLK12 036244 2 CS .375-16 X 1.00 HX G513 602243 1 BELT ROUTING DECAL (42")

781419 1 BELT ROUTING DECAL (52")14 601815 1 BATTERY WARNINGS DECAL

7-4 124973EX_0119

Seat Service Parts

NOTES:


1 119783 1 ARMREST KIT2 793315 1 SEAT SWITCH

2

1

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