Exmark Lazer Z Lawn Mower Lhp4820Kc Users Manual 4500 567
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2015-02-04
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LAZER Z MODELS ADVANTAGE SERIES MODELS ® For Serial Nos. 850,000 & Higher Lazer Z (LZA Units) Part No. 4500-567 Rev. D -1- READ OPERATOR’S MANUAL BEFORE OPERATING OR SERVICING EXMARK EQUIPMENT. TABLE OF CONTENTS Description Page Brake Handle Assembly .................................................18 Caster Wheel Assembly .................................................12 Controls Group ...............................................................15 Decal Group ....................................................................29 Deck Group ................................................................... 3-9 Deck Support Group .......................................................13 Deck Idler Assembly .........................................................9 Electrical Diagram ...........................................................30 Electrical Group ..............................................................28 Electrical Logic Schematic ..............................................31 Engine Group ............................................................ 23-24 Fuel Tank Group .............................................................21 Fuel Tank Assembly .......................................................22 Height of Cut Assembly ..................................................14 Hydraulic Group ....................................................... 25-26 Mainframe Group ............................................................10 Motion Control Group ....................................................16 Park Brake Group ..........................................................18 Pump Idler Assembly ......................................................27 ROPS Assembly .............................................................11 Seat Group .....................................................................19 Seat W/Tracks Assembly ................................................20 -2- 48” DECK GROUP Item Part No. Description Qty. Item Part No. Description Qty. 1 116-1978 Asm, 484 Deck With Decals ................. 1 15:2 116-0381 Spindle ................................................... 1 2 98-5975 Washer, Spring Disc 3/8 ....................... 3 15:3 116-1286 Guard, Top ............................................ 1 3 109-7429 Washer, Blade Drive ............................. 3 15:4 104-0753 Nut, Flange ............................................ 1 4 116-0133 Extension-Spring ................................... 1 16 109-6935 Cover-Belt, RH ...................................... 1 5 99-2842 Spacer ................................................... 3 17 109-6936 Cover-Belt, LH ....................................... 1 6 103-6401 Blade, Notched ..................................... 3 18 109-6982 Wireform-Cover ..................................... 2 103-6391 Blade, Mulching .................................... 3 19 109-7188 Asm, Discharge Chute ........................... 1 103-6386 Blade, Low Lift ...................................... 3 19:1 109-2738 Chute, Discharge ................................... 1 103-6381 Blade, Solid ........................................... 3 19:2 109-8675-01 Bracket, Discharge Chute ...................... 1 103-6396 Blade, Extreme ..................................... 3 19:3 3231-22 Bolt, Carriage 3/8-16 x 1 ........................ 3 7 1-603299 Roller-Scalp, Anti .................................. 3 19:4 109-6658 Nut, Nyloc 3/8-16 Flg ............................. 3 8 1-613098 Pulley-Idler ............................................ 1 20 116-1965 Belt, V-B X 175.75 ................................. 1 9 1-633109 Idler-Flat ................................................ 1 21 109-9010-01 Baffle, Discharge ................................... 1 10 116-0674 Sheave, Blade Drive ............................. 3 22 3290-357 Nut, Whizlock 3/8-16 ............................. 3 11 109-2872 Spacer-Pulley........................................ 2 23 3231-22 Bolt, Carriage 3/8-16 x 1 ........................ 2 12 109-2883 Asm, Deck Idler..................................... 1 24 3231-28 Bolt, Carriage 3/8-16 x 1 1/4 .................. 2 13 116-0005 Bolt, Blade SEM .................................... 3 25 3231-44 Bolt, Carriage 3/8-16 x 2 1/2 .................. 2 14 109-6658 Nut, Nyloc 3/8-16 Flg ............................ 31 26 103-4051 Kit, Anti-Scalp Roller.............................. 3 15 116-1384 Asm, Cutter Housing Complete ............ 3 27 116-1967 Asm, Complete Deck ............................. 1 15:1 116-0924 Asm, Cutter Housing ............................. 1 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140). Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N MK484. -3- 48” DECK W/DECALS ASSEMBLY – 116-1978 Item Part No. Description Qty. Item Part No. Description Qty. 2 1-303508 Decal, Warning, Discharge ..................... 1 6 109-3148 Decal, Bolt Torque ..................................1 3 1-403005 Decal, Danger......................................... 2 7 116-0033 Decal, Ultracut 48 Series 4 .....................1 4 1-633922 Decal, Antiscalp ...................................... 1 8 116-2630 Decal, Belt Routing .................................1 5 98-5954 Decal, Cover, Missing ............................ 2 -4- 52” DECK GROUP Item Part No. Description Qty. Item Part No. Description Qty. 1 116-1984 Asm, 524 Deck With Decals ................. 1 15:2 116-0381 Spindle ................................................... 1 2 98-5975 Washer, Spring Disc 3/8 ....................... 3 15:3 116-1286 Guard, Top ............................................ 1 3 109-7429 Washer, Blade Drive ............................. 3 15:4 104-0753 Nut, Flange ............................................ 1 4 116-0133 Extension-Spring ................................... 1 16 109-6935 Cover-Belt, RH ...................................... 1 5 99-2842 Spacer ................................................... 3 17 109-6936 Cover-Belt, LH ....................................... 1 6 103-6402 Blade-Notched ...................................... 3 18 109-6982 Wireform-Cover ..................................... 2 103-6392 Blade, Mulching .................................... 3 19 109-7188 Asm, Discharge Chute ........................... 1 103-6387 Blade, Low Lift ...................................... 3 19:1 109-2738 Chute, Discharge ................................... 1 103-6382 Blade, Solid ........................................... 3 19:2 109-8675-01 Bracket, Discharge Chute ...................... 1 103-6397 Blade, Extreme ..................................... 3 19:3 3231-22 Bolt, Carriage 3/8-16 x 1 ........................ 3 7 1-603299 Roller-Scalp, Anti .................................. 3 19:4 109-6658 Nut, Nyloc 3/8-16 Flg ............................. 3 8 1-613098 Pulley-Idler ............................................ 1 20 109-9915-01 Baffle, Discharge 52/60 ......................... 1 10 109-2872 Spacer-Pulley........................................ 2 21 116-0675 Sheave, Blade Drive 6.50 ...................... 3 11 109-2883 Asm, Deck Idler..................................... 1 22 3290-357 Nut, Whizlock 3/8-16 ............................. 3 12 116-1966 Belt, V-B X 186.00" ............................... 1 23 3231-22 Bolt, Carriage 3/8-16 x 1 ........................ 2 13 116-0005 Bolt, Blade SEM .................................... 3 24 3231-28 Bolt, Carriage 3/8-16 x 1 1/4 .................. 2 14 109-6658 Nut, Nyloc 3/8-16 Flg ............................ 31 25 3231-44 Bolt, Carriage 3/8-16 x 2 1/2 .................. 2 15 116-1384 Asm, Cutter Housing Complete ............ 3 26 103-4051 Kit, Anti-Scalp Roller.............................. 3 15:1 116-0924 Asm, Cutter Housing ............................. 1 27 116-1968 Asm, Complete Deck ............................. 1 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140). Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N MK524. -5- 52” DECK W/DECALS ASSEMBLY – 116-1984 Item Part No. Description Qty. Item Part No. Description Qty. 2 1-303508 Decal, Warning Discharge ...................... 1 6 109-3148 Decal, Bolt Torque .................................. 1 3 1-403005 Decal, Danger......................................... 2 7 116-2630 Decal, Belt Routing ................................. 1 4 1-633922 Decal, Antiscalp ...................................... 1 8 116-0034 Decal, Ultracut 52 Series 4 ..................... 1 5 98-5954 Decal, Cover Missing ............................. 2 -6- 60” DECK GROUP Item Part No. Description Qty. Item Part No. Description Qty. 109-9915-01 Baffle, Discharge ................................... 1 1 116-1987 Asm, Deck 604 Push With Decals ........ 1 13 2 103-4051 Kit, Anti-Scalp Roller ............................. 4 14 116-0005 Bolt, Blade Sem ..................................... 3 3 103-6403 Blade, Notched .................................... 3 15 116-0094 Cover-Belt, RH ...................................... 1 103-6393 Blade, Mulching .................................... 3 16 116-0133 Extension-Spring ................................... 1 103-6388 Blade, Low Lift ...................................... 3 17 116-0676 Sheave, Blade Drive 7.25 ...................... 3 103-6383 Blade, Solid ........................................... 3 18 116-1384 Asm, Cutter Housing Complete ............. 3 Asm, Cutter Housing ............................. 1 103-6398 Blade, Extreme ..................................... 3 18:1 116-0924 4 109-0996 Pulley, Idler 8" Flat ................................ 1 18:2 116-0381 Spindle ................................................... 1 5 1-633109 Idler, Flat ............................................... 1 18:3 116-1286 Guard, Top ............................................ 1 6 109-2872 Spacer, Pulley ....................................... 2 18:4 104-0753 Nut, Flange ............................................ 1 7 109-2883 Asm, Deck Idler..................................... 1 19 109-8073 Belt, V-5V-198.75 .................................. 1 8 109-6658 Nut, Nyloc 3/8-16 Flg ............................ 36 20 3231-22 Bolt, Carriage 3/8-16 x 1 ........................ 2 9 109-6938 Cover-Belt, LH ...................................... 1 21 3231-28 Bolt, Carriage 3/8-16 x 1 1/4 .................. 6 10 109-6982 Wireform, Cover .................................... 2 22 3231-44 Bolt, Carriage 3/8-16 x 2 1/2 .................. 2 11 109-7188 Asm, Discharge Chute .......................... 1 23 1-603299 Roller-Scalp, Anti ................................... 4 11 109-7188 Asm, Discharge Chute .......................... 1 24 98-5975 Washer, Spring Disc 3/8 ........................ 4 11:1 109-2738 Chute, Discharge .................................. 1 25 99-2842 Spacer, Wheel ....................................... 4 11:2 109-8675-01 Bracket, Discharge Chute ..................... 1 26 3290-357 Nut, Whizlock 3/8-16 ............................. 4 11:3 3231-22 Bolt, Carriage 3/8-16 x 1 ....................... 3 27 116-3445 Plate, Reinf Push Tower ........................ 2 11:4 109-6658 Nut, Nyloc 3/8-16 Flg ............................ 3 28 116-3217 Asm, Complete Deck ............................. 3 12 109-7429 Washer, Blade Drive ............................. 3 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140). Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N MK604. . -7- 60” DECK W/DECALS ASSEMBLY – 116-1987 Item Part No. Description Qty. Item Part No. Description Qty. 2 1-303508 Decal-Warning, Discharge ..................... 1 6 109-3148 Decal, Bolt Torque ..................................1 3 1-403005 Decal-Danger ......................................... 2 7 116-2630 Decal-Belt Routing ..................................1 4 1-633922 Decal, Antiscalp ...................................... 1 8 116-0025 Decal, Ultracut 60 Series 4 .....................1 5 98-5954 Decal-Cover, Missing ............................. 2 -8- DECK IDLER ASSEMBLY – 109-2883 Item Part No. Description Qty. Item Part No. Description Qty. 1 43-0940 Spacer-Hub, Blower ............................... 1 9 109-7399 Pin, Spring Anchor ..................................1 2 103-2916 Guard, Top ............................................. 1 10 109-6658 Nut, Nyloc 3/8-16 Flg ..............................2 3 103-3504 Bearing, Spherical .................................. 2 11 109-7409 Screw, Shoulder 3/8-16 x 5 .....................1 4 103-3505 Seal, Double Lip ..................................... 1 12 323-8 Screw, HH 3/8-16 x 1 1/2 ........................1 5 103-3506 Seal, Single Lip ...................................... 1 13 32120-10 Ring, Retaining........................................2 6 103-8743 Pulley, Idler 5"Flanged ........................... 1 14 302-19 Zerk, 1/4-28 Str .......................................1 7 106-7159 O-Ring .................................................... 2 -9- MAINFRAME GROUP Item 1 Part No. Description Qty. Item Part No. Description Qty. 116-2124 Frame, Main 48/52 W/Decals .................. 1 10 116-0057-03 Bumper, Rear RH..................................... 1 116-2126 Frame, Main 60 W/Decals ....................... 1 11 104-8301 Nut, Nyloc 3/8-16 Flg ...............................11 1:2 107-2112 Decal, Warning ........................................ 1 12 3231-22 Bolt, Carriage 3/8-16 x 1 .......................... 7 1:3 103-2076 Decal, Caution Hot Surface ..................... 2 13 3231-21 Bolt, Carriage 3/8-16 x 3/4 ....................... 4 1:4 116-0205 Decal, Belt Drive ...................................... 2 14 116-0579 Asm, Motion Control Cover W/Decal RH ..... 1 1:5 117-2718 Decal, Spark Arrester .............................. 1 14:2 109-7232 Decal, Motion Control............................... 1 1:6 116-1654 Decal, Fuel Fill ......................................... 1 14:3 109-7929 Decal, Park Brake .................................... 1 2 109-8863-03 Plate, Rear Guard.................................... 1 15 116-0580 Asm, Motion Control Cover W/Decal LH 1 3 116-0024-01 Floorpan .................................................. 1 15:2 109-7232 Decal, Motion Control............................... 1 4 1-513658 Bumper .................................................... 2 16 116-0043-03 Guard, Muffler .......................................... 1 5 116-2882 Asm, ROPS Service ................................ 1 17 116-0026 Decal, Lazer AS Model ............................ 1 6 1-811010 Plug ......................................................... 2 18 32144-10 Screw, HWH 1/4-20 x .62......................... 4 7 Asm, Caster Wheel ................................. 2 25 116-2999-01 Guard, Belt ............................................... 1 9 116-0180 Bumper, Rear LH W/Decal ...................... 1 32 103-2883 Decal, Exmark Logo ................................. 1 9:2 103-2076 Decal, Caution Hot Surface ..................... 1 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140). Exmark black touch up spray paint – gloss black. See page 10 -10- ROPS ASSEMBLY – 116-2882 Item Part No. Description 3 109-6653 4 116-0019 4:2 5 Qty. Item Part No. Description Spacer .................................................... 2 8 3233-10 Bolt, Carriage 1/2-13 x 3 1/2 ................... 2 Asm, Rops Upper W/Decal .................... 1 9 325-17 Screw, HH 1/2-13 x 4 .............................. 4 107-2102 Decal, Warning, Folding Rops ................ 1 10 109-9505 Washer, Spring Disc 1/2 ......................... 4 109-5337 Bumper, Rops......................................... 2 11 109-9233 Bumper, Rubber Push-In ........................ 1 13 116-0960 Spacer ..................................................... 2 6 116-0104 Asm, Spring Pin ...................................... 2 7 99-5107 Nut, Lock 1/2-13 ..................................... 6 -11- Qty. CASTER WHEEL ASSEMBLY Item Part No. Description Qty. Item Part No. Description Qty. 1 1-543509 Cone, Bearing Tapered Roller ............ 2 5:2:2 103-0063 Seal, Double Lip .................................. 2 2 1-543511 Seal, Grease ....................................... 1 5:2:3 103-3051 Spacer, Nut .......................................... 2 3 116-1963-01 Wld, Caster Fork ................................. 1 5:2:4 103-3155 Axle, Caster ......................................... 1 4 1-633508 Washer, Spring Disc ........................... 3 5:3 325-42 Screw, HH 1/2-13 x 8 .......................... 1 5 116-1949 Asm, Wheel And Tire W/Axle.............. 1 5:4 3296-23 Nut, Nyloc 1/2-13 ................................. 1 5:1 103-2768 Guard, Seal ......................................... 2 6 103-4882 Cap-Grease ......................................... 1 5:2:1 1-633585 Bearing, Cone Tapered Roller ............ 2 7 3296-51 Nut, Nyloc 3/4-10 ................................. 1 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140). Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on spacer nut, item 5:2:3. . -12- DECK SUPPORT GROUP Item Part No. Description Qty. Item Part No. Description Qty. 4 99-5107 Nut, Lock 1/2-13 ..................................... 6 8 116-0818-03 Support-Bearing, Cross Shaft Rear ........ 2 23 32128-37 Nut, Whizlock 7/16-14 (48” & 52”) ........... 4 32128-37 9 109-7173 Bearing-Cross, Rear Shaft ..................... 2 24 109-9066 Nut, Whizlock 7/16-14 (60”) .................... 6 Yoke-Adjust, Deck................................... 4 10 3231-4 Bolt, Carriage 3/8-16 x 1 1/2................... 2 25 3274-18 Screw, SH 5/16-18 x 1 1/4 ...................... 4 11 104-8301 Nut, Nyloc 3/8-16 Flg .............................. 10 26 3218-2 Nut, Jam 5/16-18..................................... 8 12 109-9409 Support-Cross Shaft, Bearing Front ....... 2 27 116-0459-03 Lift-Deck, Rear ........................................ 1 13 109-9410 Bearing-Shaft Front, Cross ..................... 2 29 116-0780 Screw, Shoulder HHF 1/2-13 x 1.12 ....... 2 14 116-1700 Bolt, Carriage 1/2-13 x 2 1/2 spl neck .... 4 30 116-0797-03 Link-Lift, Deck ......................................... 1 15 109-9840 Screw, Hex Flange 3/8-16 x .80 ............. 2 31 116-0886 Asm, Spring Extension (60”) ................... 1 Pin-Hoc ................................................... 1 16 116-1970 Asm, HOC .............................................. 1 32 109-8757 17 109-9065 Screw, HH 7/16-14 x 2 (48” & 52”) ......... 1 33 116-3452-01 Wld, Foot Lever ....................................... 1 324-10 Screw, HH 7/16-14 x 2 1/2 (60”) ............. 1 34 3256-28 Washer, 3/4 SAE..................................... 2 18 3296-23 Nut, Nyloc 1/2-13 ................................... 1 35 92-7674 Screw, SHCS 3/8-16 x 2.212 .................. 1 19 3231-2 Bolt, Carriage 3/8-16 x 1......................... 2 40 3231-5 Bolt, Carriage 3/8-16 x 1 3/4 ................... 4 20 116-2217-03 Wld, Cross Shaft Front ........................... 1 41 116-2428 Bushing, Flanged .................................... 2 116-2428 Bushing, Flanged .................................... 4 21 Deck Lift Chain Asm ............................... 2 21:2 109-9065 Screw, HH 7/16-14 x 2 ........................... 1 42 3256-4 Washer, 3/8 Std ...................................... 2 21:3 32128-37 Nut, Whizlock 7/16-14 ............................ 1 43 109-9065 Screw, HH 7/16-14 x 2 (48” & 52”) .......... 2 22 116-0559 Bolt, HH 1/2-13 x 4 tap ........................... 1 324-10 Screw, HH 7/16-14 x 2 1/2 (60”) ............. 2 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140) Exmark black touch up spray paint – gloss black. -13- HEIGHT OF CUT ASSEMBLY – 116-1970 Item Part No. Description 1 62-1330 2 3 Qty. Item Part No. Description Bolt-Shoulder .......................................... 1 7 116-1961 Asm, HOC Plate W/Decal ....................... 1 109-7130 Grommet................................................. 1 7:2 116-2927 Decal, Cut Of Height ............................... 1 104-8301 Nut, Nyloc 3/8-16 Flg .............................. 1 8 109-8250 Grip, Lever .............................................. 1 4 109-7124 Spring, Extension ................................... 1 9 325-8 Screw, HH 1/2-13 x 1 1/4 ........................ 1 5 109-7128 Rod, Transport Lock ............................... 1 10 99-5107 Nut, Lock 1/2-13 ...................................... 1 6 116-0118 Pawl, Transfer Lock ................................ 1 -14- Qty. CONTROLS GROUP Item 1 1:2 Part No. Description Qty. Item Part No. Description Qty. Bolt, Carriage #10-24 x 1/2 ..................... 4 109-8484 Console, Panel W/Decal (48” & 52”) ...... 1 4 1-807513 116-1845 Console, Panel W/Decal (60”) ................ 1 5 3296-2 Nut, Nyloc #10-24 ................................... 4 109-8483 Decal, Control Panel .............................. 1 7 32105-15 Screw, Machine 1/4-20 x 3/4................... 4 1:3 109-7330 Decal, Fuse ............................................ 1 8 116-1278 Console, RH Narrow Asm ....................... 1 2 116-1972 Asm, Throttle Cable (48” & 52”).............. 1 8:2 107069 Clip .......................................................... 4 116-0969 Asm, Throttle Cable (60”) ....................... 1 9 109-9457 Console.LH Narrow Asm......................... 1 3 116-1973 Asm, Choke Cable (48” & 52”) ............... 1 10 105-1853 Clamp, Hose (60”) ................................... 1 109-8165 Asm, Choke Cable (60”) ......................... 1 11 116-1875 Plug, Plastic ............................................ 1 -15- MOTION CONTROL GROUP Item 1 Part No. Description Qty. Item Part No. Description Qty. 116-0880 Asm, Mot Ctrl/Bushing RH ..................... 1 20 109-6590 Asm, Steering Handle LH........................ 1 1:2 109-8054 Bushing, Flanged ................................... 4 20:1 109-5668 Grip, Control Lever .................................. 1 2 116-0881 Asm, Mot Ctrl/Bushing LH ...................... 1 21 104-8301 Nut, Nyloc 3/8-16 Flg .............................. 4 2:2 109-8054 Bushing, Flanged ................................... 4 22 323-7 Screw, HH 3/8-16 x 1 1/4 ........................ 4 3 116-0648 Screw, HH 5/16-18 x 1 W/Patch ............. 2 23 109-5575 Spring, Leaf Rtn ...................................... 2 4 109-4581 Arm, Pump Control ................................. 2 24 109-8107 5 9080046 Screw, HH 1/4-20 x 7/8 .......................... 2 24:2 3219-2 Nut, Hex 5/16-24 ..................................... 2 Asm, Pump Linkage Rear ....................... 2 6 1-303435 Washer, Spring Disc 1/4 ......................... 2 24:3 1-323245 Spring, Compression............................... 2 7 116-0027 Damper, Motion Control ......................... 2 24:4 1-633152 Balljoint ................................................... 1 8 104-8300 Nut, Nyloc 5/16-18 Flg ............................ 8 24:5 1-543017 Balljoint ................................................... 1 9 3230-2 Bolt, Carriage 5/16-18 x 1....................... 2 25 109-9505 Washer, Spring Disc 1/2 ......................... 4 11 109-5891 Hub, Threaded........................................ 2 26 3256-6 Washer .................................................... 2 12 325-12 Screw, HH 1/2-13 x 3 ............................. 2 27 32128-56 Nut, Hex 1/2-13 Flange ........................... 2 16 116-0039 Lever, Motion Control RH ....................... 1 29 3256-23 Washer .................................................... 2 17 116-0040 Lever, Motion Control LH........................ 1 30 3218-5 Nut, Jam 1/2-13....................................... 2 19 109-6589 Asm, Steering Handle RH ...................... 1 31 115-1794 Screw, Hex Flange 5/16-18 x 1 1/2 ......... 2 19:1 109-5668 Grip, Control Lever ................................. 1 Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube). -16- PARK BRAKE GROUP Item Part No. Description Qty. Item Part No. Description Qty. 1 116-1878 Asm, Brake Handle ................................ 1 9 109-2889 Caliper-Brake ..........................................2 2 3230-2 Bolt, Carriage 5/16-18 x 1....................... 2 10 109-0958 Plate, Brake Mount..................................2 3 104-8300 Nut, Nyloc 5/16-18 Flg ............................ 2 11 92-5727 Screw, HH 3/8-16 x 1 1/4 patch lock .......4 4 60-1730 Pin-Clevis ............................................... 2 12 112-8379 Swivel ......................................................2 5 3272-1 Pin, Cotter 1/16 x 1/2 .............................. 2 13 104-7201 Nut, Nyloc 1/4-20 Flg ..............................2 6 117-6163 Asm, Wheel Hub And Stud ..................... 2 14 116-0165 Decal, Hub, Wheel ..................................2 6:2 1-633926 Stud-Wheel ............................................. 4 17 3296-13 Nut, Nyloc 1/4-28 ....................................2 7 116-1940 Asm, Wheel & Tire (48”) ......................... 2 18 116-2643 Decal, Hub, Wheel ..................................2 116-1941 Asm, Wheel & Tire (52”) ......................... 2 19 115-3584 Cable .......................................................1 116-3138 Asm, Wheel & Tire (60”) ......................... 2 20 115-3585 Cable .......................................................1 109-3645 Wheel (48”) ............................................. 1 22 1-809036 Nut, Slotted 1-20 .....................................2 109-2875 Wheel (52”) ............................................. 1 23 1-806800 Pin, Cotter 9/64 x 1 1/2 ...........................2 109-2871 Wheel (60”) ............................................. 1 24 3256-24 Washer, 3/8 SAE.....................................4 7:2 116-1948 Tire (48” & 52”) ....................................... 1 25 116-0940 Tie-Cable.................................................1 116-3139 Tire (60”) ................................................. 1 26 3219-1 Nut, Hex 1/4-28 .......................................2 8 242-50 Nut, Lug 1/2-20 ....................................... 8 27 3257-42 Key, Woodruff .........................................2 7:1 -17- BRAKE HANDLE ASSEMBLY – 116-1878 Item Part No. Description Qty. Item 1 99-5107 Nut, Lock 1/2-13 ..................................... 1 10 115-3581 Rod-Release, Brake ................................1 2 117-0380 Spacer .................................................... 1 11 115-3592 Grip .........................................................1 3 115-3580 Arm-Brake, LH ........................................ 1 12 112-8387 Bolt, HH Shoulder 1/4-20 x 1.64 .............1 4 117-0376 Spring-Torsion, RH ................................. 1 13 117-0375 Spring-Torsion, LH ..................................1 5 115-3574 Plate-Latch ............................................. 1 14 115-3579 Arm-Brake, RH ........................................1 6 104-7201 Nut, Nyloc 1/4-20 Flg .............................. 1 15 117-0379 Bolt, Shoulder 1/2-13 x 5.57....................1 7 116-1876-03 Brake Handle Asm ................................. 1 16 3256-26 Washer, 1/2 SAE.....................................1 8 114-1207 Washer-Special ...................................... 1 17 115-2750 Knob ........................................................1 9 114-8187 Spring-Compression ............................... 1 Exmark black touch up spray paint – gloss black. -18- Part No. Description Qty. SEAT GROUP Item Part No. Description Qty. Item 1 116-3380 Seat, Exmark .......................................... 1 11 116-0192-03 Plate, Seat Support .................................1 4 116-2323 Mount, Seat W/Decals ............................ 1 12 3230-22 Bolt, Carriage 5/16-18 x 1 Sp ..................4 4:2 109-7069 Decal, Console ....................................... 1 21 103-2883 Decal, Exmark Logo ................................1 4:3 116-0211 Decal, Service Aid .................................. 1 25 3217-6 Nut, Hex 5/16-18 .....................................2 6 3230-23 Bolt, Carriage 5/16-18 x 3/4, short neck 2 26 1-323539 Spacer, Blade Drive ................................2 8 104-8300 Nut, Nyloc 5/16-18 Flg ............................ 10 32 103-2882 Decal, Exmark Logo ................................1 10 9266934 Screw, HWH 5/16 x 1/2 TF ..................... 2 Exmark black touch up spray paint – gloss black -19- Part No. Description Qty. SEAT W/TRACKS ASSEMBLY – 116-3380 Item Part No. Description Qty. Item Part No. Description Qty. 1 116-2871 Cushion-Seat .......................................... 1 7 103-8383 2 110-5719 Armrest Kit W/Brackets .......................... 1 8 32128-20 Screw, HWH 1/4-20 x 3/4 Taptite............7 Nut, Whizlock 5/16-18 .............................4 3 103-3520 Cushion, Seat Back ................................ 1 9 26-4840 Spacer-Pin, Mounting..............................8 4 116-2878 Switch-Seat ........................................... 1 10 3256-3 Washer, 5/16 Std ....................................6 5 1-643255 Track-Seat ............................................. 1 11 110-4163 Pad, Arm ................................................. 6 116-2981 Seat Belt Kit ........................................... 1 Included in items 2 and 6 -20- FUEL TANK GROUP Item Part No. Description Qty. Item Part No. Description Qty. 1 116-2035 Fuel Tank Asm ....................................... 1 6 105-1853 Clamp-Hose ............................................ 1 2 32128-33 Nut, Whizlock 1/4-20 .............................. 2 7 109-0678 Hose ........................................................ 1 3 109-2365 Bumper-Rubber (W/Stud) ....................... 2 -21- FUEL TANK ASSEMBLY – 116-2035 Item Part No. Description 2 46-6560 Qty. Item Part No. Description Qty. Bushing .................................................. 2 7 109-0650 Hose, Fuel ...............................................1 3 116-2459 Kit, Fuel Line With Grommet .................. 1 8 2412-98 Clamp, Hose ...........................................2 4 116-2288 Fitting, 90 Elbow ..................................... 1 9 116-1981 Sender, Fuel 8 Gal ..................................1 5 116-2251 Cap, Fuel ................................................ 1 10 3253-17 Washer, Lock .........................................5 6 1-603770 Valve, Fuel ............................................. 1 11 9107944 Screw, Pan 10-24 X 3/4 ..........................5 -22- ENGINE GROUP – 20HP KAWASAKI Item Part No. Description Qty. Item Part No. Description Qty. 2 98-5975 Washer, Spring Disc 3/8 ......................... 4 13 116-2612-01 Clutch, Anchor ........................................ 1 3 109-6919 Washer, Clutch ....................................... 1 14 323-7 Screw, HH 3/8-16 x 1 1/4 ........................ 4 4 1-603610 Washer, Spring Disc 7/16 ....................... 2 15 33114-020 Screw, HH M8-1.25 x 20mm ................... 1 5 1-807259 Key, Machine 1/4 x 1/4 x 1 ..................... 1 16 109-9761 Screw, HH 7/16-20 x 1 1/2 W/Loctite ...... 1 6 104-8301 Nut, Nyloc 3/8-16 Flg .............................. 1 17 3231-22 Bolt, Carriage 3/8-16 x 1 ......................... 1 7 116-2117 Muffler..................................................... 1 18 3234-5 Screw, HH FLG 5/16-18 x 3/4 ................. 2 U-Nut....................................................... 2 8 116-1946 Sheave, Pump Drive .............................. 1 19 94-2413 9 110-3447 Hose, Fuel .............................................. 1 20 109-4490 Asm, Oil Drain Hose W/Plug ................... 1 10 116-1947 Clutch ..................................................... 1 20:1 109-1012 Plug ......................................................... 1 11 116-2157 Bracket, Muffler ...................................... 1 21 1-303334 Washer, Spring ....................................... 1 12 2412-98 Clamp, Hose ........................................... 2 22 105-1853 Clamp, Hose ........................................... 1 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140) Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on clutch bolt. -23- ENGINE GROUP – 27HP KOHLER Item Part No. Description 2 109-9905 3 116-1620 4 5 Qty. Item Part No. Sheave ................................................... 1 14:1 109-1012 Plug ......................................................... 1 Kit, Clutch CMS 200 ............................... 1 15 3234-5 Screw, HH FLG 5/16-18 x 3/4 ................. 3 109-6919 Washer, Clutch ....................................... 1 16 1-807259 Key, Machine 1/4 x 1/4 x 1 ...................... 1 1-603610 Washer, Spring Disc 7/16 ....................... 2 17 104-8301 Nut, Nyloc 3/8-16 Flg .............................. 2 6 109-9762 Screw, HH 7/16-20 x 2 W/Loctite ........... 1 18 116-2612-01 Anchor, Clutch......................................... 1 7 3231-22 Bolt, Carriage 3/8-16 x 1......................... 1 19 94-2413 U-Nut ....................................................... 3 9 116-2360 Bracket, Muffler ...................................... 1 22 109-0286 Hose, Fuel Line 35" ................................. 1 10 116-1713 Muffler..................................................... 1 23 2412-98 Clamp, Hose ........................................... 2 11 32144-102 Screw, HWH 3/8-16 X 1 1/2 Taptite ....... 4 24 105-1853 Clamp, Hose ........................................... 1 12 98-5975 Washer, Spring Disc 3/8 ......................... 4 27 1-303435 Washer, Spring Disc 1/4 ......................... 1 14 116-0013 Asm, Oil Drain Hose ............................... 1 28 33113-020 Screw, HH M6-1 x 12mm ........................ 1 Exmark red touch up paint (spray paint – P/N 1-850337 - .6 oz liquid bottle – P/N 103-9140) Use Teflon Pipe Sealant or equivalent on threads. Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on clutch bolt. -24- Description Qty. HYDRAULIC GROUP Item Part No. Description 1 116-1255 2 109-6658 3 Qty. Item Part No. Description Asm, Pump Idler ..................................... 1 8 3233-34 Bolt, Carriage 1/2-13 x 2 1/2 ...................6 Nut, Nyloc 3/8-16 Flg .............................. 1 9 99-5107 Nut, Lock 1/2-13 ......................................6 116-2976 Hydro, LH 12CC No Fan ........................ 1 10 325-8 Screw, HH 1/2-13 x 1 1/4 ........................4 4 116-1953 Belt, V ..................................................... 1 11 116-2977 Hydro, RH 12CC No Fan ........................1 5 116-0133 Spring, Extension ................................... 1 12 109-9828 Oil, Exmark Premium Hydro (32 oz) .......4 6 109-9375 Cradle, Machined Hydro ......................... 1 13 116-1218 Oil, Exmark Premium Hydro (1 gal) ........1 7 116-1502 Bolt-Carriage .......................................... 1 116-3282 Kit, Hydro Service ...................................1 Not shown Kit contains: (1) V-Belt, (4) Exmark Premium Hydro Oil 32 oz Bottles, and (2) Hydro filters -25- Qty. HYDRAULIC GROUP Item Part No. Description Qty. Item Part No. Description Qty. 1 116-1758 Bracket, Anchor Cable ........................... 1 11 116-1371 Kit, Output Shaft Seal Hydro ...................1 2 116-3052 Cover, Shaft............................................ 1 12 116-2992 Cup, Nose Hydro.....................................1 3 116-0234 Kit, Pulley Hydro ..................................... 1 13 116-1630 Asm, Check Valve ...................................1 4 116-0235 Handle, Bypass Valve Hydro .................. 1 14 116-1631 Check Plug W/O-Ring .............................1 5 116-0236 Dipstick, Hydro W/Gasket....................... 1 15 3257-42 Key, Woodruff 5/16 x 1............................1 6 116-0237 Gasket, Dipstick Hydro ........................... 1 17 116-0164 Filter, Hydro.............................................1 7 116-1367 Kit, Swash Block Hydro .......................... 1 18 116-3050 Motor, Wheel LH – Dry 240cc .................1 8 116-1368 Kit, Pump Seal Hydro ............................. 1 116-3051 Motor, Wheel RH – Dry 240cc ................1 9 116-1369 Kit, Motor Seal Hydro ............................. 1 10 116-1370 Kit, Tube Seal Hydro .............................. 1 19 -26- 116-3287 Housing, LH ............................................1 116-3288 Housing, RH ............................................1 PUMP IDLER ASSEMBLY – 116-1255 Item Part No. Description 2 43-0940 3 103-3504 4 103-3505 Qty. Item Part No. Description Qty. Spacer-Hub, Blower ............................... 1 8 323-8 Screw, HH 3/8-16 x 1 1/2 ........................ 1 Bearing, Spherical .................................. 2 9 32120-10 Ring, Retaining........................................ 2 Seal, Double Lip ..................................... 1 10 302-19 Zerk, 1/4-28 Str ....................................... 1 5 103-3506 Seal, Single Lip ...................................... 1 11 109-8076 Pulley, Idler 5" X 1" Nylon ....................... 1 6 109-6658 Nut, Nyloc 3/8-16 Flg .............................. 1 12 109-7399 Pin, Spring Anchor .................................. 1 7 106-7159 O-Ring .................................................... 2 -27- ELECTRICAL GROUP Item Part No. Description Qty. Item Part No. Description Qty. 2 115-2796 Harness-Wire, Main (Air-Cooled) ........... 1 10 114-1218 Cable-Battery, Negative .......................... 1 2:1 103-3895 Diode-TVS .............................................. 1 11 3234-5 Screw, HH FLG 5/16-18 x 3/4 ................. 2 2:2 218-578 Fuse-10 Amp .......................................... 1 12 104-8300 Nut, Nyloc 5/16-18 Flg ............................ 2 2:3 109355 Fuse-15 Amp .......................................... 1 13 1-303287 Tie, Cable 5 1/2 (Small) .......................... 3 2:4 109102 Fuse-25 Amp .......................................... 2 14 82-2190 Switch...................................................... 1 2:5 116-0053 Cap-Plug................................................. 1 15 116-0229 Switch, Ignition ........................................ 1 3 116-0916 Fuel/Hour Meter Asm ............................. 1 16 116-0124 Switch, PTO 10A ..................................... 1 4 1-603511 Key, Ignition ............................................ 1 17 104-2065 Screw, HWH #10-24 x 3/8....................... 1 103-2106 Key, Exmark Logo .................................. 1 18 115-3864 Cable-Battery, Positive............................ 1 5 110-6765 Switch-Single Pole N.O. ......................... 2 19 3256-24 Washer, 3/8 SAE..................................... 1 6 116-0042-03 Strap-Tie Down, Battery ......................... 1 22 1-303335 Tie, Cable 7 15/16 (Large) ...................... 1 7 1-633651 Bolt-Holddown ........................................ 2 23 109-2407 Insulator, Solenoid .................................. 1 8 1-543792 Wingnut, Nyloc 1/4-20 ............................ 2 24 1-543393 Insulator, Battery ..................................... 1 9 1-643275 Relay, 12VDC 40 Amp ........................... 1 Exmark black touch up spray paint - gloss black. Use dielectric grease on all wiring harness connectors. -28- DECAL GROUP Item Part No. Description Qty. Item Part No. Description Qty. 1 109-7069 Decal, Console ....................................... 1 15 109-8483 Decal, Control Panel ...............................1 2 107-2102 Decal, ROPS Folding ............................. 1 16 117-2718 Decal, Spark Arrester ..............................1 3 1-403005 Decal, Danger......................................... 2 17 116-1654 Decal, Fuel Fill ........................................1 4 109-3148 Decal, Bolt Torque .................................. 1 18 116-0165 Decal, Wheel Hub ...................................2 5 107-2112 Decal, Warning Slope ............................. 1 19 116-2643 Decal, Wheel Hub ...................................2 6 1-303508 Decal, Discharge Warning ...................... 1 20 109-7330 Decal, Fuse .............................................1 7 116-0205 Decal, Belt Drive ..................................... 2 21 103-2883 Decal, Exmark Logo ................................2 8 98-5954 Decal, Danger......................................... 2 22 116-2630 Decal, Belt Routing .................................1 9 109-7232 Decal, Motion Control ............................. 2 23 116-0033 Decal, UltraCut 48 Series 4.....................1 10 103-2076 Decal, Hot Surface ................................. 3 24 116-0034 Decal, UltraCut 52 Series 4.....................1 11 116-2927 Decal, Cut of Height ............................... 1 25 109-9439 Decal, UltraCut 60 Series 4.....................1 12 1-633922 Decal, Anti-Scalp .................................... 1 26 116-0026 Decal, Lazer AS ......................................1 13 116-0211 Decal, Service Aid .................................. 1 27 103-2882 Decal, Exmark Logo ................................1 14 109-7929 Decal, Park Brake .................................. 1 . -29- ELECTRICAL DIAGRAM -30- ELECTRICAL LOGIC SCHEMATIC -31- NOTES -32- SERVICE RECORD Date Description of Work Done Service Done By -33- -34- © 2011 Exmark Mfg. Co., Inc. Industrial Park Box 808 Beatrice, NE 68310 All Rights Reserved Part No. 4500-567 Rev. D (402) 223-6300 Fax (402) 223-5489 Printed In USA
Source Exif Data:
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