bigdog mowers r diablo parts manualthe engine owner’s manual provides information regarding the...

•••••

200 South Ridge Road

•••Hesston, Kansas

•67062

BigDog® MowersR Diablo®

Parts Manual

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

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.

WARNING

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

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

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.

115599_1113 c-1

Table of ContentsGeneral Information

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

Section 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Section 3Hydraulic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Transmission Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

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

Section 5Engine, Kawasaki FX691V & FX730V . . . . . . . . . . . . . . . . . . . . . . 5-2Engine Service Parts, Kawasaki FX691V & FX730V . . . . . . . . . . . 5-6Fuel System—S/N 12080978 & Higher. . . . . . . . . . . . . . . . . . . . . . 5-8Fuel System—S/N Prior to 12080978. . . . . . . . . . . . . . . . . . . . . . . 5-10Fuel System Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

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

Section 754" Service Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-254" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-454" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-660" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-860" Deck Pulleys & Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1060" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12Spindle Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Section 8Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Seat Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4ROPS—Foldable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

c-2 115599_1113

115599_1113 1-1

General Information

This manual covers BigDog® Mowers models 931378 & 931386.

Service Literature

PART NO.

OPERATOR’S MANUALWARRANTY STATEMENTGENERAL SERVICE MANUAL

Options Available From Your Dealer

PART NO.

54" 2-BAG CATCHER54" DECK MULCH KIT54" DECK CONTAINMENT KIT60" 2-BAG CATCHER60" DECK MULCH KIT60" DECK CONTAINMENT KITHOUR METER KITSTEERING EXTENSION KITLIGHT KITFLEX FORKS®

SEAT SPRING 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 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.

DESCRIPTION

603743115620115619

DESCRIPTION

929687112611112615930834113934113933367656333724112418603717108743

1-2 115599_1113

Hardware Description Codes & Abbreviations

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

ABBREVIATION

CARRIAGE 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

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 DESCRIPTION

CB MBCE MSCN NTCP SCCS SHCW SB

FDRW SSFW ODHX IDLW

.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

115599_1113 2-1

Section 2

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

Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-2 115599_1113

Frame

7

12

10

2

17

14

2

1

65

23

4

8

9

13

11 10

10

16

15

1

2

3

18

115599_1113 2-3

Frame

INDEX NO. PART NO. QTY.

54" FRAME (WITH DECALS & HARDWARE)

60" FRAME (WITH DECALS & HARDWARE)

3/8-16 THREAD RIVET NUT

CN .312-18 X .20 MAX THK

FUEL INDICATOR DECAL

ENGINE COMPARTMENT DECAL

HOT DECAL

PUMP BELT WARNING DECAL

RS STEERING DECAL

DECK HEIGHT DECAL

SERIAL NUMBER / SPEC DECAL

LS STEERING DECAL

BIG DOG R LOGO DECAL

MADE IN USA DECAL

SAFE OPERATION DECAL

3/8-16 THREAD HEX RIVET NUT

5/16-18 THREAD RIVET NUT

TOW VALVE DECAL

STEP TREAD

NOTES:

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

2. Patent numbers plate.

3. EPA compliance plate.

DESCRIPTION

1 551192 1

551193 1

2 808493 8

3 601069 2

4 791848 1

5 601967 1

6 602041 1

7 600899 1

8 785220 1

9 603407 1

10 N/A 3

11 785139 1

12 603724 1

13 727172 1

14 601993 1

15 600994 2

16 808485 1

17 601099 1

18 601987 1

2-4 115599_1113

Footrest

1

2

34

4

6

5

7

8

115599_1113 2-5

Footrest


FLOOR PAN

CB .375-16 X .75 STD ZN

NT .375-16 HX ZY NL

FW .406 X .812 X .060 SAE

CB .375-16 X 1.00 G5 ZNY

NT .375-16 HX G5 ZNY

R754 DECAL

R760 DECAL

STEP TREAD

NOTES:

DESCRIPTION

1 190023 1

2 011320 2

3 086660 2

4 767954 4

5 025395 2

6 054502 2

7 603725 1

603726 1

8 602323 3

2-6 115599_1113

Engine Guard

12

3

5

5

6

4

7

10

8

89

6

INDEX NO. PART NO. QTY

REAR ENGINE PLATE GUARD

FW .406 X .812 X .060 SAE

CS .375-16 X 1.25 HX G5 ZN

NT .500-13 HX G8 ZY NL

FW .510 X 2.15 X .187 SPL

PLASTIC WHEEL ASSEMBLY

CS .500-13 X 4.25 HX G5

FW .531 X 1.063 X .090 SAE

PLASTIC WHEEL

NT .500-13 HX JAM ZNYC

NOTES:

DESCRIPTION

1 190002 1

2 767954 6

3 052860 6

4 781567 2

5 344267 4

6 788166 2

7 781708 2

8 767962 4

9 031997 2

10 053199 2

115599_1113 3-1

Section 3

Hydraulic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Transmission Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-2 115599_1113

Hydraulic Transmissions

2021

16

19

6

18

17

7

5

8

12

4

1

2

2

3

4

9

10

9

11

13

2

15

215

14

17

2

1

115599_1113 3-3

Hydraulic Transmissions


CS .312-18 X 2.25 HX G5

FW .343 X .687 X .051/.080H

CS .312-18 X 2.50 HX G5

WIRE TIE

CS .625-11 X 1.75 HX G5

IDLER PULLEY 4.00" OD

SPRING 1/4 COIL PL 1.23

FW .781 X 1.25 X .024 ZN

BUSHING

PUMP TENSIONER

FW .760 X 1.625 X .08 ZNYC

SB .750 X 2.00 SH .625-11

BELT, A SEC, 67.6 EL

TRANSMISSION ASSEMBLY

NT .312-18 HX G5 ZNYC

OVERFLOW TANK (WITH CAP)

OVERFLOW TANK CAP

FW .281 X .625 X .051/.080 HD ZN/YL

NT .250-20 HX ZY NL

CS .250-20 X .75 HX G5

TOW LINK ROD

CP .062D X 1.00 LG HML Z

NOTES:

1. Torque to 100 ft-lbs.


DESCRIPTION

1 038828 4

2 768523 16

3 710087 4

4 000331 3

5 025007 1

6 784827 1

7 036384 1

8 704791 1

9 770867 2

10 111771 1

11 025296 1

12 601084 1

13 602253 1

14 N/A 1

15 034272 8

16 600759 1

600767 1

17 768515 4

18 068551 2

19 055939 2

20 601088 2

21 048553 2

3-4 115599_1113

Transmission Assembly

1 67

117

3

10

5

4

4

8

9

12

11

8

7

613

13

14

14

15

2

1

1

7

12

115599_1113 3-5

Transmission Assembly


LS TRANSMISSION

RS TRANSMISSION

HYDRAULIC FITTING, 45 DEG

SPRING CLAMP

OVERFLOW HOSE


FW .343 X .687 X .051/.080H

SPRING CLAMP

OVERFLOW HOSE

FITTING, 90 - 9/16 SAE

BALL STUD

STEERING DAMPER

CS .375-16 X 2.00 G5 ZNYC

FW .406 X 1.00 X .12 HRD Z

SPACER TUBE

NOTES:


DESCRIPTION

1 603741 1

2 603740 1

3 600880 1

4 601001 2

5 601018 1

6 034272 2

7 768523 4

8 601474 2

9 601055 1

10 601219 1

11 781922 2

12 600221 2

13 016410 2

14 712919 2

15 600987 1

3-6 115599_1113

Transmission Service Parts

7 6

1

5

4

23

8


FAN/PULLEY KIT

RETAINING CLIP

BRAKE ARM

CHARGE COVER KIT

O-RING

LS FILTER GUARD

RS FILTER GUARD (NOT SHOWN)

OIL FILTER

4 BOLT HUB KIT

NOTES:

DESCRIPTION

1 603866 1

2 600972 1

3 601221 1

4 603572 1

5 603223 1

6 600975 1

600974 1

7 600976 1

8 601433 1

115599_1113 3-7

This page intentionally left blank.

3-8 115599_1113

Steering

2

STEERINGSUB-ASSEMBLY

3

3

3

3

3

4

14

8

8

13

17

7

9

10

11

12

56

15

1

16

3

1

1

115599_1113 3-9

Steering


LOCK COLLAR 0.757 ID

NT .312-24 HX NL ZN

FW .343 X .687 X .051/.080H

PUMP ROD

CS .375-16 X 1.375 HX G5

NT .375-16 HX JAM G5 Z

CS .250-20 X .75 HX G5

FW .281 X .625 X .051/.080H

STEER TUBE SUPPORT

CS .312-18 X 1.00 HX G5

PLATED PIVOT TUBE

LW .312 INT-EXT TOOTH


BALL STUD


SPACER

NT .312-24 HX ZNYC

NOTES:

1. Part of the Transmission Assembly.

DESCRIPTION

1 784439 2

2 023655 2

3 768523 13

4 600981 2

5 005116 2

6 706168 2

7 055939 4

8 768515 8

9 108968 2

10 036236 1

11 361295 1

12 029876 2

13 034272 2

14 781922 2

15 024927 4

16 604456 2

17 041152 2

3-10 115599_1113

Steering Sub-Assembly1

2

5

4

3

3

3

3

6

5

3

7

7

34

8


STEERING BAR GRIP

STEERING BAR (WITH GRIP)

FW .406 X .812 X .060 SAE

CS .375-16 X 1.75 HX G5

NT .375-16 NL G5

LEFT STEERING ARM (SHOWN)

RIGHT STEERING ARM

BUSHING

LS STEER PIVOT (SHOWN)

RS STEER PIVOT

NOTES:

DESCRIPTION

1 781260 2

2 360487 2

3 767954 12

4 705178 6

5 086660 6

6 107843 1

107842 1

7 770867 4

8 107848 1

107847 1

115599_1113 3-11


3-12 115599_1113

Brake

1

4

2

3

7

13

2

12

9

8

9

26

2

10

5

214

18

21

17

15

16

MOWERFRAME

HYDRAULICTRANSMISSION

11125

8

87

STEERINGARM

115599_1113 3-13

Brake


NT .375-16 NL G5

FW .406 X .812 X .060 SAE

SWITCH

CS .375-16 X 3.50 HX G5 Z

BRAKE ROD ASSEMBLY


NT .312-24 HX NL ZN

FW .343 X .687 X .051/.080H

BUSHING

LS BRAKE BELL CRANK

RS BRAKE BELL CRANK

CS .375-16 X 1.50 HX G5

SHORT BRAKE LINK ROD

SPRING

LS BRAKE SPRING LINK

RS BRAKE SPRING LINK (NOT SHOWN)

CS .250-20 X .75 HX G5

NT .250-20 HX FL LK ZNY

OVERTRAVEL SPRING

NOTES:

DESCRIPTION

1 086660 4

2 767954 12

3 601087 2

4 005108 2

5 601410 2

6 054502 2

7 023655 4

8 768523 8

9 765339 4

10 107893 1

11 107892 1

12 080655 2

13 600991 2

14 601131 2

15 109203 1

109202 1

16 055939 2

17 016816 2

18 601051 2

3-14 115599_1113

115599_1113 4-1

Section 4

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

Front Tire Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

4-2 115599_1113

Wheel & Tire

1 3

12

4

5

6

7

8

9

115599_1113 4-3

Wheel & Tire


TIRE/WHEEL ASSEMBLY 22 X 11-10

WHEEL BACKUP PLATE

WHEEL NUT

CS .500-13 X 1.25 HX G5 ZN

FW .510 X 2.15 X .187 SPL

FW .531 X 1.375 X .125 ZNY

BEARING

SPACER

FRONT TIRE S/A LEFT

FRONT TIRE S/A RIGHT (NOT SHOWN)

NOTES:

1. Torque to 65–75 ft-lbs.

DESCRIPTION

1 603749 2

2 111875 2

3 061077 8

4 705954 2

5 344267 2

6 712976 2

7 784223 4

8 784603 2

9 604570 1

10 604569 1

4-4 115599_1113

Front Tire Breakdown

4

5

21

3

3

7

7

6

89

10

115599_1113 4-5

Front Tire Breakdown


FORK

CS .750-10 X 9.50 HX ZY

FW .760 X 1.625 X .08 ZNYC

NT .750-10 HX ZY NL

TIRE/WHEEL 13 X 6.5

TIRE 13 X 6.50

WHEEL BEARING

BEARING SPACER

WHEEL 6 X 4.5

TIRE VALVE

NOTES:

DESCRIPTION

1 190112 1

2 041475 1

3 025296 2

4 061101 1

5 603755 1

6 747741 1

7 039677 2

8 782771 1

9 603756 1

10 019521 1

4-6 115599_1113

Drive Wheel Breakdown

NOTES:

INDEX NO. PART NO. QTY. DESCRIPTION

1 603738 1 TIRE 22 X 11-10

2 603737 1 WHEEL 10X 8.5

3 019521 1 VALVE STEM

1

2

3

115599_1113 5-1

Section 5

Engine, Kawasaki FX691V & FX730V. . . . . . . . . . . . . . . . . . . . . . . . 5-2

Engine Service Parts, Kawasaki FX691V & FX730V . . . . . . . . . . . . 5-6

Fuel System—S/N 12080978 & Higher . . . . . . . . . . . . . . . . . . . . . . . 5-8

Fuel System—S/N Prior to 12080978 . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-2 115599_1113

Engine, Kawasaki FX691V & FX730V

914

15

7

1

2

1

5

64

4 3

19

12

20

17

1812

11

10

13

84

6

3

2

316

115599_1113 5-3



KAWASAKI FX691V & FX730V ENGINE

MUFFLER

CS .312-18 X 1.000 HX G5

FW .343 X .687 X .051/.080H

CLUTCH ANCHOR


OIL DRAIN VALVE

CB .312-18 X .750 FUL ZN

MUFFLER SHIELD

GROUND STRAP

LW .375 INT-EXT TOOTH

CS .375-16 X 1.25 HXG5 P85

KEY 1/4 SQ X 0.66 LG

PULLEY

FW .406 X .812 X .060 SAE

CLUTCH KIT

WIRE TIE, SMALL/SHORT

CLUTCH HARNESS PIGTAIL

FW .453 X 1.12 X .119 HRD

CS .437-20 X 2.50 HXG5 P85

NOTES:

1. Supplied with the engine.

2. Torque the bolt to 45–48 ft-lbs. Replace (do not reuse) the cap screw if it’s removed or loosened. Use only hand tools to install this fastener.

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

DESCRIPTION

1 N/A 1

2 603150 1

3 036236 2

4 768523 8

5 113946 1

6 034272 6

7 796524 1

8 016253 2

9 108969 1

10 111894 1

11 793885 1

12 602580 4

13 712372 1

14 603255 1

15 767954 3

16 601785K 1

17 000331 3

18 791251 1

19 602680 1

20 785659 1

5-4 115599_1113


25

23

30A FUSE

1

17

22

6

12

10

11

21

4

4

6

26

25

24

24

A

B

4

4

4

115599_1113 5-5



NEGATIVE BATTERY CABLE

POSITIVE BATTERY CABLE

1/4" FUEL LINE

CLAMP, 3/16"

HOSE CLAMP

3/16" VAPOR LINE

NOTES:

4. Part of the wire harness.

DESCRIPTION

21 601063 1

22 744276 1

23 015818 18"

24 603112 2

25 000323 2

26 603326 33"

FUEL & VAPOR LINE LENGTHS

18" FILTER TO FUEL VALVE (FUEL)

33" ENGINE PORT TO TEE (VAPOR)

A

B

5-6 115599_1113

Engine Service Parts, Kawasaki FX691V & FX730V

4

3

1

2

5


MAIN AIR FILTER

SAFETY AIR FILTER

OIL FILTER

IN-LINE FUEL FILTER

VACUATOR VALVE

NOTES:

DESCRIPTION

1 785261 1

2 785279 1

3 602581 1

4 068478 1

5 763318 1

115599_1113 5-7


5-8 115599_1113

Fuel System—S/N 12080978 & Higher

3

2

1

4

4

11

415

15

14 16

12

16

5

6

7

8

9

10

135

6

9

10

7

8

11

1

C

13

4

16

A

B

D E

115599_1113 5-9

Fuel System—S/N 12080978 & Higher


RS FUEL TANK ASSEMBLY

LS FUEL TANK ASSEMBLY

RATCHETING GAS CAP 3.5"

HOSE CLAMP

CS .312-18 X 1.00 HX G5

FW .343 X .687 X .051/.080H

FW .406 X 1.00 X.12 HRD Z

CS .375-16 X .75 HX G5

LOOP CLAMP

NT .312-18 HX FLK ZNYC

FUEL VALVE 3-WAY

PLASTIC TEE, 3/16"

WIRE TIE

VACUUM BREAKER

1/4" FUEL LINE

3/16" VAPOR LINE

FUEL LINE LENGTHS

RIGHT TANK TO VALVE (FUEL)

LEFT TANK TO VALVE (FUEL)

RIGHT TANK TO TEE (VAPOR)

TEE TO VACUUM BREAKER (VAPOR)

LEFT TANK TO VACUUM BREAKER (VAPOR)

NOTES:


DESCRIPTION

1 604058 1

2 604059 1

3 602916 2

4 000323 4

5 036236 2

6 768523 2

7 712919 6

8 055822 6

9 043570 2

10 016832 2

11 745059 1

12 604281 1

13 000331 1

14 604305 1

15 015818 36"

16 603326 46"

12"

24"

25"

5"

16"

A

B

C

D

E

5-10 115599_1113

Fuel System—S/N Prior to 12080978

3

2

1

4

4

4

11

415

15

14 154

12

15

5

6

7

8

9

10

135

6

9

10

7

8

411

1

C

1

3

4

4

15

A

B

D E

4

115599_1113 5-11

Fuel System—S/N Prior to 12080978


RS FUEL TANK ASSEMBLY

LS FUEL TANK ASSEMBLY

RATCHETING GAS CAP 3.5"

HOSE CLAMP

CS .312-18 X 1.00 HX G5

FW .343 X .687 X .051/.080H

FW .406 X 1.00 X.12 HRD Z

CS .375-16 X .75 HX G5

LOOP CLAMP

NT .312-18 HX FLK ZNYC

FUEL VALVE 3-WAY

PLASTIC TEE 1/4" X 1/4" X 3/16"

WIRE TIE

VACUUM BREAKER

1/4" FUEL LINE

FUEL LINE LENGTHS

RIGHT TANK TO VALVE (FUEL)

LEFT TANK TO VALVE (FUEL)

RIGHT TANK TO TEE (VAPOR)

TEE TO VACUUM BREAKER (VAPOR)

LEFT TANK TO VACUUM BREAKER (VAPOR)

NOTES:


DESCRIPTION

1 603032 1

2 603031 1

3 602916 2

4 000323 10

5 036236 2

6 768523 2

7 712919 6

8 055822 6

9 043570 2

10 016832 2

11 745059 1

12 603025 1

13 000331 1

14 603024 1

15 015818 82"

12"

24"

25"

5"

16"

A

B

C

D

E

5-12 115599_1113

Fuel System Service Parts

7

4

5

23

S/N 11090186-12080977

1

23

S/N PRIOR TO 11090186

6

5

S/N 12080978 & HIGHER

23


VENT FITTING KIT

SUCTION HOSE GROMMET

SUCTION HOSE ASSEMBLY 19.5"

FUEL VENT VALVE

GROMMET

VENT FITTING

VACUUM BREAKER FILTER

NOTES:

DESCRIPTION

1 117118 1

2 785295 1

3 601527 1

4 604199 1

5 604200 1

6 604287 1

7 603161 1

115599_1113 6-1

Section 6

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

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-2 115599_1113

Battery

1

2

3

5

45

5

6

6

7

8

115599_1113 6-3

Battery


CS .312-18 X 4.00 HX G5

FW .343 X .687 X .051/.080H

BATTERY CLAMP STRAP

CS .250-20 X .75 HX G5

LW .250 INT-EXT TOOTH Z


RED BATTERY CABLE BOOT

GM 1.50 X 2.12 X 1.75

WIRE TIE (NOT SHOWN)

NOTES:

DESCRIPTION

1 714618 2

2 768523 2

3 348417 1

4 055939 2

5 029868 4

6 024927 2

7 771428 1

8 794644 2

9 000331 1

6-4 115599_1113

Instrument Panel

13

2

3

7

7

1

10

6

6

14

5

5

9

8

11

12

16

171

18

1

15

1110

4

10A FUSE

15A FUSE

115599_1113 6-5

Instrument Panel


CHOKE CABLE

PTO SWITCH

RED INDICATOR LIGHT

KEY ASSEMBLY

CB 10-24 X .500 ZYNC

NT #10-24 HX NL ZN

IGNITION SWITCH

FW .219 X .500 X .048 ZNYC

THROTTLE CABLE

CS .250-20 X .500 HX G5

FW .281 X .625 X .051/.080 HD ZN/YL

INSTRUMENT PANEL DECAL

INSTRUMENT PANEL (WITH DECAL)

WIRE TIE

HOUR METER

WIRE HARNESS

SEALED RELAY (WITH BRACKET)

CLUTCH CONNECTOR REPAIR KIT

NOTES:

1. Part of the wire harness.

DESCRIPTION

1 601097 1

2 776476 1

3 712257 1

4 785808 1

5 601098 4

6 059832 4

7 045898 1

8 704932 2

9 601096 1

10 055947 3

11 768515 3

12 602468 1

13 550446 1

14 000331 7

15 769166 1

16 603790 1

17 601053 3

18 114052 1

6-6 115599_1113

115599_1113 7-1

Section 7

54" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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

54" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

60" Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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

60" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Spindle Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Deck Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-2 115599_1113

54" Service Deck

1

2

3

4

45

63

115599_1113 7-3

54" Service Deck


54" DECK (WITH DECALS & HARDWARE)

BELT ROUTING DECAL

DECK DANGERS DECAL

CN .312-18 X .20 MAX THK

DISCHARGE CHUTE DECAL

THROWN OBJECTS DECAL

NOTES:

DESCRIPTION

1 550424 1

2 781419 1

3 601837 2

4 601069 4

5 601624 1

6 601892 1

7-4 115599_1113

54" Deck Pulleys & Spindles1

2

3

4

6 57

8

9

1

10

11

1

12

13

14

15

14

16

18

21

20

2317

17

2

3

4

19

17

24

22

25

27

21

21 26

20

115599_1113 7-5

54" Deck Pulleys & Spindles


CS .625-11 X 1.50 HX G5

FW .625 X 1.00 X .134 ZNYC

DUST SHIELD WITH OFFSET

IDLER PULLEY, NHI 5.0"

IDLER SLIDE

TENSION SPRING

CHAIN

CS .312-18 X 1.25 FLT SH

IDLER SLIDE

CS .625-11 X 1.25 HX G5 Z

FW .680 X 1.750 X .14 SAE

DRIVE PULLEY 5.68 OP


FW .406 X .812 X .060 SAE

CS .375-16 X 1.375 HX G5

BLADE SPINDLE

FW .343 X .687 X .051/.080H

NT .312-18 HXZY NL


PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)

FW .531 X 1.063 X .090 SAE

CS .312-18 X .75 HX G5

HEAVY DUTY PULLER


CS .500-13 X 4.25 HX G5

PLASTIC WHEEL


NOTES:


DESCRIPTION

1 794446 3

2 028118 3

3 603057 3

4 781856 3

5 109770 1

6 781302 1

7 259812 1

8 784199 4

9 601619 2

10 781872 3

11 017152 3

12 786889 3

13 054502 12

14 767954 24

15 005116 12

16 783506 3

17 768523 8

18 058776 4

19 781567 2

20 788166 2

21 767962 6

22 034280 2

23 109444 2

24 034272 2

25 781708 2

26 031997 2

27 053199 2

7-6 115599_1113

54" Deck

1

14

15

16 1

4

5

3

8

7

6

10

11

9

13

12

11

12

17

20

18

19

FRONT WALL

DISCHARGECHUTE

134

5

122

2

115599_1113 7-7

54" Deck


BELT, B 152" EL

LS PULLEY COVER

RS PULLEY COVER

CS .312-18 X .75 HX G5

FW .344 X 1.00 X.12 HRD Z

DISCHARGE CHUTE

TORSION SPRING

CHUTE PIN

CHUTE BRACKET

CHUTE ADAPTER PLATE

CB .375-16 X 1.00 STD CD

NT .375-16 HXZY NL

FW .406 X .812 X .060 SAE

BLADE, 18.50"-L-F-CW

BLADE, F18.50"-H-F-CW

BLADE, 18.50"-MUL-F-CW

BLADE, 18.50"-GAT-F-CW

CW .631 2.25 X .187 PNT

CS .625-11 X 1.25 HX G5 Z

NT .312-18 HXZY NL

"A" BLOWOUT BAFFLE

CB .312-18 X .75 FUL ZN

FW .343 X .687 X .051/.080H

NOTES:


2. Do not torque the nut; the discharge chute must pivot freely.

DESCRIPTION

1 789388 1

2 602749 1

3 602748 1

4 034280 4

5 712927 4

6 601806 1

7 601824 1

8 601843 1

9 111067 1

10 190037 1

11 025395 4

12 086660 5

13 767954 4

14 601124 3

797696 3

797704 3

797712 3

15 782474 3

16 781872 3

17 058776 2

18 111999 1

19 016253 2

20 768523 2

7-8 115599_1113

60" Service Deck

3

1

6

3

4

52

115599_1113 7-9

60" Service Deck


60" DECK (WITH DECALS & HARDWARE)

BELT ROUTING DECAL

DECK DANGERS DECAL

CN .312-18 X .20 MAX THK

DISCHARGE CHUTE DECAL

THROWN OBJECTS DECAL

NOTES:

DESCRIPTION

1 550961 1

2 781419 1

3 601837 2

4 601069 4

5 601624 1

6 601892 1

7-10 115599_1113

60" Deck Pulleys & Spindles1

2

7

8

9

1

10 1

12

13

14

1520

21

19

17

24

23

20

22

6 5

4

3

11

14

2

4

3

16

18

25

27

18

18 26

17

20

115599_1113 7-11

60" Deck Pulleys & Spindles


CS .625-11 X 1.50 HX G5

FW .625 X 1.00 X .134 ZNYC

DUST SHIELD WITH OFFSET

IDLER PULLEY, NHI 5.0"

IDLER SLIDE

TENSION SPRING

CHAIN, 21 LINK

CS .312-18 X 1.25 FLT SH

IDLER SLIDE UHMW

CS .625-11 X 1.25 HX G5 Z

FW .680 X 1.75 X .14 SAE

DECK DRIVE PULLEY


FW .406 X .812 X .060 SAE

BLADE SPINDLE

CS .375-16 X 1.375 HX G5

PLASTIC WHEEL ASSEMBLY (WITH HARDWARE)

FW .531 X 1.063 X .090 SAE


FW .343 X .687 X .051/.080H

NT .312-18 HX ZY NL

HEAVY DUTY PULLER


CS .312-18 X .75 HX G5

CS .500-13 X 4.25 HX G5

PLASTIC WHEEL


NOTES:


DESCRIPTION

1 794446 3

2 028118 3

3 603057 3

4 781856 3

5 109770 1

6 781302 1

7 373191 1

8 784199 4

9 601619 2

10 781872 3

11 017152 3

12 601447 3

13 054502 12

14 767954 24

15 783506 3

16 005116 12

17 788166 2

18 767962 6

19 781567 2

20 768523 8

21 058776 4

22 109444 2

23 034272 2

24 034280 2

25 781708 2

26 031997 2

27 053199 2

7-12 115599_1113

60" Deck

2

12

9

1

11

4

4

7

13

18

10

16

19

1

3

9

10

10

5

4

5

8

6

8

15

14

17

FRONT WALL

DISCHARGECHUTE

2

115599_1113 7-13

60" Deck


DISCHARGE CHUTE

TORSION SPRING

CHUTE PIN

NT .375-16 HXZY NL

FW .406 X .812 X .060 SAE

CHUTE BRACKET

CHUTE ADAPTOR PLATE

CB .375-16 X 1.00 G5 ZNY

CS .312-18 X .75 HX G5

FW .343 X .687 X .051/.080H

RS PULLEY COVER

LS PULLEY COVER

BELT, B 162

BLADE, 20.50"-L-F-CW

BLADE, 20.50"-MUL-F-CW

BLADE, 20.50"-GAT-F-CW

BLADE, F20.50"-H-F-CW

CW .631 X 2.25 X .187 PNT

CS .625-11 X 1.25 HX G5 Z

CB .312-18 X .75 FUL ZN

NT .312-18 HXZY NL

BLOWOUT BAFFLE

NOTES:


2. Do not torque the nut; the discharge chute must pivot freely.

DESCRIPTION

1 601806 1

2 601824 1

3 601843 1

4 086660 5

5 767954 4

6 111067 1

7 190052 1

8 025395 4

9 034280 4

10 768523 6

11 113882 1

12 113883 1

13 601715 1

14 793794 3

794214 3

794230 3

794685 3

15 782474 3

16 781872 3

17 016253 2

18 058776 2

19 113835 1

7-14 115599_1113

Spindle Service Parts

2

5

4

1

3

2


BLADE SPINDLE RETAINER RING

BLADE SPINDLE BEARING

BLADE SPINDLE SPACER

BLADE SPINDLE HOUSING

BLADE SPINDLE SHAFT

NOTES:

DESCRIPTION

1 783548 1

2 783555 2

3 783530 1

4 783514 1

5 783522 1

115599_1113 7-15


7-16 115599_1113

Deck Lift

1

2

3

4

5

6

7

56

7

7

89

10

10

8

9

9

87

7

11

12

13

10

14

8

9

89

15

16

7

65

17

115599_1113 7-17

Deck Lift


STOP HANDLE

HEIGHT ADJ STOP

DECK LIFT INDICATOR

DECK LIFT ROD

CS .437-14 X 1.75 HX G5 ZN

DECK LIFT CHAIN

NT .437-14 HX FL ZN

FW .781 X 1.50 X .120 ZN

E-CLIP 1.00 X .625 X .050

GREASE FITTING STRAIGHT

CS .312-18 X 1.50 FUL THD ZN

NT .312-18 HX G5 ZN

DECK LEVELER YOKE

FW .531 X 1.063 X .09 SAE HRD ZN

CE .750 X 2.12 X 1.75 HEADLESS

DECK LIFT SPRING

CS .437-14 X 1.75 FUL THD G5 ZN

NOTES:

DESCRIPTION

1 348318 1

2 348284 1

3 784488 1

4 601942 1

5 055749 7

6 360131 4

7 704643 16

8 601681 6

9 781294 7

10 015495 4

11 756270 1

12 034272 1

13 348458 1

14 767962 6

15 781229 1

16 782995 1

17 781831 1

7-18 115599_1113

Deck Mounting Hardware

5

14

14

7

7

18

19

115599_1113 7-19

Deck Mounting Hardware


CS .500-13 X 2.00 GR ZN

NT .500-13 HX G5 ZN

NOTES:

DESCRIPTION

18 078949 2

19 008193 2

7-20 115599_1113

115599_1113 8-1

Section 8

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

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

ROPS—Foldable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-2 115599_1113

Seat

6

45

5

1

32

6

6

4

5

5

5

5

11

8

9

12

13

14

10

7

1

1

115599_1113 8-3

Seat


SEAT WITH REMOVABLE BACK

BATTERY WARNINGS DECAL

SEAT PAN STOP

CS .312-18 X .875 HX G5 ZN

FW .343 X .687 X .051/.080H

NT .312-18 HX NL

CS .312-18 X .75 HX G5

SEAT LATCH ASSEMBLY

WIRE TIE

SEAT PAN (WITH DECAL)


CS .375-16 X 1.25 HX G5 ZN

FW .406 X .812 X .060 SAE

SEAT SPRING 150 LB/IN

NOTES:

1. Do not torque; the seat pan and seat pan stop must pivot freely.

DESCRIPTION

1 604575 1

2 601815 1

3 109240 1

4 064014 3

5 768523 16

6 058776 7

7 034280 3

8 603884 1

9 000331 2

10 550988 1

11 034272 3

12 052860 2

13 767954 2

14 601450 2

8-4 115599_1113

Seat Service Parts

2

7

6

1

3

4

5


ARM PADS (WITH HARDWARE)

SEAT BACK

SEAT BACK COVER

SEAT BOTTOM

SEAT BOTTOM COVER

ARM REST BRACKETS (WITH HARDWARE)

SEAT BELT

STANDARD SEAT TRACK

SEAT SWITCH

NOTES:

DESCRIPTION

1 603809 1

2 605135 1

603894 1

3 605136 1

603893 1

4 603808 1

5 601444 1

6 603146 1

7 603148 1

115599_1113 8-5


8-6 115599_1113

ROPS—Foldable

1

1

2

34

5

6

7

4

4

78

8

9

1

115599_1113 8-7

ROPS—Foldable


ROPS KIT (WITH DECALS, SEAT BELT & HARDWARE)

CS .500-13 X 3.50 HX G5

ROPS STOP

NT .500-13 UNT LK G8 ZN

HAND KNOB

LYNCH PIN W/ LANYARD

CS .500-13 X 3.25 HX G5

FW .531 X 1.063 X .090 SAE

ROPS DECAL

NOTES:


DESCRIPTION

1 601439 1

2 061812 1

3 601472 1

4 023317 6

5 601470 2

6 601471 2

7 077859 5

8 767962 8

9 601635 2

8-8 115599_1113

bigdog mowers r diablo parts manualthe engine owner’s manual provides information regarding the...

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