BIG DOG MOWER CO. ALPHA · 2019-10-14 · BIG DOG® MOWER CO. ALPHA ... This manual covers BigDog®...

200 South Ridge RoadHesston, Kansas

67062

BIG DOG® MOWER CO. ALPHA®

Parts Manual

The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner’s manual.

Federal law and California State law prohibit the following acts or the causing thereof:1. The removal or rendering inoperative by any person other than for purposes of maintenance,

repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or

2. The use of the equipment after such device or element of design has been removed or rendered inoperative by any person.

NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER

This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER.

Inspect spark arrester daily; replace every 500 hours or as needed.

WARNINGThe engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

119296_0118 c-1

Table of Contents

General InformationService Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Options Available From Your Dealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 236" Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-242" & 52" Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Fenders & Instrument Panel, Kawasaki . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Fenders & Instrument Panel, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Section 3Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Transmission Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Steering & Brake—S/N 16053188 & Higher . . . . . . . . . . . . . . . . . . . . . . 3-8Steering & Brake—S/N Prior to 16053188 . . . . . . . . . . . . . . . . . . . . . . 3-10Steering Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Section 4Wheel & Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Drive Wheel Breakdown—18 X 7.0–8. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Drive Wheel Breakdown—18 X 8.5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Section 5Engine, Kawasaki FR541V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Engine Service Parts, Kawasaki FR541V. . . . . . . . . . . . . . . . . . . . . . . . 5-6Engine, Kawasaki FR651V & FR691V . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Engine Service Parts, Kawasaki FR651V & FR691V . . . . . . . . . . . . . . 5-12Fuel System, Kawasaki. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14Engine, Kohler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Engine Service Parts, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20Engine Service Parts, Kohler Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21Fuel System, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Section 636" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-436" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-642" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-842" Deck Pulleys & Spindles—S/N 1601A762 & Higher. . . . . . . . . . . . 6-1042" Deck Pulleys & Spindles—S/N Prior to 1601A762 . . . . . . . . . . . . . 6-1242" Deck—S/N 14030001 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1442" Deck—S/N Prior to 14030001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

c-2 119296_0118

36"/42" Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1852" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2052" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2252" Deck—S/N 14030001 & Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2452" Deck—S/N Prior to 14030001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2652" Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Section 7Seat—Without Armrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Seat—With Armrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4Seat Service Parts—605009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

119296_0118 1-1

General Information

This manual covers BigDog® Alpha Mower models 932897, 932913, 933374, 933416, 933606, 934422, 934430, 935973, 935981, 935999 & 936575.

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. DESCRIPTION605045 OPERATOR’S MANUAL119552 WARRANTY STATEMENT119293 GENERAL SERVICE MANUAL

PART NO. DESCRIPTION933010 CATCHER119937 36" MULCH KIT117578 42" MULCH KIT117581 52" MULCH KIT119603 ENGINE GUARD KIT119600 LIGHT KIT (42")333724 STEERING EXTENSION KIT799288 FLEX FORK KIT119783 ARMREST KIT (42")

1-2 119296_0118

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

119296_0118 2-1

Section 2

36" Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

42" & 52" Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Fenders & Instrument Panel, Kawasaki. . . . . . . . . . . . . . . . . . . . . . . 2-6

Fenders & Instrument Panel, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-2 119296_0118

36" Frame

28

BUMPER

5

22

25

231

16

21

20

19

6

169

9

17

9

6

13

615

12

6

15

1414

9

11

6

2

42

8

9 107

3

12

6

12918

13

12

26 27

12

27

12

13

6

27

26

26

6

6

9

27

26

6

9

63 22

2 22

27

24

13

119296_0118 2-3

36" 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. Patent numbers decal.4. Torque all hardware to a minimum of 33 ft-lbs.

INDEX NO. PART NO. QTY. DESCRIPTION

1 123637-3 1 SEAT SUPPORT2 029629 10 CS .375-16 X .75 HX FLK3 123636-3 1 SPRING SUPPORT4 553643 1 BUMPER (WITH DECALS)5 602041 1 HOT DECAL6 604176 30 CS .375-16 X .75 HX FLK PLN7 552421 1 ENGINE PLATE (WITH DECAL)8 190183 1 RS REAR BRACKET9 604177 30 NT .375-16 HX FLK PLN

10 600899 1 PUMP BELT WARNING DECAL11 190184 1 LS REAR BRACKET12 016899 10 NT .375-16 HX G5 FLK13 601982 5 CN .250-20 X .15 MAX THK14 190189 2 CROSS SUPPORT15 190185 2 RS FRONT BRACKET16 190186 2 HYDRO BRACKET17 190187 1 BATTERY TRAY18 552422 1 FOOT PAN (WITH DECAL)19 552424 1 RS FRAME CHANNEL (WITH DECAL)20 190226 1 FRONT CROSS FRAME21 552423 1 LS FRAME CHANNEL (WITH DECALS)22 N/A 3 SERIAL NUMBER / SPEC DECAL23 601967 1 ENGINE COMPARTMENT DECAL24 605782 1 LEVEL FUEL FILL DECAL25 601981 1 SAFE OPERATION DECAL26 604307 6 PUSH BUTTON MOUNT27 000331 6 WIRE TIE28 605073 1 BUMPER DECAL

2-4 119296_0118

42" & 52" Frame

7

6

28

20

22

3

1

3

15

23

144

9

21

9

3

14

18

5

10

12

3

1

2

7

8

3

9

4

4

9

15

912

13

19

9

3

11

3

311

9

25

3

25

927

16

3

9

17

25

26

26

9

9

17

11

4

9

17

917

3

220

3 20

24

119296_0118 2-5

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. Patent numbers decal.4. Torque all hardware to a minimum of 33 ft-lbs.


1 123637-3 1 SEAT SUPPORT2 123636-3 1 SPRING SUPPORT3 029629 10 CS .375-16 X .75 HX FLK4 604176 30 CS .375-16 X .75 HX FLK PLN5 190183 1 RS REAR BRACKET6 602041 1 HOT DECAL7 553643 1 BUMPER (WITH DECALS)8 552421 1 ENGINE PLATE (WITH DECAL)9 604177 30 NT .375-16 HX FLK PLN

10 190184 1 LS REAR BRACKET11 601982 5 CN .250-20 X .15 MAX THK12 190186 2 HYDRO BRACKET13 552424 1 RS FRAME CHANNEL (WITH DECAL)14 190185 2 RS FRONT BRACKET15 190189 2 CROSS SUPPORT16 600899 1 PUMP BELT WARNING DECAL17 016899 10 NT .375-16 HX FLK G518 552423 1 LS FRAME CHANNEL (WITH DECALS)19 601967 1 ENGINE COMPARTMENT DECAL20 N/A 3 SERIAL NUMBER / SPEC DECAL21 190188 1 FRONT CROSS FRAME22 552422 1 FOOT PAN (WITH DECALS)23 601981 1 SAFE OPERATION DECAL24 605782 1 LEVEL FUEL FILL DECAL25 604307 6 PUSH BUTTON MOUNT26 000331 6 WIRE TIE27 190187 1 BATTERY TRAY28 605073 1 BUMPER DECAL

2-6 119296_0118

Fenders & Instrument Panel, Kawasaki

1

8

95

42

6

7

12

13

13

14

10

11

15

19

20

5

13

13

16

23

2224

3

1817

119296_0118 2-7

Fenders & Instrument Panel, Kawasaki

NOTES:


1 601097 1 CHOKE CABLE2 776476 1 PTO SWITCH3 769166 1 HOUR METER4 605808 1 KEY ASSEMBLY5 045898 1 IGNITION SWITCH6 552300 1 INSTRUMENT PANEL (WITH DECAL)7 604889 1 INSTRUMENT PANEL DECAL8 055947 1 CS .250-20 X .500 HX G59 601098 2 CB 10-24 X .500 ZYNC

10 601096 1 THROTTLE CABLE11 704932 2 FW .219 X .500 X .048 ZNYC12 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 552432 1 FOOTREST (WITH DECAL)18 605072 1 BIG DOG DECAL19 029629 2 CS .375-16 X .75 HX FLK20 016899 2 NT .375-16 HX FLK G521 000331 2 WIRE TIE (NOT SHOWN)22 604876 1 WIRE HARNESS23 114052 1 CLUTCH CONNECTOR REPAIR KIT24 601053 2 SEALED RELAY (WITH BRACKET)

2-8 119296_0118

Fenders & Instrument Panel, Kohler

1

7

8

4

32

5

6

11

12

12

13

9

10

14

18

19

4

12

12

15

22

17

16

21

23

119296_0118 2-9

Fenders & Instrument Panel, Kohler

NOTES:


1 776476 1 PTO SWITCH2 769166 1 HOUR METER3 605808 1 KEY ASSEMBLY4 045898 1 IGNITION SWITCH5 553214 1 INSTRUMENT PANEL (WITH DECAL)6 605996 1 INSTRUMENT PANEL DECAL7 055947 1 CS .250-20 X .500 HX G58 601098 2 CB 10-24 X .500 ZYNC9 768879 1 THROTTLE CABLE10 704932 2 FW .219 X .500 X .048 ZNYC11 059832 2 NT #10-24 HX NL ZN12 604324 8 CS .250-20 X .75 HX FLG13 601982 1 CN .250-20 X .15 MAX THK14 605083 1 RS FENDER15 605082 1 LS FENDER16 552432 1 FOOTREST (WITH DECAL)17 605072 1 BIG DOG DECAL18 029629 2 CS .375-16 X .75 HX FLK19 016899 2 NT .375-16 HX FLK G520 000331 1 WIRE TIE (NOT SHOWN)21 605835 1 WIRE HARNESS22 114052 1 CLUTCH CONNECTOR REPAIR KIT23 601053 2 SEALED RELAY (WITH BRACKET)

2-10 119296_0118

Battery

12

7

5

6

6

3

5 4

BATTERY

6

POSITIVE BATTERYCABLE

7

6

NEGATIVE BATTERYCABLE

9

119296_0118 2-11

Battery

NOTES:

1. When performing service on the mower, disconnect the negative battery cable 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

2-12 119296_0118

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

119296_0118 2-13

This page intentionally left blank.

2-14 119296_0118

Lights

1

1

1

3

3

5

6

4

2

5

119296_0118 2-15

Lights

NOTES:

1. Part of the Fender & Instrument Panel Assembly.


1 190181 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)

2-16 119296_0118

119296_0118 3-1

Section 3

Transmission Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Transmission Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Steering & Brake—S/N 16053188 & Higher . . . . . . . . . . . . . . . . . . . 3-8

Steering & Brake—S/N Prior to 16053188 . . . . . . . . . . . . . . . . . . . 3-10

Steering Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-2 119296_0118

Transmission Assembly

1

3

1

2

3

5

11

12

13

14

6

7

8 9

1617

16

17

18

19

10

4

4

1 19

18

19 1

18

18

18

18

18

1

FRONT OFMOWER

7

15

18

119296_0118 3-3


NOTES:

1. Torque to 17 ft-lbs.


1 710087 4 CS .312-18 X 2.50 HX G52 604343 1 CB .375-16 X 2.25 STD ZN3 043067 4 CS .312-18 X 3.00 HX G5 Z4 016899 2 NT .375-16 HX G5 FLK5 603907 1 DRIVE BELT6 080655 1 CS .375-16 X 1.50 HX G57 767954 10 FW .379 X .813 X .0638 604491 1 2.0" IDLER PULLEY9 604490 1 SPRING

10 005108 1 CS .375-16 X 3.50 HX G5 Z11 116289 1 IDLER SPACER12 116287 1 IDLER ARM13 712893 1 FW .406 X 1.25 X .12 HRD Z14 086660 1 NT .375-16 G5 NL15 054502 5 NT .375-16 HX G516 706549 2 HP .080D X 1.1917 116218 2 TOW VALVE LINK18 768523 16 FW .343 X .687 X .051/.080H19 058776 8 NT .312-18 HX G5 ZY NL

3-4 119296_0118


20

20

7

21

15

157

7

20

7157

720

23

22

25 26

2725

25

28

24 25

25

2526

28

27

FRONT OFMOWER

24

7

119296_0118 3-5


NOTES:


20 056036 4 CS .375-16 X 2.25 HX G521 123634-3 1 HYDROSTAT CROSS BRACE22 604127 1 RS TRANSMISSION23 604128 1 LS TRANSMISSION24 116143 2 ACTUATOR25 768515 8 FW .281 X .625 X .06626 601051 2 OVERTRAVEL SPRING27 068551 2 NT .250-20 HX ZY NL28 601131 2 SPRING

3-6 119296_0118

Transmission Service Parts

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

119296_0118 3-7


3-8 119296_0118

Steering & Brake—S/N 16053188 & Higher

LEFT SIDE SHOWNRIGHT SIDE SIMILAR

13

2

15

12

1

14

17

3

32

3

FRONT OF

1

17

14

16

15

18

FRONT OF

6

7

8

4

11

9

5

5

8

19

20

21 20

22

STEERING COVERASSEMBLY

102

MOWER

MOWER2

119296_0118 3-9

Steering & Brake—S/N 16053188 & Higher

NOTES:

1. Part of the Hydraulic 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 772483 2 SB .312 X .75 SH .250-208 605273 2 STEERING ROD ASSEMBLY9 068551 2 NT .250-20 HX ZY NL

10 023655 2 NT .312-24 HX G5 NL11 606575 2 CLIP12 767954 4 FW .379 X .813 X .06313 110370 2 STEERING HANDLE (WITH GRIP)

781260 1 GRIP14 029629 5 CS .375-16 X .75 HX FLK15 036244 4 CS .375-16 X 1.00 HX G516 016899 6 NT .375-16 HX G5 FLK17 034272 2 NT .312-18 HX G518 029751 1 CS .375-16 X 1.00 HX FLK19 604173 2 YOKE, 5/16-2420 041152 6 NT .312-24 HX ZNYC21 603905 2 STEERING ROD22 116144 2 STEERING BUSHING

3-10 119296_0118

Steering & Brake—S/N Prior to 16053188


21

14

17

3

32

3

FRONT OF MOWER

1

1616

14

18

FRONT OF MOWER

6

78

4

10

9

5

5

8

19

20

21 20

22

STEERING COVERASSEMBLY

11

12

15

12

14

13

119296_0118 3-11

Steering & Brake—S/N Prior to 16053188

NOTES:

1. Part of the Hydraulic Assembly.


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 772483 2 SB .312 X .75 SH .250-208 605273 2 STEERING ROD ASSEMBLY9 068551 2 NT .250-20 HX ZY NL

10 606575 2 CLIP11 054502 4 NT .375-16 HX G5 ZNY12 767954 8 FW .379 X .813 X .06313 110370 2 STEERING BAR (WITH GRIP)

781260 1 STEERING BAR GRIP14 029629 5 CS .375-16 X .75 HX FLK15 080655 4 CS .375-16 X 1.50 HX G516 016899 6 NT .375-16 HX FLK G517 034272 2 NT .312-18 HX G518 029751 1 CS .375-16 X 1.00 HX FLK19 604173 2 YOKE, 5/16-2420 041152 6 NT .312-24 HX ZNYC21 603905 2 STEERING ROD22 116144 2 STEERING BUSHING

3-12 119296_0118

Steering Cover Assembly

8

27

11

14

1

2

3

9

10

16

12

89

2217

12

1521

1821

14

2019

24

1

2

3

2

2

11

13

13 15

17

17

17

18

18

18

192321

21

25

4

7

6 5

26

10

29

7

28

119296_0118 3-13

Steering Cover Assembly

NOTES:


1 604452 2 CS .250-20 X 2.00 HX FLTHD2 768515 4 FW .281 X .625 X .0663 605529 2 STEERING STOP4 551912 1 LATCH WITH DECAL5 029629 1 CS .375-16 X .75 HX FLK6 016899 1 NT .375-16 HX FLK G57 055939 2 CS .250-20 X .75 HX G58 601822 2 NUT PLATE .420 CENTERS9 781211 2 PUSH BUTTON SWITCH10 086660 2 NT .375-16 HX G5 ZY NL11 781708 2 CS .500-13 X 4.25 HX G512 781567 2 NT .500-13 HX G8 ZY NL13 063198 4 CS 10-24 X .75 HX FLK ZN14 005108 2 CS .375-16 X 3.50 HX G5 Z15 604288 2 STEERING SPACER16 606106 1 LS STEERING BOX (S/N 16053188 & HIGHER)

604300 1 LS STEERING BOX (S/N PRIOR TO 16053188)17 768523 8 FW .343 X .687 X .051/.080H18 058776 4 NT .312-18 NL G519 604179 2 BRAKE ROD20 116142 1 LS BRAKE BELLCRANK21 765339 4 BUSHING22 606105 1 RS STEERING BOX (S/N 16053188 & HIGHER)

604299 1 RS STEERING BOX (S/N PRIOR TO 16053188)23 116141 1 RS BRAKE BELLCRANK24 785220 1 RS STEERING DECAL25 785139 1 LS STEERING DECAL26 604275 1 DECK HEIGHT DECAL27 552456 1 STEERING COVER28 605074 1 KICK PAN DECAL29 781153 2 BUSHING

3-14 119296_0118

119296_0118 4-1

Section 4

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

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

Drive Wheel Breakdown—18 X 7.0–8 . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Drive Wheel Breakdown—18 X 8.5–8 . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-2 119296_0118

Wheel & Tire

12

3

456

6

7

8

1

119296_0118 4-3

Wheel & Tire

NOTES:

1. Torque to 65–75 ft-lbs.


1 604963 2 TIRE/WHEEL ASSEMBLY 18 X 8.5-8 (42" & 52" MOWERS)605263 2 TIRE/WHEEL ASSEMBLY 18 X 7.0-8 (36" MOWERS)

2 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 119296_0118

Front Wheel Breakdown

2

5

6

4

1

7

78

6

3

3


119296_0118 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 119296_0118

Drive Wheel Breakdown—18 X 7.0–8

NOTES:


1 605433 1 TIRE, 18 X 7.0-82 605264 1 WHEEL ASSEMBLY, 8 X 63 019521 1 VALVE STEM

2

3

1

119296_0118 4-7

Drive Wheel Breakdown—18 X 8.5–8

NOTES:


1 604267 1 TIRE, 18 X 8.5-82 604964 1 WHEEL ASSEMBLY, 8 X 6.9373 019521 1 VALVE STEM

2

3

1

4-8 119296_0118

119296_0118 5-1

Section 5

Engine, Kawasaki FR541V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Engine Service Parts, Kawasaki FR541V . . . . . . . . . . . . . . . . . . . . . 5-6

Engine, Kawasaki FR651V & FR691V . . . . . . . . . . . . . . . . . . . . . . . 5-8

Engine Service Parts, Kawasaki FR651V & FR691V . . . . . . . . . . . 5-12

Fuel System, Kawasaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Engine, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Engine Service Parts, Kohler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Engine Service Parts, Kohler Pro . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Fuel System, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-2 119296_0118

Engine, Kawasaki FR541V

12

11

15

2

1

5

3

6

8

9

16

7

14

13

4

10

7

2

3

14

1

119296_0118 5-3


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 FR541V ENGINE2 604369 1 O-RING3 604350 1 OIL DRAIN VALVE4 604463 12" OIL DRAIN HOSE5 602999 1 MUFFLER6 016899 1 NT .375-16 HX G5 FLK7 767954 5 FW .379 X .813 X .0638 116290 1 CLUTCH ANCHOR9 036244 1 CS .375-16 X 1.00 HX G5

10 602580 4 CS .375-16 X 1.25 HX G8 P8511 604185 1 STUB SHAFT PUMP PULLEY12 604244K 1 CLUTCH KIT13 791251 1 CLUTCH HARNESS PIGTAIL14 000331 3 WIRE TIE15 602680 1 FW .453 X 1.12 X .119 HRD16 604271 1 CS .437-20 X 4.00 HX G5

5-4 119296_0118


25

15A

BLK

22

23

18

1918

17

20RED

BLK

26

2424

A

14

5

6

6

66

6

6

RED 6

6 BLK

PUR

RED

FUSE

1821

21

1

SEAT SUPPORTWITH GROMMET

119296_0118 5-5


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 030817 1 STARTER SOLENOID20 044255 1 NT #10-32 HX ZN21 024927 2 NT .250-20 HX G522 029876 1 LW .325 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 LINE LENGTH

18" TANK TO FUEL FILTER (FUEL)A

5-6 119296_0118

Engine Service Parts, Kawasaki FR541V

NOTES:


1 604240 1 AIR FILTER2 068478 1 IN-LINE FUEL FILTER3 602581 1 OIL FILTER

2

3

1

119296_0118 5-7


5-8 119296_0118

Engine, Kawasaki FR651V & FR691V

1

1

2

9

12

13

5

6

7

14

4

3

6

2

10

11

8

3

14

119296_0118 5-9


NOTES:


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 FR651V & FR691V ENGINE2 604463 12" OIL DRAIN HOSE3 604016 1 MUFFLER4 016899 1 NT .375-16 HX G5 FLK5 116290 1 CLUTCH ANCHOR6 767954 5 FW .379 X .813 X .0637 036244 1 CS .375-16 X 1.00 HX G58 602580 4 CS .375-16 X 1.25 HX G8 P859 604185 1 STUB SHAFT PUMP PULLEY

10 000331 3 WIRE TIE11 791251 1 CLUTCH HARNESS PIGTAIL12 604244K 1 CLUTCH KIT13 602680 1 FW .453 X 1.12 X .119 HRD14 604271 1 CS .437-20 X 4.00 HX G5

5-10 119296_0118


16

19

17

15

16

20

21

1816

24

2223

6

5

5

5

5

A

5

5

BLK

RED

15AFUSE

BLK

5RED

10

BLK

PUR

RED

155

22

SEAT SUPPORTWITH GROMMET

1

119296_0118 5-11


NOTES:

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


15 055939 2 CS .250-20 X .75 HX G516 768515 4 FW .281 X .625 X .06617 044255 1 NT #10-32 HX ZN18 030817 1 STARTER SOLENOID19 024927 2 NT .250-20 HX G520 029876 1 LW .325 INT-EXT TOOTH21 720516 1 CS M8 X 1.25 X 16 HX FL 10.922 000323 2 HOSE CLAMP23 015818 18" 1/4" FUEL LINE24 604274 1 3/16" FORMED VAPOR LINE

FUEL LINE LENGTH

18" TANK TO ENGINEA

5-12 119296_0118

Engine Service Parts, Kawasaki FR651V & FR691V

NOTES:


1 603059 1 AIR FILTER2 068478 1 IN-LINE FUEL FILTER3 602581 1 OIL FILTER4 604350 1 OIL DRAIN VALVE5 604369 1 O-RING

2

3

1

5

4

119296_0118 5-13


5-14 119296_0118

Fuel System, Kawasaki

8

9

10

6

73

4

67

6

7

2

11

12

13

14

1

15

15B

B

4 3

5A

1415C

16

FRONT OFMOWER

119296_0118 5-15

Fuel System, Kawasaki

NOTES:


1 605958 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 (S/N 15079323 & HIGHER)

SEAL & WEATHERSTRIP LENGTH

9.25"

5"

12"

ABC

5-16 119296_0118

Engine, Kohler1

2

9

1314

5

6

7

15

4

3

2

12

8

3

14

10

11

1

119296_0118 5-17

Engine, Kohler

NOTES:


removed or loosened. Use only hand tools to install this fastener.3. Torque to 30 ft-lbs. Use only hand tools to install this fastener.4. Torque to 18 ft-lbs.


1 N/A 1 KOHLER KT610, KT725 & KT735 ENGINES2 604463 12" OIL DRAIN HOSE3 605793 1 MUFFLER4 016899 1 NT .375-16 HX G5 FLK5 121625 1 CLUTCH ANCHOR6 767954 1 FW .379 X .813 X .0637 036244 1 CS .375-16 X 1.00 HX G58 605814 4 SC .375-16 X 1.25 FLG9 605574 1 PULLEY10 712372 1 KEY 1/4 SQ X .66 LG11 605595 1 CLUTCH BUSHING12 791251 1 CLUTCH HARNESS PIGTAIL13 605827K 1 CLUTCH KIT14 602680 1 FW .453 X 1.12 X .119 HRD15 785048 1 CS .437-20 X 3.00 HX G5 P85

5-18 119296_0118

Engine, Kohler

17

19

23

2118

22

17

2627

28

6

55

A

5

5

BLK

RED

15AFUSE

BLK

24

RED

25

20 19

5RED

16

26

5

5

119296_0118 5-19

Engine, Kohler

NOTES:

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


16 029868 1 LW .250 INT-EXT TOOTH Z17 768515 4 FW .281 X .625 X .06618 603617 1 SC .250-20 X .50 HX FL STP19 024927 3 NT .250-20 HX G520 017038 1 LW .250 MED SPRING ZNYC21 055939 2 CS .250-20 X .75 HX G522 030817 1 STARTER SOLENOID23 044255 1 NT #10-32 HX ZN24 605894 1 3/16" FORMED VAPOR LINE25 604966 1 TRIM LOCK26 000331 2 WIRE TIE27 000323 2 HOSE CLAMP28 015818 18" 1/4" FUEL LINE

FUEL LINE LENGTH

18" TANK TO FUEL FILTER (FUEL)A

5-20 119296_0118

Engine Service Parts, Kohler


1 605989 1 AIR CLEANER ELEMENT2 747303 1 OIL FILTER3 606020 1 OIL DRAIN VALVE4 068478 1 IN-LINE FUEL FILTER

1

2

3

4

119296_0118 5-21

Engine Service Parts, Kohler Pro


1 605990 1 AIR CLEANER ELEMENT2 606095 1 OIL FILTER3 606020 1 OIL DRAIN VALVE4 068478 1 IN-LINE FUEL FILTER

1

2

3

4

5-22 119296_0118

Fuel System, Kohler

8

9

10

6

7 3

4

67

6

7

2

11

12

13

15

1

16

16B

B

1516C

5A

5A

14

119296_0118 5-23

Fuel System, Kohler

NOTES:


1 605958 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 CROSS

10 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 601400 1 GM .63 X 1.13 X .88 X .1315 604307 2 PUSH BUTTON MOUNT16 033035 22" WEATHERSTRIP

SEAL & WEATHERSTRIP LENGTH

9.25"

5"

12"

ABC

5-24 119296_0118

119296_0118 6-1

Section 6

36" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

36" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

42" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

42" Deck Pulleys & Spindles—S/N 1601A762 & Higher . . . . . . . . . 6-10

42" Deck Pulleys & Spindles—S/N Prior to 1601A762 . . . . . . . . . . 6-12

42" Deck—S/N 14030001 & Higher. . . . . . . . . . . . . . . . . . . . . . . . . 6-14

42" Deck—S/N Prior to 14030001 . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

36"/42" Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

52" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

52" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

52" Deck—S/N 14030001 & Higher. . . . . . . . . . . . . . . . . . . . . . . . . 6-24

52" Deck—S/N Prior to 14030001 . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

52" Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-2 119296_0118

36" Service Deck

NOTES:


1 552706 1 36" DECK (WITH DECALS)2 604221 1 DANGER/CHUTE DECAL3 604222 1 DANGER/OBJECTS DECAL4 793513 1 36" DECK ID DECAL

1

3

2

4

119296_0118 6-3


6-4 119296_0118

36" Deck Pulleys & Spindles

15

24

10

14

4

2

1

161

25

4

13

18

23

5

5

6 2

177

8

3

9

10

1

2

2

3

11

12

21

19

20

22

119296_0118 6-5


NOTES:

1. Torque to 18 ft-lbs.2. Torque to 73 ft-lbs.3. Torque to 30 ft-lbs. The idler arm should pivot freely.4. Torque to 50–75 ft-lbs.


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 119936 1 36" PIVOTING IDLER ARM7 605379 1 IDLER SPRING8 604110 1 SPRING TENSIONER ANCHOR9 604251 1 NT .312-18 HX NL JAM G2 ZN10 768523 9 FW .343 X .687 X .051/.080H11 601839 1 PIVOT SPACER BUSHING12 117539 1 SPACER13 604253 1 CB .50-13 X 2.00 STD ZN14 606943 2 NT .562-18 HX G5 NL15 605443 2 DRIVE PULLEY 36"16 604123 2 PULLEY SPACER17 604219 1 IDLER PULLEY, 4.00" FLAT18 036236 8 CS .312-18 X 1.00 HX G519 604251 1 NT .312-18 HX NL JAM G2 ZN20 122398 1 TENSIONING PULLEY STOP21 037887 1 CB .312-18 X 1.00 FULL ZN22 083147 1 CB .312-18 X .620 G5 ZN23 080655 1 CS .375-16 X 1.50 HX G524 604254 1 CB .50-13 X 2.50 STD ZN25 604214 2 SPINDLE ASSEMBLY

6-6 119296_0118

36" Deck

2

21

4

22

517

18

1

24

26

15

15 25

16

13

5

67

8

612

1110

1415

16

19

20

23

2

1

13

9

7

2

3

119296_0118 6-7

36" Deck

NOTES:

1. Torque to 48 ft-lbs.2. Torque to 2–5 ft-lbs on these 4 self-tapping screws.3. Do not torque; the discharge chute must pivot freely.


1 604324 4 CS .250-20 X .75 HX FLG2 605254 1 RS PULLEY COVER3 604403 1 LS PULLEY COVER4 771824 1 BELT, A 117" EL5 606593 2 CS .375-16 X 2.00 HX G5 P856 116157 2 DECK LIFT LINK7 016899 2 NT .375-16 HX G5 FLK 8 601839 1 PIVOT SPACER BUSHING9 605016 1 DECK LEVELING NUT

10 116155 2 DECK LINK11 116911 1 LEVELER CAM12 767954 1 FW .379 X .813 X .06313 706168 1 NT .375-16 HX G5 Z JAM14 781567 1 NT .500-13 HX G8 ZY NL15 767962 3 FW .531 X 1.063 X .17516 788166 1 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)17 604268 1 DISCHARGE CHUTE18 086660 1 NT .375-16 HX G5 ZY NL19 604331 1 CHUTE SPRING20 604346 1 DISCHARGE CHUTE PIN21 783753 2 BLADE, 17.86"-L-F-CW

603995 2 BLADE, 17.86"-M-F-CW787721 2 BLADE, 17.86"-H-F-CW603848 2 BLADE, 17.86"-CAT-F-CW794198 2 BLADE, 17.86"-MUL-F-CW785436 2 BLADE, 17.86"-GAT-F-CW

22 602680 2 FW .453 X 1.12 X .119 HRD23 754101 2 CS .437-20 X 1.25 HX G5 ZNY24 781708 1 CS .500-13 X 4.25 HX G525 031997 1 PLASTIC WHEEL26 053199 1 NT .500-13 HX JAM ZNYC

6-8 119296_0118

42" Service Deck

NOTES:


1 552345 1 42" DECK (WITH DECALS)2 793521 1 42" DECK ID DECAL3 604222 1 DANGER/OBJECTS DECAL4 604221 1 DANGER/CHUTE DECAL

123

4

119296_0118 6-9


6-10 119296_0118

42" Deck Pulleys & Spindles—S/N 1601A762 & Higher

13

22

17

12

42

1

14

1

23

2

11

16

21

5

56 2

157

8

3

1

3

3

4

18

199

10

20

119296_0118 6-11

42" Deck Pulleys & Spindles—S/N 1601A762 & Higher

NOTES:

1. Torque to 18 ft-lbs.2. Torque to 50–75 ft-lbs.3. Torque to 73 ft-lbs.4. Torque to 30 ft-lbs. The idler arm should 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 606943 2 NT .562-18 HX G5 NL13 603987 2 PULLEY14 604123 2 PULLEY SPACER15 604219 1 IDLER PULLEY, 4.00" FLAT16 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

6-12 119296_0118

42" Deck Pulleys & Spindles—S/N Prior to 1601A762

13

19

17

12

4

2

1

14

1

20

2

11

16

18

5

56 2

157

8

3

9

10

1

3

3

4

119296_0118 6-13

42" Deck Pulleys & Spindles—S/N Prior to 1601A762

NOTES:

1. Torque to 18 ft-lbs.2. Torque to 50–75 ft-lbs.3. Torque to 73 ft-lbs.4. Torque to 30 ft-lbs. The idler arm should pivot freely.


1 781567 2 NT .500-13 HX G8 ZY NL2 767962 2 FW .531 X 1.063 X .1753 603986 1 IDLER PULLEY, 4.00" FLAT4 086660 1 NT .375-16 HX G5 ZY NL5 712893 2 FW .406 X 1.25 X .12 HRD Z6 117512 1 IDLER ARM7 604291 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 604172 2 NT .562-18 HX G5 ZN13 603987 2 PULLEY14 604123 2 PULLEY SPACER15 604219 1 IDLER PULLEY, 4.00" FLAT16 036236 8 CS .312-18 X 1.00 HX G517 768523 8 FW .343 X .687 X .051/.080H18 080655 1 CS .375-16 X 1.50 HX G519 604254 1 CB .50-13 X 2.50 STD ZN20 604214 2 SPINDLE ASSEMBLY

6-14 119296_0118

42" Deck—S/N 14030001 & Higher1

20

3

21

416

17

2

23

25

14

14 24

15

21

4

5

6

7

511

109

1314

15

18

19

22 1

12

8

2

2

3

119296_0118 6-15

42" Deck—S/N 14030001 & Higher

NOTES:



1 604403 2 42" PULLEY COVER2 604324 4 CS .250-20 X .75 HX FLG3 793828 1 BELT, 116" EL4 606593 2 CS .375-16 X 2.00 HX G5 P855 116157 2 DECK LIFT LINK6 016899 2 NT .375-16 HX G5 FLK7 601839 1 PIVOT SPACER BUSHING8 605016 1 DECK LEVELING NUT9 116155 2 DECK LINK

10 116911 1 LEVELER CAM11 767954 1 FW .379 X .813 X .06312 706168 1 NT .375-16 HX G5 Z JAM 13 781567 1 NT .500-13 HX G8 ZY NL14 767962 3 FW .531 X 1.063 X .17515 788166 1 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)16 604268 1 DISCHARGE CHUTE17 086660 1 NT .375-16 HX G5 ZY NL18 604331 1 CHUTE SPRING19 604346 1 DISCHARGE CHUTE PIN20 603992 2 BLADE, 20.50"-M-F-CW

793794 2 BLADE, 20.50"-L-F-CW794685 2 BLADE, F20.50"-H-F-CW793935 2 BLADE, 20.50"-CAT-F-CW794214 2 BLADE, 20.50"-MUL-F-CW794230 2 BLADE, 20.50" -GAT-F-CW


6-16 119296_0118

42" Deck—S/N Prior to 140300011

19

3

20

415

16

2

21

4

5

67

51098

1213

14

17

18

21 1

11

2

2

3

7

6

119296_0118 6-17


NOTES:

1. Torque to 48 ft-lbs.2. Torque to 8 ft-lbs on these 4 self-tapping screws.3. Do not torque; the discharge chute must pivot freely.


1 604403 2 42" PULLEY COVER2 604324 4 CS .250-20 X .75 HX FLG3 793828 1 BELT, 116" EL4 606593 2 CS .375-16 X 2.00 HX G5 P855 116157 2 DECK LIFT LINK6 016899 3 NT .375-16 HX G5 FLK7 601839 2 PIVOT SPACER BUSHING8 116155 2 DECK LINK9 116911 1 LEVELER CAM

10 767954 1 FW .379 X .813 X .06311 706168 1 NT .375-16 HX G5 Z JAM 12 781567 1 NT .500-13 HX G8 ZY NL13 767962 3 FW .531 X 1.063 X .17514 788166 1 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)15 604268 1 DISCHARGE CHUTE16 086660 1 NT .375-16 HX G5 ZY NL17 604331 1 CHUTE SPRING18 604346 1 DISCHARGE CHUTE PIN19 603992 2 BLADE, 20.50"-M-F-CW20 602680 2 FW .453 X 1.12 X .119 HRD21 754101 2 CS .437-20 X 1.25 HX G5 ZNY22 781708 1 CS .500-13 X 4.25 HX G523 031997 1 PLASTIC WHEEL24 053199 1 NT .500-13 HX JAM ZNYC

6-18 119296_0118

36"/42" Deck Lift

1

26

1213

3 11

10

5

9

9

13

2

78

LEFT SIDE OF MOWER

RIGHT SIDE OF MOWER

5

4

5

7

3

1

8

5

1

1

1

4

3

14

4

44

119296_0118 6-19

36"/42" Deck Lift

NOTES:

1. Part of the Steering Cover Assembly.


1 120677 1 LIFT HANDLE2 116151 2 PIVOT BLOCK3 029629 4 CS .375-16 X .75 HX FLK4 016899 6 NT .375-16 HX G5 FLK5 604515 4 NT .375-16 FL NY GF6 604377 1 GRIP7 712919 2 FW .406 X 1.00 X .12 HRD Z8 601839 2 PIVOT SPACER BUSHING9 005116 2 CS .375-16 X 1.375 HX G510 027714 1 CE .500 X 1.25 X .156 X 1.09311 017251 1 CP .156D X 1.00 LG HML Z12 767962 1 FW .531 X 1.063 X .17513 029751 2 CS .375-16 X 1.00 HX FLK14 121232 1 DECK PIVOT KIT

6-20 119296_0118

52" Service Deck

NOTES:


1 552346 1 52" DECK (WITH DECALS)2 604221 1 DANGER/CHUTE DECAL3 785535 1 52" DECK DECAL4 604222 1 DANGER/OBJECTS DECAL

1

2

34

119296_0118 6-21


6-22 119296_0118


2

15

1

77 9

4

3

20

11

8

12

1816

13

14

1

56

10

1

23

3

1

19

22

5

17

21

3

3

3

5

17

21

119296_0118 6-23


NOTES:

1. Torque to 50–75 ft-lbs.2. Torque to 18 ft-lbs.3. Torque to 73 ft-lbs.


1 781567 3 NT .500-13 NL2 121780 1 BELT GUIDE3 767962 3 FW .531 X 1.063 X .1754 603986 1 IDLER PULLEY, 4.00" FLAT5 604251 6 NT .312-18 HX G2 ZN NL JAM 6 604252 4 FW .340 X .675 X .035 ZN7 604110 2 SPRING TENSIONER ANCHOR8 122388 1 IDLER SPRING9 604194 1 IDLER SLED

10 604079 2 IDLER SLIDE11 604253 1 CB .50-13 X 2.00 STD ZN12 606943 3 NT .562-18 HX G5 NL13 036236 12 CS .312-18 X 1.00 HX G514 768523 12 FW .343 X .687 X .051/.080H15 603988 3 DRIVE PULLEY "B-SEC"16 604123 3 PULLEY SPACER17 017129 2 FW .440 X 1.00 X .083 ZNY18 604231 1 IDLER PULLEY, 5.00" O.D.19 604219 1 IDLER PULLEY, 4.00" FLAT20 604214 3 SPINDLE ASSEMBLY21 083147 6 CB .312-18 X .620 G5 ZN22 604254 2 CB .50-13 X 2.50 STD ZN

6-24 119296_0118

52" Deck—S/N 14030001 & Higher1

4

8

5

20

23

1819

21

2

10

3

6

2

7

9

9

10

12

11

11

1615

24

26

19

19 25

20

1

17

22

14

13

3

2

119296_0118 6-25

52" Deck—S/N 14030001 & Higher

NOTES:



1 604337 1 RS PULLEY COVER2 604324 4 CS .250-20 X .75 HX FLG3 791988 1 BELT, B 140.77" EL4 604338 1 LS PULLEY COVER5 604268 1 DISCHARGE CHUTE6 604346 1 DISCHARGE CHUTE PIN7 604331 1 CHUTE SPRING8 086660 1 NT .375-16 HX G5 ZY NL9 606593 2 CS .375-16 X 2.00 HX G5 P85

10 116157 2 DECK LIFT LINK11 016899 2 NT .375-16 HX G5 FLK12 601839 1 PIVOT SPACER BUSHING13 605016 1 DECK LEVELING NUT14 116155 2 DECK LINK15 116911 1 LEVELER CAM16 767954 1 FW .379 X .813 X .06317 706168 1 NT .375-16 HX JAM G5 Z18 781567 2 NT .500-13 HX G8 ZY NL19 767962 6 FW .531 X 1.063 X .17520 788166 2 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)21 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


6-26 119296_0118


4

8

5

19

22

1718

20

2

10

3

6

2

7

9

9

10

12

11

1514

1

16

21

13

11

12

2

3

119296_0118 6-27


NOTES:

1. Torque to 48 ft-lbs.2. Torque to 8 ft-lbs on these 4 self-tapping screws.3. Do not torque; the discharge chute must pivot freely.


1 604337 1 RS PULLEY COVER2 604324 4 CS .250-20 X .75 HX FLG3 791988 1 BELT, B 140.77" EL4 604338 1 LS PULLEY COVER5 604268 1 DISCHARGE CHUTE6 604346 1 DISCHARGE CHUTE PIN7 604331 1 CHUTE SPRING8 086660 1 NT .375-16 HX G5 ZY NL9 606593 2 CS .375-16 X 2.00 HX G5 P85

10 116157 2 DECK LIFT LINK11 016899 3 NT .375-16 HX FLK G512 601839 2 PIVOT SPACER BUSHING13 116155 2 DECK LINK14 116911 1 LEVELER CAM15 767954 1 FW .379 X .813 X .06316 706168 1 NT .375-16 HX JAM G5 Z17 781567 2 NT .500-13 HX G8 ZY NL18 767962 6 FW .531 X 1.063 X .17519 788166 2 PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)20 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


6-28 119296_0118

52" Deck Lift

1

2 3

6

10

13

39

8

4

4

12

12

13

2

7

11

3

LEFT SIDE OF MOWER

RIGHT SIDE OF MOWER

5 4

4

11

7

3

1

1

1

1

14

14

1515

4

4

5

119296_0118 6-29

52" Deck Lift

NOTES:

1. Part of the Steering Cover Assembly.


1 120677 1 LIFT HANDLE2 116151 2 PIVOT BLOCK3 029629 8 CS .375-16 X .75 HX FLK4 016899 10 NT .375-16 HX G5 FLK5 604515 2 NT .375-16 FL NY GF6 604377 1 GRIP7 116916 2 DECK LINK PLATE8 027714 1 CE .500 X 1.25 X .156 X 1.0939 017251 1 CP .156D X 1.00 LG HML Z

10 767962 1 FW .531 X 1.063 X .17511 601839 2 PIVOT SPACER BUSHING12 005116 2 CS .375-16 X 1.375 HX G513 029751 2 CS .375-16 X 1.00 HX FLK14 604515 2 NT .375-16 FL NY GF15 121232 1 DECK PIVOT KIT

6-30 119296_0118

119296_0118 7-1

Section 7

Seat—Without Armrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Seat—With Armrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Seat Service Parts—605009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-2 119296_0118

Seat—Without Armrests

1

2

4

76

10

9

8

11

11

12

1

5

3

2

13

14

119296_0118 7-3

Seat—Without Armrests

NOTES:

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


1 605023 1 SEAT2 552379 1 SEAT PAN (WITH DECALS)3 604307 1 PUSH BUTTON MOUNT4 086660 2 NT .375-16 HX G5 ZY NL5 000331 1 WIRE TIE6 768523 4 FW .343 X .687 X .051/.080H7 036236 4 CS .312-18 X 1.00 HX G58 029629 2 CS .375-16 X .75 HX FLK9 793851 2 COMPRESSION SPRING 1.25 X 4.00 X .188

10 016899 2 NT .375-16 HX G5 FLK 11 036244 2 CS .375-16 X 1.00 HX G512 601815 1 BATTERY WARNINGS DECAL13 602243 1 BELT ROUTING DECAL14 793315 1 SEAT SWITCH

7-4 119296_0118

Seat—With Armrests

1

2

87

12

12

1

6

3

2

9

10

11

14

13

4

4

5

4

4

119296_0118 7-5

Seat—With Armrests

NOTES:

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


1 605009 1 SEAT2 552379 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 FLK10 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 601815 1 BATTERY WARNINGS DECAL14 602243 1 BELT ROUTING DECAL (36"/42" MOWERS)

781419 1 BELT ROUTING DECAL (52" MOWERS)

7-6 119296_0118

Seat Service Parts—605009

NOTES:


1 119783 1 ARMREST KIT2 793315 1 SEAT SWITCH

1

2

BIG DOG MOWER CO. ALPHA · 2019-10-14 · BIG DOG® MOWER CO. ALPHA ... This manual covers BigDog®...

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Transcript of BIG DOG MOWER CO. ALPHA · 2019-10-14 · BIG DOG® MOWER CO. ALPHA ... This manual covers BigDog®...