big dog mower co. blackjack parts manual · hydraulic system ... .562 105 143 m10 37 50 ... cs...

200 South Ridge RoadHesston, Kansas

67062

BIG DOG® MOWER CO.BLACKJACK

Parts Manual

121538EX_1116 c-1

Table of Contents

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

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

Section 3Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Transmission Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Steering & Brake—S/N 16042182 & Higher . . . . . . . . . . . . . . . . . . . . . . 3-8Steering & Brake—Prior to S/N 16042182 . . . . . . . . . . . . . . . . . . . . . . 3-16Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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

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

Section 6Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Fenders & Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Section 748" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-248" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-448" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-654" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-854" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1054" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12Deck Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Section 8Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

c-2 121538EX_1116

121538EX_1116 1-1

General Information

This manual covers Big Dog® Blackjack models: 935304EX & 935312EX.

Service Literature

PART NO.GENERAL SERVICE MANUALWARRANTY STATEMENTOPERATOR’S MANUAL

Options Available From Your Dealer

PART NO.2-BAG CATCHER KITMULCH KIT (48")MULCH KIT (54")STEERING LEVER EXTENSION KITFLEX FORKS KIT

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 Big Dog® mowers. Use of this manual in conjunction with other Big Dog® mower and component manuals will provide the information necessary to service and maintain Big Dog® mow-ers.

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.

DESCRIPTION121536121540605687

DESCRIPTION933804119101119060333724605677

1-2 121538EX_1116

Hardware Description Codes & Abbreviations

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

ABBREVIATIONCARRIAGE BOLT MACHINE BUSHINGCLEVIS PIN MACHINE SCREWCLIP NUT NUTCOTTER PIN SELF TAPPING CAP SCREWCAP SCREW SOCKET HEADCUP WASHER SHOULDER BOLTFENDER WASHER SET SCREWFLAT WASHER OUTSIDE DIAMETERHEX HEAD INSIDE DIAMETERLOCK WASHER WELD NUT

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.

SIZE FT-LBS N•M SIZE FT-LBS N•M

DESCRIPTION ABBREVIATION DESCRIPTIONCB MBCE MSCN NTCP SCCS SHCW SB

FDRW SSFW ODHX IDLW WN

.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

121538EX_1116 2-1

Section 2

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

2-2 121538EX_1116

Frame

3 2

54

1

6

1

717

18

16

4

1

7

20

19

21

22

4

8

9

1011

11

10

11

1015

149

9

9

9

9

1312

121538EX_1116 2-3

Frame

INDEX NO. PART NO. QTY.

3/8-16 THREAD RIVET NUTFRAME LATCHHAND GRIPCS .375-16 X .75 HX FLKFUEL TANK SUPPORTTIP OVER DANGER DECALNT .375-16 FLK G5FRAME (WITH DECAL)GREASE FITTING STRAIGHTWIRE TIEPUSH BUTTON MOUNTNT .312-18 HX G5FW .343 X .687 X .051/.080HCARRIER GUIDE BLOCKCS .312-18 X 1.50 FLT SH ZYMUFFLER SHIELDNT .375-16 HX G5 ZNYFW .379 X .813 X .063BUMPER (WITH DECALS)HOT DECALCB .375-16 X 1.00 G5 ZNYBUMPER DECALWIRE HARNESS (NOT SHOWN)WIRE TIE (NOT SHOWN)

NOTES:

DESCRIPTION

1 808493 62 120370 13 605299 14 029629 85 190263 16 605650 17 016899 68 552931 19 015495 1010 000331 411 604307 312 034272 413 768523 414 604888 215 797910 416 121430 117 054502 218 767954 219 552928 120 602041 121 025395 222 605073 123 605547 124 602725 1

2-4 121538EX_1116

121538EX_1116 3-1

Section 3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

Steering & Brake—S/N 16042182 & Higher . . . . . . . . . . . . . . . . . . . 3-8

Steering & Brake—Prior to S/N 16042182 . . . . . . . . . . . . . . . . . . . 3-16

Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-2 121538EX_1116

Hydraulic System

1

19

1

3

132

34

6

7

5

8

9

101112

21

14

16

17

19

2021

2425

2625

241

2

3

3

21

20

15

20

20

20

18

18

23

22

20

121538EX_1116 3-3

Hydraulic System


BELT, A 57.880" ELCS .625-11 X 2.25 HX G5 ZYIDLER PULLEYIDLER SPACERTENSION ARMNT .375-16 HX G5 ZY NLBUSHINGPUMP IDLER SPRINGFW .406 X .688 X .060 ZNYCCS .375-16 X 1.25 HX G5FW .625 X 1.00 X .134NT .625-11 HX G5 ZNYCCS .625-11 X 1.25 HX G5 ZFW .781 X 1.25 X .024 ZNBUSHINGFW .760 X 1.625 X .08SB .750 X 2.00 SH .625-11CS .312-18 X 2.50 HX G5CS .312-18 X 3.00 HX G5 ZFW .343 X .687 X .051/.080HNT .312-18 HX G5RS TRANSMISSION, ZT2800LS TRANSMISSION, ZT2800CS .375-16 X 2.00 HX G5FW .379 X .813 X .063SPACER TUBE

NOTES:

1. Torque to 17 ft-lbs.2. Torque to 100 ft-lbs.3. Torque to 30 ft-lbs.

DESCRIPTION

1 786533 12 601983 13 605657 24 121319 15 121728 16 086660 17 605481 18 605655 19 704718 110 052860 111 028118 112 016972 113 781872 114 704791 115 781153 216 025296 117 601084 118 710087 419 043067 420 768523 1621 034272 822 604708 123 604709 124 016410 225 767954 226 605539 1

3-4 121538EX_1116

Hydraulic System

2728

29

32 33

34

35 41

3738

36

39 40 43

34

443738

30

31

34

42

121538EX_1116 3-5

Hydraulic System


FW .281 X .625 X .066NT .250-20 HX ZY NLOVERFLOW TANK (WITH CAP)OVERFLOW TANK CAPWIRE TIEGROMMET 2.25"CB .250-20 X .625 ZNYCCS .375-16 X .75 HX FLKSPRING CLAMPOVERFLOW HOSE, 6"FTG, -8MBT/-8MBT, 90HP .080D X 1.19TOW VALVE LINKFTG, -6MORB/-8MBT STRNT .375-16 HX G5 FLKOVERFLOW HOSE, 7"HOSE CLAMPOVERFLOW HOSE, 19"FITTING, 90 - 9/16 SAE

NOTES:

DESCRIPTION

27 768515 228 068551 229 601996 1

600767 130 000331 131 603289 132 601503 233 029629 134 601001 635 605744 136 605562 137 706549 238 118310 239 605730 140 016899 141 605745 142 045088 143 605746 144 601219 1

3-6 121538EX_1116

Transmission Service Parts

3

8

6

1

45

7

2


RTN, RIGHTRTN, LEFT (NOT SHOWN)HG RTN SPRINGFAN/PULLEY KITLS FILTER GUARD KIT (WITH BOLTS)RS FILTER GUARD KIT (WITH BOLTS) (NOT SHOWN)OIL FILTER4-BOLT HUB KIT (INCLUDES NUT)BRAKE ARMRETAINING CLIP

NOTES:

DESCRIPTION

1 604901 1604902 1

2 604903 13 602094 14 600975 1

600974 15 600976 16 600970 17 601221 18 600972 1

121538EX_1116 3-7

This page intentionally left blank.

3-8 121538EX_1116

Steering & Brake—S/N 16042182 & Higher

18

196

2022

236

246

1

1

102

2

1

17

15

14

13

15

1314

13

23

45

67

8

76

126

11

9

LEFT SIDE SHOWNRIGHT SIDE SIMILAR

121538EX_1116 3-9



NT .312-18 HX NL G5NT .250-20 HX ZY NLFW .281 X .625 X .066SB .312 X .75 SH .250-20CN .312-18 X .20 MAX THKFW .343 X .687 X .051/.080HBALL STUDDAMPERSTEERING RODNT .312-24 NL G5BRAKE RODNT .312-18 HX G5NT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .375-16 X 1.50 HX G5FRAME LATCH TURNBUCKLESPRING 2.5CLIPSPRINGLS BRAKE SPRING LINKRS BRAKE SPRING LINK (NOT SHOWN)NT .250-20 HX FL LK ZNYCS .250-20 X .75 HX G5OVERTRAVEL SPRING

NOTES:

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

DESCRIPTION

1 058776 82 068551 23 768515 24 772483 25 601069 26 768523 187 781922 48 603983 29 605273 210 023655 211 605622 212 034272 213 086660 914 767954 1615 080655 416 605297 217 034652 118 603332 219 601131 220 109203 121 109202 122 016816 223 055939 224 601051 2

3-10 121538EX_1116


1314

2726

1425

2829

3031 14

13 1314

27

3214

33

1314

3314

34

3031

2928

3635

3536

13 14

121538EX_1116 3-11



CS .375-16 X 1.25 HX G5LATCH ARMBUSHINGCS .375-16 X 2.00 HX G5CAM FOLLOWER SPACERLATCH BEARING BUSHINGBUSHING .500 X .625CS .375-16 X 2.00 BH BOCARRIER LATCHCS .375-16 X 1.50 BH BOSB .50 X .75SH .375-16TDSPRING

NOTES:

DESCRIPTION

25 052860 126 119303 127 765339 328 016410 229 120131 230 605618 231 605619 232 605680 133 118882 234 604816 135 728550 236 605243 2

3-12 121538EX_1116


38

37

53

39

48

50

56

45

44

37

57

58

43

40

41

39

4743

52

51

FRONT OF THE MOWER

49

46

4548

72 4

54 33

55

42

121538EX_1116 3-13



CE .500 X 4.00 X 3.50 HD LSCS .500-13 X 4.00 HX G5 ZFW .500 X 1.25 X .075 ZNYLIFT PIVOT PLATE LSLIFT PIVOT SPACERLIFT PIVOT PLATE RSFW .531 X 1.063 X .175LYNCH PIN .500 DIANT .500-13 UNT LK G8NT .375-16 HX FLK G5CS .500-13 X 1.00 HX G5 ZNCS .375-16 X 1.00 HX FLKCS .375-16 X .75 HX FLKSB .500 X 1.250 SH .375 ACTUATOR MOUNTACTUATOR ASSEMBLYNT .625-18 HX G5 ZKROD ENDINNER ACTUATOR SPACEROUTER ACTUATOR SPACERFW .656 X 1.312 X .090 ZNYCS .625-11 X 3.000 HX G5

NOTES:

3. Part of the actuator assembly, 606159.4. In the event the serial number decal becomes damaged or illegible,

please contact your dealer to order a replacement.

DESCRIPTION

37 605241 138 089938 139 704759 240 118889 141 605630 142 118888 143 767962 344 605240 145 023317 146 016899 1147 016527 248 029751 449 029629 750 760330 151 190233 152 606159 153 605489 154 605488 155 118890 156 118891 157 728030 158 029934 1

3-14 121538EX_1116


6566

67

6860

61

62 63

7114

48

59

69

45

49

46

FRONT OF THE MOWER

FRONT OF THE MOWER

46

4949

16

64

6

1

6

121538EX_1116 3-15



STEERING SUB-ASSEMBLYCS .312-18 X 1.00 BTNHD ZNLOCKING SPRING PLUNGERPLUNGER BRACKETNT .625-11 HXZY NL THINCS .312-18 X 1.000 HX G5CS 10-24 X .75 HX FLK ZNPLUNGER SWITCH SWITCH BRACKETNUT PLATE .420 CENTERSRS STEERING HANDLE (WITH GRIP)STEERING BAR GRIPLS STEERING HANDLE (NOT SHOWN)CS .375-16 X 1.00 HX G5SERIAL NUMBER / SPEC DECAL

NOTES:

DESCRIPTION

59 N/A 160 602231 261 604872 162 190244 163 602728 164 036236 265 063198 266 602538 167 120430 168 601822 169 605383 1

781260 170 605384 171 036244 472 N/A 1

3-16 121538EX_1116

Steering & Brake—Prior to S/N 16042182

17

186

1921

226

236

1

1

1

16

14

13

12

14

1513

12

23

45

67

8

76

116

10

9


121538EX_1116 3-17



NT .312-18 HX NL G5NT .250-20 HX ZY NLFW .281 X .625 X .066SB .312 X .75 SH .250-20CN .312-18 X .20 MAX THKFW .343 X .687 X .051/.080HBALL STUDDAMPERSTEERING RODBRAKE RODNT .312-18 HX G5NT .375-16 HX G5 ZY NLFW .379 X .813 X .063CS .375-16 X 1.50 HX G5FRAME LATCH TURNBUCKLESPRING 2.5CLIPSPRINGLS BRAKE SPRING LINKRS BRAKE SPRING LINK (NOT SHOWN)NT .250-20 HX FL LK ZNYCS .250-20 X .75 HX G5OVERTRAVEL SPRING

NOTES:

1. Part of the transmission.

DESCRIPTION

1 058776 82 068551 23 768515 24 772483 25 601069 26 768523 187 781922 48 603983 29 605273 210 605622 211 034272 212 086660 913 767954 1614 080655 815 605297 216 034652 117 603332 218 601131 219 109203 120 109202 121 016816 222 055939 223 601051 2

3-18 121538EX_1116


1213

2625

1324

2728

2930 13

12 1213

26

3113

32

1213

3213

33

2930

2827

3534

3435

12 13

121538EX_1116 3-19



CS .375-16 X 1.25 HX G5LATCH ARMBUSHINGCS .375-16 X 2.00 HX G5CAM FOLLOWER SPACERLATCH BEARING BUSHINGBUSHING .500 X .625CS .375-16 X 2.00 BH BOCARRIER LATCHCS .375-16 X 1.50 BH BOSB .50 X .75SH .375-16TDSPRING

NOTES:

DESCRIPTION

24 052860 125 119303 126 765339 327 016410 228 120131 229 605618 230 605619 231 605680 132 118882 233 604816 134 728550 235 605243 2

3-20 121538EX_1116


37

36

52

38

47

49

55

44

43

36

56

57

42

39

40

38

4642

51

50

FRONT OF THE MOWER

48

45

4547

70 3

53 22

54

41

121538EX_1116 3-21



CE .500 X 4.00 X 3.50 HD LSCS .500-13 X 4.00 HX G5 ZFW .500 X 1.25 X .075 ZNYLIFT PIVOT PLATE LSLIFT PIVOT SPACERLIFT PIVOT PLATE RSFW .531 X 1.063 X .175LYNCH PIN .500 DIANT .500-13 UNT LK G8NT .375-16 HX FLK G5CS .500-13 X 1.00 HX G5 ZNCS .375-16 X 1.00 HX FLKCS .375-16 X .75 HX FLKSB .500 X 1.250 SH .375 ACTUATOR MOUNTACTUATOR ASSEMBLYNT .625-18 HX G5 ZKROD ENDINNER ACTUATOR SPACEROUTER ACTUATOR SPACERFW .656 X 1.312 X .090 ZNYCS .625-11 X 3.000 HX G5

NOTES:

2. Part of the actuator sub-assembly, 606159.3. In the event the serial number decal becomes damaged or illegible,

please contact your dealer to order a replacement.

DESCRIPTION

36 605241 137 089938 138 704759 239 118889 140 605630 141 118888 142 767962 343 605240 144 023317 145 016899 1146 016527 247 029751 448 029629 749 760330 150 190233 151 606159 152 605489 153 605488 154 118890 155 118891 156 728030 157 029934 1

3-22 121538EX_1116


6465

66

6759

60

61 62

6913

1314

47

58

68

45

48

45

FRONT OF THE MOWER

FRONT OF THE MOWER

45

4848

16

63

6

1

6

121538EX_1116 3-23



STEERING SUB-ASSEMBLYCS .312-18 X 1.00 BTNHD ZNLOCKING SPRING PLUNGERPLUNGER BRACKETNT .625-11 HXZY NL THINCS .312-18 X 1.000 HX G5CS 10-24 X .75 HX FLK ZNPLUNGER SWITCH SWITCH BRACKETNUT PLATE .420 CENTERSSTEERING HANDLE (WITH GRIP)STEERING BAR GRIPNT .375-16 HX G5 ZNYSERIAL NUMBER / SPEC DECAL

NOTES:

DESCRIPTION

58 N/A 159 602231 260 604872 161 190244 162 602728 163 036236 264 063198 265 602538 166 120430 167 601822 168 360487 2

781260 169 054502 470 083279 1

3-24 121538EX_1116

Steering Sub-Assembly4

2

57

8

9

610

11 1213

11

1319

15

18

20

1213

23

13

17

2425

2627

28

29

3031

32

33

5

1

3

21

14


FRONT OFMOWER

FRONT OFMOWER

LEFT SIDE ONLY

35

6

34

121538EX_1116 3-25

Steering Sub-Assembly


STEERING COVER (WITH DECALS)CS .500-13 X 4.25 HX G5LS STEERING DECALCS .250-20 X 2.00 HX FLTHDNT .375-16 HX G5 ZY NLFW .281 X .625 X .066NUT PLATE .420 CENTERSPUSH BUTTON SWITCHSTEERING STOPCS .250-20 X .75 HX G5BUSHINGNT .312-18 HX G5 ZY NLFW .343 X .687 X .051/.080HRS STEERING DECALLS BRAKE BELLCRANKRS BRAKE BELLCRANK (NOT SHOWN)STEERING SPACERNT .500-13 HX G8 ZY NLCS 10-24 X .75 HX FLK ZNCS .375-16 X 3.50 HX G5 ZLS STEERING BOX (S/N 16042182 & HIGHER)LS STEERING BOX (S/N PRIOR TO 16042182)RS STEERING BOX (NOT SHOWN) (S/N 16042182 & HIGHER)RS STEERING BOX (NOT SHOWN) (S/N PRIOR TO 16042182)BRAKE RODLATCH SPACERBUSHING .625 I.D.FRAME LATCHFW .406 X 1.00 X .12 HRD ZCS .375-16 X 1.75 HX G5NT .500-13 HX G5 ZNYCBUSHING .500 X .625LATCH BEARING BUSHINGFW .531 X .812 X .089 HDCS .500-13 X 1.25 HX G5ENGINE COMPARTMENT DECALBUSHING

NOTES:

DESCRIPTION

1 552929 12 781708 23 785139 14 604452 25 086660 36 768515 47 601822 28 781211 29 605529 2

10 055939 211 765339 412 058776 413 768523 814 785220 115 116142 116 116141 117 604288 218 781567 219 063198 420 005108 221 606106 1

604300 122 606105 1

604299 123 604179 224 119304 125 602539 126 119302 127 712919 128 705178 129 008193 130 605619 131 605618 132 604486 133 705954 134 601967 135 781153 4

3-26 121538EX_1116

121538EX_1116 4-1

Section 4

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

Front Tire Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

4-2 121538EX_1116

Wheel & Tire

1 2

3

4

5

6

6

7

8

1

121538EX_1116 4-3

Wheel & Tire


TIRE/WHEEL ASSEMBLY 20 X 8-10 (48" MOWER)TIRE/WHEEL ASSEMBLY 20 X 10-10 (54" MOWER)WHEEL NUTCS .500-13 X 1.25 HX G5FW .510 X 2.15 X .187 SPLFW .531 X 1.375 X .125 ZNYBEARINGSPACERFRONT WHEEL ASSEMBLY

NOTES:

1. Torque to 65–75 ft-lbs.

DESCRIPTION

1 605033 2605150 2

2 061077 83 705954 24 344267 25 712976 26 784223 47 784603 28 N/A 2

4-4 121538EX_1116

Front Tire Assembly

1

2

3

3

4

5

6 LEFT SIDE SHOWNRIGHT SIDE SIMILAR

121538EX_1116 4-5

Front Tire Assembly


CASTERCS .500-13 X 5.50 G5 ZFW .531 X 1.063 X .175NT .500-13 JAM NY LKGAUGE WHEEL SPACERWHEEL, 9.0 X 3.5 X 4.0 HUB

NOTES:

DESCRIPTION

1 190241 12 766154 13 767962 24 707398 15 604089 16 605689 1

4-6 121538EX_1116

Drive Wheel Breakdown

1

2

3

605033 TIRE & WHEEL ASSEMBLY (48" MOWERS)


TIRE 20 X 10-10WHEEL 10 X 7TIRE VALVE

NOTES:

DESCRIPTION

1 600692 1 TIRE 20 X 8-102 605034 1 WHEEL 10 X 73 019521 1 TIRE VALVE

605150 TIRE & WHEEL ASSEMBLY (54" MOWERS)

INDEX NO. PART NO. QTY. DESCRIPTION

1 600684 12 605151 13 019521 1

121538EX_1116 5-1

Section 5

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

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

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

5-2 121538EX_1116

Engine

1

2

7

13

14

4

8

15

3

2

10

5

3

14

4

9

11 12

16

16

12

121538EX_1116 5-3

Engine


ENGINE, KAWASAKI FR691VOIL DRAIN HOSEMUFFLERFW .379 X .813 X .063CS .375-16 X 1.25 HX G8 P85CB .375-16 X 1.00 G5 ZNYPULLEYCLUTCH ANCHORNT .375-16 HX G5 ZNYKEY 1/4 SQ X 0.66 LGCLUTCH BUSHINGWIRE TIECLUTCH KITFW .453 X 1.12 X .119 HRDCS .437-20 X 3.25 HX G5 P85CLUTCH HARNESS PIGTAIL

NOTES:

1. Supplied with the engine.2. Torque to 45–48 ft-lbs. Use only hand tools to install this fastener.3. Torque to 30–35 ft-lbs. Use only hand tools to install this fastener.4. Torque to 22 ft-lbs.

DESCRIPTION

1 N/A 12 605317 13 604016 14 767954 65 602580 46 025395 27 605574 18 121402 19 054502 210 712372 111 605595 112 000331 713 605576K 114 602680 115 601834 116 791251 1

5-4 121538EX_1116

Engine

21

24

23

20

21

19

18

22

21

12

28

B

RED

FUSE

BLK

1RED

12

PUR

RED

17

BLKBRN

21

25

25

12

27

12

2624

26 A

21

6

5

5

5

5

5

5

5

5

ORG530A

25

25

121538EX_1116 5-5

Engine


CS M8 X 1.25 X 16 HX FL 10.9FW .343 X .687 X .051/.080HLW .312 INT-EXT TOOTHCS .250-20 X .75 HX G5FW .281 X .625 X .051/.080 HD ZN/YLSTARTER SOLENOIDNT #10-32 HX ZNNT .250-20 HX G5 ZNYCHOSE CLAMP1/4" FUEL LINEINLINE FUEL SHUTOFF VALVE3/16" FORMED VAPOR LINE

NOTES:

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

DESCRIPTION

17 720516 118 768523 119 029876 120 055939 221 768515 622 030817 123 044255 124 024927 425 000323 426 015818 13"27 605601 128 605611 1

FUEL LINE LENGTH

6.5" TANK TO VALVE

6.5" VALVE TO ENGINE

A

B

5-6 121538EX_1116

Engine Service Parts

3

1

2


AIR FILTEROIL FILTERIN-LINE FUEL FILTER

NOTES:

DESCRIPTION

1 603059 12 602581 13 068478 1

121538EX_1116 5-7


5-8 121538EX_1116

Fuel System

4

1 1

2

5

6

7

8

1

9

10

11

12

13

14

SEATSUPPORT

2

3AB

C

121538EX_1116 5-9

Fuel System


CS .375-16 X .75 HX G5 FLKFUEL TANK STRAPSEAL 3/8 X 3/4RATCHETING GAS CAP, 3.5"FUEL TANKWEATHERSTRIPTRIMFUEL NECK DOUBLERNT .375-16 HX FLK G5VAPOR LINE 3/16 FORMEDGM .750 X .188 X 1.00 X .123/16" PLASTIC TEE3/16" TO 3/16" STRAIGHT BOOTVAPOR SYSTEM FILTER

NOTES:

DESCRIPTION

1 029629 62 190274 23 713198 14"4 603807 15 605245 16 033035 15.5"7 033001 4"8 121234 19 016899 210 605610 111 047456 112 605690 113 605564 114 604323 1

WEATHERSTRIP & TRIM LENGTHS

7"

7.75"

4"

A

B

C

5-10 121538EX_1116

121538EX_1116 6-1

Section 6

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

Fenders & Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-2 121538EX_1116

Battery

1

2

7

5

6

6

3

5 4

BATTERY

6

POSITIVE BATTERYCABLE

7

6

NEGATIVE BATTERYCABLE

8

121538EX_1116 6-3

Battery


TIE DOWN STRAPCS .250-20 X 7.50 HX G5FW .281 X .625 X .066RED BATTERY CABLE BOOTNT .250-20 HX G5LW .250 INT-EXT TOOTH ZCS .250-20 X .75 HX G5CN .250-20 X .15 MAX THKWIRE TIE (NOT SHOWN)

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.

DESCRIPTION

1 604178 12 604465 23 768515 24 771428 15 024927 26 029868 47 055939 28 601982 29 000331 2

6-4 121538EX_1116

Fenders & Instrument Panel

7

1

17

14

8

716

712

7

8

15

19

3

5

13

712

9

2

7

10

11

4

4

20

2122

12

78

23

FRONT OFMOWER

18

15A FUSE10A FUSE

1

1

6

121538EX_1116 6-5



CHOKE CABLEPTO SWITCHFUEL GAUGE/HOUR METERIGNITION SWITCHKEY ASSEMBLYROCKER SWITCHFW .281 X .625 X .066NT .250-20 HX ZY NLCB 10-24 X .500 ZYNCINSTRUMENT PANEL DECALINSTRUMENT PANEL (WITH DECAL)CS .250-20 X .75 HX G5CONTROLLERCB .250-20 X .75 FUL ZNRS FENDER BRACKETNT .250-20 HX G5FUSE BRACKETWIRE TIECS .375-16 X .75 HX FLKFW .219 X .500 X .048NT #10-24 HX NL ZNTHROTTLE CABLENT .375-16 HX FLK G5

NOTES:

1. Part of the wire harness.

DESCRIPTION

1 601097 12 776476 13 605483 14 045898 15 605808 16 797308 17 768515 128 068551 49 601098 610 606225 111 553033 112 055939 413 605553 114 794784 415 120673 116 024927 417 121258 118 000331 219 029629 220 704932 621 059832 622 601096 123 016899 2

6-6 121538EX_1116


21

21

20

20

CONTROLLER

9

BREAKER

36

38

39

31

3214

7

16

30

242425

25

28

28

34

33

27

37

29

2426

26

35

121538EX_1116 6-7

Fenders & Instrument Panell


CS .250-20 X .75 HX FLGCS .25-20 BH TX BZFW .281 X .625 X .066RS FENDER1/4-20 THREAD RIVET NUTLS FENDERRESERVOIR MOUNTCN .250-20 X .15 MAX THKLS FENDER BRACKETSAFE OPERATION DECALKICK PAN DECALWIRE HARNESS ADAPTERCLUTCH CONNECTOR REPAIR KITFUSE HOLDERSEALED RELAY (WITH BRACKET)WIRE HARNESS

NOTES:

DESCRIPTION

24 604324 525 605473 426 605628 427 605527 128 808477 429 605528 130 120785 131 601982 132 120674 133 601981 134 605682 135 605554 136 114052 137 601047 138 601053 239 605547 1

6-8 121538EX_1116

121538EX_1116 7-1

Section 7

48" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

48" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

48" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

54" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

54" Deck Pulleys & Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

54" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Deck Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-2 121538EX_1116

48" Service Deck

1

2

3

4

5


48" DECK (WITH DECALS)DANGER/CHUTE DECALBELT ROUTING DECALDANGER/OBJECTS DECAL48" DECK ID DECAL

NOTES:

DESCRIPTION

1 552598 12 604221 13 605251 14 604222 15 793976 1

121538EX_1116 7-3


7-4 121538EX_1116

48" Deck Pulleys & Spindles

3

4

5

6

24

13

27

29

30

17

18

1923

19

26 7

8

32

31

28

27

13

12

16

1

25

29

11

82

1

11

10

6

3

20 21 22

3

14

15

9

121538EX_1116 7-5



CS .500-13 X 1.25 HX G5FW .515 X 1.65 X .125 HD ZYPULLEY SPACERDRIVE PULLEY B-SECNT .375-16 HX G5FW .379 X .813 X .063NT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175BELT GUIDE (KIT)BELT GUIDEBELT GUIDE SPACERIDLER PULLEY, 5.00" O.D.IDLER PULLEY, 4.00" FLATCS .625-11 X 1.25 HX G5 ZFW .625 X 1.00 X .134V IDLER PULLEYNT .312-18 HX FLK ZNYCIDLER PIVOT BUSHINGBEARING DISCPIVOT IDLER SHIELDFW .343 X .687 X .051/.080HCS .312-18 X .625 HX G5IDLER ARM DUAL PIVOTPULLEY, IDLER FLAT 4.00"BELT, B 171.00" ELIDLER SPRINGSPINDLE ASSEMBLYCS .375-16 X 1.375 HX G5FW .531 X 2.00 X .25CS .500-13 X 3.50 HX G5CS .500-13 X 2.75 HX G5 ZCB .312-18 X .75 FUL ZN

NOTES:

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

DESCRIPTION

1 705954 32 798603 33 604661 64 604665 35 054502 126 767954 247 781567 38 767962 39 122745 1

10 190270 111 605285 212 604231 113 604219 214 781872 215 028118 216 603785 117 016832 118 605238 119 605505 220 190271 121 768523 122 064006 123 120006 124 604795 125 602078 126 605497 127 601804 328 005116 1229 605516 330 061812 231 721910 132 016253 1

7-6 121538EX_1116

48" Deck

1

1

6

3

16

1112

14

2

4

2

5

7

20

22

12

12 21

13

1

13

15

3

78

109

1112

191817

9

2

2

REAR OFDECK

4

121538EX_1116 7-7

48" Deck


PULLEY COVERCS .250-20 X .75 HX FLGDISCHARGE CHUTEDISCHARGE CHUTE PINCHUTE SPRINGNT .375-16 HX G5 ZY NLCS .375-16 X 1.375 HX FL G5PULLERPIVOT SPACER BUSHINGNT 0.375-16 FL NY GFNT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175PLASTIC WHEEL ASSEMBLY BLADE, 16.50"-L-F-CWBLADE, F16.50"-L-F-CWBLADE, F16.50"-H-F-CWBLADE, 16.50"-MUL-F-CWBLADE, 16.50"-GAT-F-CWBLADE, 16.50"-CAT-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 ZCB .500-13 X 4.50 STD ZNSPACER 3.22 PLASTIC WHEELCS .500-13 X 4.25 HX G5PLASTIC WHEELNT .500-13 HX JAM ZNYC

NOTES:

1. Torque to 118 ft-lbs.2. Torque to 2–5 ft-lbs on these self-tapping screws.3. Do not torque; the discharge chute must pivot freely.4. Do not torque; the puller must pivot freely.

DESCRIPTION

1 605453 22 604324 23 604609 14 604346 15 604331 16 086660 17 605532 28 121446 19 605659 210 604515 211 781567 412 767962 613 788166 214 601123 3

601014 3795757 3796623 3796631 3796649 3

15 782474 316 781872 317 602339 218 602345 219 602263 220 781708 121 031997 122 053199 1

7-8 121538EX_1116

54" Service Deck

12

3

4

5


54" DECK (WITH DECALS)DANGER/CHUTE DECALBELT ROUTING DECAL54" DECK ID DECALDANGER/OBJECTS DECAL

NOTES:

DESCRIPTION

1 552599 12 604221 13 605251 14 799171 15 604222 1

121538EX_1116 7-9


7-10 121538EX_1116


1

2

3

4

5

6

3

17

914

15

29

30

1819

22

21

25

7

8

32

31

28

6

27

12

12

16

1

26

29

87

13

7

20

23

24

11

2

3

10

121538EX_1116 7-11



CS .500-13 X 1.25 HX G5FW .515 X 1.65 X .125 HD ZYPULLEY SPACERPULLEY, DECK DRIVE B-SECNT .375-16 HX G5FW .379 X .813 X .063NT .500-13 NLFW .531 X 1.063 X .175BELT GUIDE (KIT)BELT GUIDEBELT GUIDE SPACERIDLER PULLEY, 5.00" O.D.IDLER PULLEY, 4.00" FLATCS .625-11 X 1.25 HX G5FW .625 X 1.00 X .134V IDLER PULLEYPULLEY, IDLER FLAT 4.00"NT .312-18 HX FLKIDLER PIVOT BUSHINGBEARING DISCIDLER ARM DUAL PIVOTPIVOT IDLER SHIELDFW .343 X .687 X .051/.080HCS .312-18 X .625 HX G5BELT, B 176.79" ELIDLER SPRINGSPINDLE ASSEMBLYCS .375-16 X 1.375 HX G5FW .531 X 2.00 X .25CS .500-13 X 3.50 HX G5CS .500-13 X 2.75 HX G5 ZCB .312-18 X .75 FUL ZN

NOTES:

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

DESCRIPTION

1 705954 32 798603 33 604661 64 604664 35 054502 126 767954 247 781567 38 767962 39 122745 1

10 190270 111 605285 212 604231 113 604219 214 781872 215 028118 216 603785 117 604795 118 016832 119 605238 120 605505 221 120006 122 190271 123 768523 124 064006 125 797720 126 605497 127 601804 328 005116 1229 605516 330 061812 231 721910 132 016253 1

7-12 121538EX_1116

54" Deck

20

22

12

12 21

13

14

2

1

4

13

5

7

10

10

87

11

12

13

15

16

18 1917

11

12

6

2

1

REAR OFDECK

9

3

2

2

121538EX_1116 7-13

54" Deck


54" DECK PULLEY COVERCS .250-20 X .75 HX FLGDISCHARGE CHUTECHUTE SPRINGDISCHARGE CHUTE PINNT .375-16 HX G5 ZY NLCS .375-16 X 1.375 HX FL G5PULLERPIVOT SPACER BUSHINGNT .375-16 FL NY GFNT .500-13 HX G8 ZY NLFW .531 X 1.063 X .175PLASTIC WHEEL ASSEMBLYBLADE, 18.50"-L-F-CWBLADE, F18.50"-L-F-CWBLADE, F18.50"-H-F-CWBLADE, 18.50"-MUL-F-CWBLADE, 18.50"-GAT-F-CWCW .631 X 2.25 X .187 PNTCS .625-11 X 1.25 HX G5 ZCB .500-13 X 4.50 STD ZNSPACER 3.22 PLASTIC WHEELCS .500-13 X 4.25 HX G5PLASTIC WHEELNT .500-13 HX JAM ZNYC

NOTES:

1. Torque to 118 ft-lbs.2. Torque to 2–5 ft-lbs on these self-tapping screws.3. Do not torque; the discharge chute must pivot freely.

DESCRIPTION

1 605452 22 604324 23 604609 14 604331 15 604346 16 086660 17 605532 28 121446 19 605659 210 604515 211 781567 512 767962 713 788166 314 601124 3

601012 3797696 3797704 3797712 3

15 782474 316 781872 317 602339 218 602345 219 602263 220 781708 121 031997 122 053199 1

7-14 121538EX_1116

Deck Carrier

177

13

12

11

17

11

21

19

3

1

4

56

65

7

15

1513

13

15

10

18

18

16

16

16

16

20

22

16

10

9

98

8

2

14

29

30

29

REAR DISCHARGE SHOWNSIDE DISCHARGE SIMILAR

121538EX_1116 7-15

Deck Carrier


FLOOR PAN (WITH DECAL)PUMP BELT WARNING DECALCB .375-16 X .75 STD ZNFOOTRESTCS .312-18 X .875 HX G5FW .343 X .687 X .051/.080H5/16-18 THREAD RIVET NUTCS #8-32 X .500 PH TRXLIGHTNT #8-32 HX NL ZNDECK LIFT LINK SPACERDECK LIFT LINKFW .379 X .813 X .063CS .375-16 X 1.00 HX G5NT .375-16 HX G5NT .437-14 HX FLG ZNDECK LIFT LINKCS .437-14 X 1.75 HX G5BUMPER ID DECALNT .375-16 FL NY GFPIVOT SPACER BUSHINGCS .375-16 X 1.375 HX FL G5

NOTES:

DESCRIPTION

1 553006 12 600899 13 011320 44 190239 15 064014 46 768523 47 808485 48 605209 49 605003 210 605208 411 118900 412 118896 113 767954 1214 036244 415 054502 816 704643 1617 110880 418 055749 819 605073 120 604515 221 605659 222 605532 2

7-16 121538EX_1116

Deck Carrier

1314

2311

1315 25

24

27

32

17

16

16

17

29

29

1513

11

1314

30

28

31

1816

16

16

18 16

26

33

REAR DISCHARGE SHOWNSIDE DISCHARGE SIMILAR

121538EX_1116 7-17

Deck Carrier


CUT HEIGHT INDICATOROUTER CUTTING HEIGHT BRACKET (WITH DECAL)DECK HEIGHT STOP PINDECK HEIGHT DECALNT .375-16 HX G5 FLKPUSH MOUNTWIRE TIEPUSH BUTTON MOUNTINNER CUTTING HEIGHT BRACKETCB .375-16 X 1.00 G5 ZNYSEALED BALL SWITCHWIRE HARNESS (NOT SHOWN)

NOTES:

DESCRIPTION

23 118893 124 552932 125 601963 126 605685 127 016899 228 605405 229 000331 1430 604307 331 190236 132 025395 233 605239 134 605294 1

7-18 121538EX_1116

121538EX_1116 8-1

Section 8

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-2 121538EX_1116

Seat

2

1

13

3

42

9 6

3

7

12

5

10

1

3

4

11

8A

121538EX_1116 8-3

Seat


SEATSEAT PAN (WITH DECALS)FW .343 X .687 X .051/.080HCS .312-18 X 1.00 HX G5LEVEL FUEL FILL DECALNT .312-18 HX G5 ZY NLSEAT BUMPERWEATHERSTRIPNT .375-16 HX G5 ZY NLCS .375-16 X 1.00 HX G5BATTERY WARNINGS DECALPUSH BUTTON MOUNTWIRE TIE

NOTES:

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

DESCRIPTION

1 605009 12 552890 13 768523 84 036236 65 605782 16 058776 27 605663 28 033035 8"

9 086660 210 036244 211 601815 112 604307 113 000331 1

WEATHERSTRIP LENGTH

4"A

8-4 121538EX_1116

Seat Service Parts

1

2


ARMREST KITSEAT SWITCH

NOTES:

DESCRIPTION

1 119783 12 793315 1

big dog mower co. blackjack parts manual · hydraulic system ... .562 105 143 m10 37 50 ... cs...

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