Exmark Lawn Mower 4500 368 User Manual

NAVIGATOR  
®
For Serial Nos.  
790,000 & Higher  
Part No. 4500-368 Rev. A  
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READ OPERATOR’S MANUAL BEFORE  
OPERATING OR SERVICING EXMARK EQUIPMENT.  
TABLE OF CONTENTS  
Description  
Page  
Blower Group.................................................................... 10  
Decals Group.................................................................... 25  
Electrical Diagram ............................................................ 23  
Electrical Logic Schematic................................................ 24  
Electrical Group...........................................................21-22  
Engine Group ..............................................................13-14  
Fuel Group.......................................................................... 9  
Hopper Group..............................................................17-20  
Hydraulic Group...........................................................15-16  
Jackshaft Group ..........................................................11-12  
Main frame Group............................................................3-5  
Park Brake Group............................................................... 6  
Speed Controls Group.....................................................7-8  
1
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MAIN FRAME GROUP  
Item  
Description  
Qty.  
Item  
Description  
Qty.  
Part No.  
Part No.  
1
2
3
4
5
6
7
8
9
103-8383  
1-633060  
1-633396  
1-633508  
1-633585  
103-9483  
1-807513  
5-0652  
Bolt, Seat Cushion.................................5  
Spacer ...................................................2  
Clip, Loom 5/8........................................1  
Washer, Spring Disk..............................6  
Bearing, Cone Tapered Roller................2  
Asm, Seat Frame W/Decal ....................1  
Bolt, Carriage #10-24 x 1/2 ....................4  
Spacer ...................................................4  
Seal, Double Lip.....................................2  
Guard, Seal............................................2  
Spacer, Nut............................................2  
31 109-4638  
32 103-9027  
33 103-9028  
34 103-9029  
35 116-1175  
36 103-9034  
37 103-9057  
38 242-50  
39 322-2  
Decal, Console ...................................... 1  
Seal, Grease.......................................... 1  
Cone, Bearing Taper Roller ................... 2  
Cup, Bearing Tapered Roller ................. 2  
Decal, Service Aid ................................. 1  
Decal, Clutch Adjustment ...................... 1  
Cap, Grease .......................................... 1  
Nut, Lug 1/2-20...................................... 8  
Screw, HH 5/16-18 x 5/8........................ 6  
Screw, HH 5/16-18 x 1........................... 3  
Screw, HH 3/8-16 x 3............................. 2  
Screw, HH 1/2-13 x 4............................. 2  
Bolt, Carriage 3/8-16 x 7/8..................... 1  
Washer, 5/16 SAE................................. 6  
Washer.................................................. 1  
Nut, Nyloc #10-24.................................. 4  
Nut, Nyloc 1/2-13................................... 1  
Nut, Nyloc 5/16-18................................. 3  
Nut, Nyloc 3/8-16................................... 3  
Nut, Nyloc 3/4-10................................... 1  
Asm, Wheel Tire & Brg 13x8.00-6 SP.... 1  
Nut, Whizlock 5/16-18 ........................... 8  
Nut, Whizlock 1/2-13 ............................. 2  
Asm, Seat W/Decal ............................... 1  
Asm, Rear Caster Wheel W/Axle........... 1  
Cable, Control Choke ............................ 1  
Asm, Wheel & Tire 18 x 10.50-10.......... 2  
Asm, Wheel & Tire 18 x 8.50-10............ 2  
Tire, 18 X 10.5-10.................................. 2  
Tire, 18 X 8.50-10.................................. 2  
103-0063  
10 103-2768  
40 322-5  
11V 103-3051  
41 323-14  
42 325-17  
43 3231-27  
44 3256-23  
45 3256-8  
46 3296-2  
47 3296-23  
48 3296-29  
49 3296-39  
50 3296-51  
51 103-5305  
52 32128-20  
53 32128-49  
54 109-2006  
55 103-9494  
56 109-4640  
57 103-4319  
103-4321  
12 103-3351-03 Wld, Rear Caster Fork ...........................1  
13 103-3520  
14 109-2008  
15 109-4306  
16 103-4155  
17 103-4318  
18 1-303287  
Seat, Back .............................................1  
Seat, Bottom..........................................1  
Asm, Mainframe W/Decals ....................1  
Pin, Lynch..............................................2  
Wheel ....................................................2  
Tie, Cable 5 1/2 (Small) .........................4  
19 103-4362-03 Wld, Seat Frame Std .............................1  
20 109-4641  
21 103-5181  
22 103-5302  
23 103-5496  
Cable, Control Throttle...........................1  
Link, Lower Seat Stop............................1  
Axle, Caster ...........................................1  
Mount, Vibration Rubber ........................4  
24 103-6596-03 Wld, Push Rod.......................................2  
25 103-7738  
26 103-8143  
27 103-8146  
28 109-4639  
29 103-8451  
30 103-8563  
Screw, HH 1/2-13 x 13...........................1  
Console, RH ..........................................1  
Console, LH...........................................1  
Asm, Control Panel W/Decals................1  
Decal, Ignition/Speed Control.................1  
Link, Seat...............................................1  
58 105-1945  
103-4320  
Exmark black touch up spray paint – Gloss black  
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on spacer nut, item #11.  
V
2
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MAIN FRAME GROUP  
3
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MAINFRAME GROUP (cont.)  
Item  
Description  
Qty.  
Item  
Description  
Qty.  
Part No.  
Part No.  
1
2
3
4
5
6
7
8
9
32128-33  
109-2365  
1-613235  
1-803035  
1-811010  
65-2690  
98-4361  
98-5954  
Nut, Whizlock 1/4-20..............................5  
Bumper..................................................2  
Washer..................................................3  
Rivet 3/16 x 1/4......................................6  
Plug .......................................................1  
Decal, Hot Surface.................................2  
Decal, Warning ......................................2  
Decal, Danger........................................2  
19 103-9022  
20 32128-20  
21 103-9274  
22 321-3  
Guide, Belt............................................. 1  
Nut, Whizlock 5/16-18 ........................... 7  
Decal, Belt Routings .............................. 1  
Screw, HH 1/4-20 x 5/8.......................... 1  
Nut, Nyloc 3/8-16................................... 6  
Screw, HH 5/16-18 x 1........................... 4  
Screw, HH 5/16-18 x 1 1/4..................... 2  
Screw, HH 3/8-16 x 1............................. 4  
Screw, HH 3/8-16 x 1 1/2....................... 2  
Washer, 5/16 SAE................................. 4  
Nut, Whizlock 3/8-16 ............................. 4  
Bolt, Carriage 3/8-16 x 2 1/2.................. 2  
Washer, 3/8 SAE................................... 6  
23 3296-39  
24 322-5  
25 322-6  
26 323-6  
109-2487-03 Wld, Fender...........................................1  
Wheel ....................................................2  
11 109-0925-03 Wld, Bumper Rear .................................1  
27 323-8  
10 103-5408  
28 3256-23  
29 3290-357  
30 3231-31  
31 3256-24  
12 103-6537  
13 103-8333  
14 103-8349  
15 103-8495  
16 103-8611  
17 103-9475  
18 103-9476  
Tab, Spring Anchor................................2  
Guide, Belt.............................................1  
Guide, Belt.............................................1  
Decal, Pinch Point .................................2  
Decal, Relay ..........................................1  
Asm Drive, Shield ..................................1  
Asm, Shield W/Decal.............................1  
32 109-5874-03 Brace, PTO............................................ 1  
33 1-213069  
34 321-6  
Spacer................................................... 1  
Screw, HH 1/4-20 x 1............................. 2  
Nut, Whizlock 1/4-20 ............................. 5  
35 32128-33  
Exmark black touch up spray paint – Gloss black  
4
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PARK BRAKE GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-303105  
1-633102  
1-633131  
1-633268  
1-806003  
1-808280  
98-5975  
Yoke, Adjustable....................................2  
Bearing, Side Flange .............................2  
Yoke, Brake Linkage..............................1  
Grip, Brake Lever...................................1  
Hairpin, Cotter........................................4  
Pin, Clevis 5/16 x 1 ................................2  
Washer, Spring Disk 3/8 ........................1  
Pin, Clevis Spring 3/8.............................1  
14 103-9469  
15 103-7377  
16 103-9915  
17 323-4  
Asm, Park Brake Handle W/Grip ........... 1  
Screw, HH 5/16-24 x 7 3/4..................... 2  
Spring, Torsion RH ................................ 1  
Screw, HH 3/8-16 x 3/4.......................... 5  
Nut, Hex 5/16-24.................................... 6  
Nut, Hex 3/8-24...................................... 1  
Washer, 3/8 SAE................................... 3  
Washer, 5/16 Std................................... 4  
Pin, Cotter 1/8 x 3/4............................... 1  
Nut, Whizlock 3/8-16 ............................. 4  
Bushing, Bronze .................................... 2  
Asm, Brake Linkage .............................. 2  
18 3219-2  
19 3219-3  
20 3256-24  
21 3256-3  
22 3272-10  
23 3290-357  
24 108519  
25 109-0714  
103-2399  
103-4383-03 Wld, Brakeshaft .....................................1  
10 103-4388  
11 103-4390  
12 103-4399  
13 103-6576  
Spring, Brake.........................................2  
Wld, Brake Pivot ....................................1  
Rod, Linkage Brake ...............................1  
Wld, Swivel Brake..................................2  
Exmark black touch up spray paint – Gloss black  
5
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SPEED CONTROLS GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-543017  
1-633102  
1-633152  
1-804524  
1-811010  
103-3060  
103-9468  
103-9730  
103-9731  
Ball Joint, (RH).......................................3  
Bearing, Side Flange .............................2  
Ball Joint, (LH) .......................................3  
Nut, Hex 5/16-24 (LH)............................5  
Plug .......................................................4  
Knob, Tracking.......................................1  
Asm, Handle W/Grip..............................2  
Asm, Steering Lever W/Bearings (RH)...1  
Asm, Actuator W/Bearings (RH) ............1  
Asm, Actuator W/Bearings (LH).............1  
Shaft, Speed Control..............................1  
31 321-5  
Screw, HH 1/4-20 x 7/8.......................... 4  
Screw, HH 1/4-20 x 1 1/4....................... 1  
Screw, HH 5/16-18 x 3/4........................ 6  
Screw, HH 5/16-18 x 1 1/4..................... 6  
Screw, HH 3/8-16 x 3/4.......................... 4  
Screw, HH 3/8-16 x 1 1/2....................... 2  
Screw, HH 5/16-18 x 1........................... 1  
Nut, Hex 5/16-18.................................... 2  
Nut, Jam 3/8-16..................................... 1  
Nut, Hex 5/16-24.................................... 4  
Setscrew, 1/4-20 x 1/4........................... 6  
Washer, 5/16 SAE................................. 3  
Washer, 3/8 SAE................................... 2  
Washer, 3/4 SAE................................... 1  
Washer, 5/16 Std................................... 9  
Key, Woodruff #9 3/4 x 3/16 .................. 3  
Nut, Whizlock 3/8-16 ............................. 8  
Nut, Nyloc 1/2-20................................... 1  
Nut, Nyloc 5/16-18................................. 7  
Nut, Whizlock 5/16-18 ........................... 1  
Nut, Whizlock 1/4-20 ............................. 6  
E-Ring ................................................... 1  
Spring, Compression ............................. 4  
Grip, Steering Handle ............................ 2  
Asm, Handle W/Grip.............................. 2  
Decal, Driveline ..................................... 1  
Asm, Pump Linkage (RH)...................... 1  
Asm, Pump Linkage (LH)....................... 1  
Decal, Wheel Motor Release ................. 1  
32 321-8  
33 322-3  
34 322-6  
35 323-4  
36 323-8  
37 322-5  
38 3217-6  
39 3218-3  
40 3219-2  
41 3245-1  
42 3256-23  
43 3256-24  
44 3256-28  
45 3256-3  
46 3257-5  
47 3290-357  
48 3296-19  
49 3296-29  
50 32128-20  
51 32128-33  
52 32151-48  
53 1-323245  
54 103-5994  
55 103-9468  
56 103-8425  
57 103-9493  
58 103-9492  
59 109-4273  
10 103-9732  
11 103-4278  
12 103-4342-03 Wld, Hub Speed Control ........................2  
13 103-4373  
14 103-4377  
15 103-4397  
16 103-4398  
17 103-9733  
18 103-5008  
19 103-5009  
20 103-5013  
21 103-5016  
22 103-5017  
23 103-5018  
24 103-5064  
25 109-5927  
26 103-5945  
Spring, Extension...................................2  
Linkage, Rod Steering (LH)....................2  
Knob, Speed Control..............................1  
Bearing, Flange Iglide............................8  
Asm, Steering Lever W/Bearings (LH)  
1
Wld, Control Arm ...................................1  
Disc, Friction..........................................2  
Wld, Speed Control Lever......................1  
Rod, Threaded Control Link ...................1  
Plate, Speed Control Friction .................1  
Washer, Spring Disk..............................3  
Bearing, Plastic 1/2................................2  
Asm, Console W/Decals........................1  
Spacer ...................................................1  
27 103-5993-03 Guide, Plenum.......................................1  
28 103-6078  
29 103-6532  
30 103-8494  
Spring, Extension...................................1  
Spring, Extension...................................2  
Hook ......................................................1  
Exmark black touch up spray paint – Gloss black.  
6
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SPEED CONTROLS GROUP  
7
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FUEL GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
1-303077  
1-513762  
1-603770  
Clamp-Line, Fuel....................................4  
Clip, Loom 1/2........................................2  
Valve, Fuel.............................................1  
Stud, Fuel Tank .....................................3  
Spring, Compression .............................3  
Washer..................................................1  
Part No. 2405010 Fuel Filter..................1  
Cap, Fuel ...............................................1  
17Q 322-5  
Screw, HH 5/16-18 x 1........................... 2  
Screw, HH 3/8-16 x 3............................. 2  
Nut, Jam 1/2-20..................................... 1  
Bolt, Carriage 1/4-20 x 3/4..................... 1  
Washer, 1/4 Std..................................... 1  
Washer, 5/16 SAE................................. 5  
Washer, 1/2 SAE................................... 1  
Nut, Nyloc 5/16-18 Thin......................... 3  
Nut, Nyloc 3/8-16................................... 2  
Nut, Nyloc 1/4-20................................... 1  
Nut, Whizlock 5/16-18 ........................... 2  
Nut, Whizlock 1/4-20 ............................. 3  
Rivet (27 HP only).................................. 9  
O-Ring................................................... 1  
Hose, Fuel Line 29" ............................... 1  
Hose, Fuel Line 2 1/2" ........................... 1  
18 323-14  
19 3220-5  
20 3229-1  
21 3256-2  
22 3256-23  
23 3256-26  
24 3296-47  
25 3296-39  
26 3296-42  
27 32128-20  
28 32128-33  
29 114439  
30 103-2784  
31 109-0284  
32 109-0304  
4Q 1-633023  
5
6
1-633349  
1-653036  
7Kohler  
8
9
109-0346  
103-5765-03 Wld, Tank Frame...................................1  
10 109-2957  
Asm, Tank Fuel......................................1  
Fitting, Fuel Bulkhead W/Screen............1  
11V 103-6057  
12 109-5344-03 Panel, Tank Shield.................................1  
13 103-7095-03 Deflector, Air (27 HP only) .....................1  
14 103-9658  
15 321-3  
Flap, Rubber (27 HP only)......................1  
Screw, HH 1/4-20 x 5/8..........................3  
Screw, HH 5/16-18 x 5/8........................3  
16 322-2  
Exmark black touch up spray paint – Gloss black  
Q
Use Pro-Lock, Retaining Type (P/N 1-840023, .5ml tube) on stud threads, item #4 going into tank and on threads at  
the head of screw, item #17.  
V
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on fuel fitting, item #11.  
Refer to Engine Owner’s Manual (Fuel Filter Must be 15 Micron or smaller).  
8
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BLOWER GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-543610  
1-603610  
18-9810  
67-7490  
109-0183  
Washer..................................................1  
Washer, Spring Disk 7/16 ......................2  
Washer, Thrust ......................................2  
Key, Machine 1/4 x 1/4 x 1 1/2...............1  
Asm, Blower Housing W/Brgs................1  
15 321-6  
Screw, HH 1/4-20 x 1............................. 2  
Screw, HH 5/16-18 x 3/4........................ 4  
Screw, HH 1/2-13 x 4............................. 1  
Screw, HH 1/2-13 x 8............................. 1  
Screw, HH 7/16-20 x 1 1/2..................... 1  
Washer, 1/4 SAE................................... 4  
Nut, Nyloc 1/2-13................................... 1  
Nut, Nyloc 1/4-20................................... 2  
Ring, Retaining...................................... 2  
Nut, Whizlock 5/16-18 ........................... 10  
Nut, Whizlock 1/2-13 ............................. 1  
Decal, Danger........................................ 2  
Asm, Blower Complete .......................... 1  
16 322-3  
17 325-17  
18 325-42  
19V 3212-6  
20 3256-22  
21 3296-23  
22 3296-42  
23 32120-8  
24 32128-20  
25 32128-49  
26 109-7318  
27O 109-0184  
103-3370-03 Wld, Blower Cover Assembly.................1  
103-3540  
103-3894  
103-4921  
Bearing, Ball ..........................................2  
Spacer, Blower.......................................1  
Spacer, Bearing.....................................1  
Wld, Impeller..........................................1  
Sheave, Blower......................................1  
Spacer, Mount .......................................1  
Asm, Discharge Chute W/Decal.............1  
10 103-5194  
11 103-6733  
12 103-6999  
13 103-9474  
14 103-9167-03 Wld, Guide.............................................1  
Exmark black touch up spray paint – Gloss black.  
V
O
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screw, item #19.  
Complete blower assembly contains all items shown except items #11, #14, #20(4), #15(2) and #22(2).  
9
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JACKSHAFT GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-303007  
1-413088  
1-543017  
1-543610  
1-603610  
1-806003  
67-7490  
Washer..................................................2  
Spacer ...................................................1  
Ball Joint (RH)........................................1  
Washer..................................................1  
Washer, Spring Disk 7/16 ......................2  
Hairpin, Cotter........................................2  
Key, Machine 1/4 x 1/4 x 1 1/2...............1  
Spacer ...................................................2  
Belt, Matched Pair .................................1  
Ball Joint (RH)........................................1  
Ball Joint (LH) ........................................1  
Asm, PTO Handle W/Grip......................1  
Belt, Guide.............................................1  
Spacer, Guard Bottom ...........................1  
Asm, Jackshaft Housing W/Bearings.....1  
Guard, Top.............................................2  
Bearing, Spherical..................................2  
Seal, Single Lip......................................2  
Sheave ..................................................1  
Jackshaft ...............................................1  
Asm, Idler Sheave .................................1  
Asm, Idler Pivot......................................1  
Asm, Pivot W/Bushing ...........................1  
Asm, Arm W/Bushing ............................1  
Spacer, Idler ..........................................1  
Bushing..................................................1  
Asm, Arm W/Bushing ............................1  
Asm, Link Clutching...............................1  
Linkage, Rod..........................................1  
Band, Brake...........................................1  
Ball Joint (RH)........................................1  
Linkage, PTO Brake Rod .......................1  
Spring, Brake.........................................1  
34 103-9486  
35 103-8254  
36 103-8277  
Asm, PTO Handle W/Grip .................... 1  
Bushing, Spring ..................................... 2  
Link, Handle........................................... 1  
37 103-8716-03 Flag, Switch........................................... 1  
38 3256-24  
39 103-9816  
40 106-7159  
41 251-347  
42 283-2  
Washer, 3/8 SAE................................... 2  
Spacer................................................... 1  
O-Ring [1.174 x .103]............................. 2  
Bearing, Ball Deep Groove .................... 2  
Pin, Clevis 3/8 x 1 1/6............................ 1  
Zerk, 1/4-28 Str...................................... 1  
Screw, HH 5/16-18 x 3/4........................ 2  
Screw, HH 5/16-18 x 1 1/4..................... 1  
Screw, HH 3/8-16 x 2 1/2....................... 1  
Screw, HH 3/8-16 x 7............................. 1  
Screw, HH 3/8-16 x 1............................. 4  
Screw, HH 3/8-16 x 1 3/4....................... 2  
Screw, HH 7/16-20 x 1 1/2..................... 1  
Nut, Hex 5/16-24.................................... 3  
Nut, Hex 3/8-24 LH................................ 1  
Nut, Hex 3/8-24...................................... 2  
Ring, Retaining...................................... 2  
Washer, Spring Disk 3/8........................ 5  
Nut, Nyloc 5/16-18................................. 1  
Nut, Nyloc 3/8-16................................... 2  
Nut, Nyloc 3/8-24................................... 1  
Ring, Retaining...................................... 2  
Grip, Control Lever ................................ 1  
Nut, Whizlock 5/16-18 ........................... 2  
Nut, Whizlock 3/8-16 ............................. 2  
E-Ring ................................................... 2  
Bushing, Bronze .................................... 6  
Spring, Extension................................... 1  
Spacer................................................... 1  
92-9025  
103-6737  
10 103-0608  
11 103-1167  
12 103-9486  
13 109-5491  
14 103-2535  
15 103-2544  
16 103-2916  
17 103-3504  
18 103-3506  
19 103-6732  
20 103-6735  
21 103-9439  
22 103-8253  
23 103-9295  
24 103-9297  
25 103-7350  
26 103-7382  
27 103-9296  
28 103-7392  
29 103-7393  
30 103-7697  
31 103-7994  
32 103-7996  
33 103-7997  
43 302-19  
44 322-3  
45 322-6  
46 323-12  
47 323-36  
48 323-6  
49 323-9  
50V 3212-6  
51 3219-2  
52 3219-20  
53 3219-3  
54 32151-13  
55 98-5975  
56 3296-29  
57 3296-39  
58 3296-6  
59 32120-10  
60 103-8153  
61 32128-20  
62 32128-43  
63 32151-48  
64 108519  
65 109-0148  
66 5-0652  
Exmark black touch up spray paint - gloss black.  
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on sheave bolt, item #50.  
V
10  
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JACKSHAFT GROUP  
11  
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ENGINE GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
32120-10  
106-7022  
323-4  
Ring, Retaining ......................................2  
Hose, Oil Drain ......................................1  
Screw, HH 3/8-16 x 3/4..........................4  
Washer..................................................1  
Washer, Spring Disk 7/16 ......................2  
Gasket, Exhaust Manifold ......................2  
Spring, Extension...................................1  
Washer, Lock 5/16 Heavy......................4  
Key, Machine 1/4 x 1/4 x 1 1/2...............1  
Washer, Spring Disk 3/8 ........................8  
Nut, Whizlock 5/16-18............................4  
Nut, Hex M8-1.25...................................4  
Valve, Oil Drain......................................1  
Guard, Top.............................................1  
Bearing, Spherical..................................2  
Seal, Single Lip......................................2  
20 103-4244  
21 103-7349  
22 109-0942  
23 103-6961  
24 109-3501  
Belt........................................................ 1  
Asm, Short Idler..................................... 1  
Sheave, Engine ..................................... 1  
Hose, Air Intake..................................... 1  
Kit, Muffler ............................................. 1  
1-543610  
1-603610  
1-653291  
1-653331  
1-805005  
67-7490  
25 109-0181-03 Shield, Exhaust...................................... 1  
26 106-5574  
27 106-7159  
28 302-11  
29 322-3  
Spacer................................................... 1  
O-Ring................................................... 2  
Zerk, 45° 1/4-28..................................... 1  
Screw, HH 5/16-18 x 3/4........................ 4  
Screw, HH 3/8-16 x 2 1/2....................... 1  
Screw, HH 3/8-16 x 3-1/4....................... 1  
Screw, HH 3/8-16 x 1 3/4....................... 5  
Clamp, Hose.......................................... 2  
Screw, HH 7/16-20 x 1 1/2..................... 1  
Washer, 3/8 SAE................................... 2  
Nut, Whizlock 3/8-16 ............................. 4  
Tie, Cable.............................................. 1  
10 98-5975  
11 32128-20  
12 33014-00  
13103-1963  
14 103-2916  
15 103-3504  
16 103-3506  
30 323-12  
31 323-20  
32 323-9  
33 2412-42  
34V 3212-6  
35 3256-24  
36 3290-357  
37 109-7896  
17 103-3695-03 Bracket, Air Filter ...................................1  
18 32128-43  
19 109-3492  
Nut, Whizlock 3/8-16..............................3  
Pulley, Idler Flat.....................................2  
Exmark black touch up spray paint – gloss black.  
Use a Teflon Pipe Sealant or equivalent on threads.  
V
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on sheave screw, item #34.  
Kohler Replacement Parts List  
(Refer to Engine Owner’s Manual)  
Description  
Kohler Part  
Engine Oil Filter..........................5205002  
Engine Air Filter..........................2508301  
Safety Filter ................................2508304  
12  
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ENGINE GROUP  
13  
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HYDRAULIC GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
116-0404  
1-543286  
1-603990  
1-603920  
1-603992  
1-632208  
1-633396  
1-803022  
1-803310  
1-805004  
1-807272  
Decal, Hydraulic Tank............................1  
Grommet................................................2  
Adapter, Straight....................................8  
O-Ring ...................................................1  
O-Ring ...................................................1  
Arm, Pump Control ................................2  
Clip, Loom 5/8........................................1  
Setscrew, 5/16-18 x 5/8 .........................2  
Setscrew, 5/16-18 x 3/8 .........................4  
Washer, Lock 1/4 Heavy........................2  
Key, 5mm x 5mm x 25mm .....................2  
Clamp, Hose..........................................7  
Adapter, Running Tee............................1  
O-Ring ...................................................1  
Adapter, Straight....................................5  
O-Ring ...................................................1  
O-Ring ...................................................1  
Asm, Hydraulic Reservoir W/Decal ........1  
Cap, W/Gasket ......................................1  
Gasket, Reservoir Cap...........................1  
Motor, Wheel (LH)..................................1  
Spacer, Wheel Motor .............................8  
Sheave ..................................................2  
Motor, Wheel (RH).................................1  
Adapter, Tee Special .............................1  
O-Ring ...................................................1  
Pump, Hydro..........................................2  
22 103-7706  
23 103-8631  
24 109-1258  
25 104-7836  
26 109-4180  
Grommet ............................................... 1  
Bracket, Clamp...................................... 1  
Hose, Hydraulic ..................................... 1  
Filter, Head............................................ 1  
Element, Filter 25 Micron....................... 1  
Element, Filter (Winter).......................... 1  
Screw, HH 1/4-20 x 5/8.......................... 2  
Screw, HH 1/4-20 x 1............................. 2  
Screw, HH 3/8-16 x 3/4.......................... 2  
Hose, Hydraulic ..................................... 1  
Screw, HH 3/8-16 x 1 1/4....................... 4  
Screw, HH 1/2-13 x 5 1/2....................... 8  
Adapter, 90° .......................................... 3  
O-Ring................................................... 1  
Washer, 1/4 SAE................................... 2  
Nut, Whizlock 1/4-20 ............................. 2  
Nut, Whizlock 3/8-16 ............................. 4  
Nut, Whizlock 1/2-13 ............................. 8  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Nut, Whizlock 3/8-16 ............................. 2  
4
5
6
7
8
9
1-523541  
27 321-3  
28 321-6  
29 323-4  
30 103-5452  
31 323-7  
10 103-1988  
11 103-1828  
1-603921  
32 325-22  
33 100-4887  
1-603921  
12 103-2156  
1-603921  
34 3256-22  
35 32128-33  
36 32128-43  
37 32128-49  
38 103-5477  
39 103-8617  
40 109-1260  
41 109-1261  
42 109-1262  
43 109-1263  
44 109-1264  
45 3290-357  
103-1020  
13 103-1947  
14 103-7615  
15 103-1949  
16O 103-3406  
17 109-7041  
18 103-4246  
19O 103-4612  
20 103-5469  
1-603921  
21Q 109-6633  
Exmark black touch up spray paint – gloss black.  
V
Use Prolock, Nut Type (P/N 1-840022, .5ml tube) on setscrews, items #6 & #7.  
Use only for operation below 32°F (0°C).  
O
Wheel Motor Service Kits  
Q
Hydro Pump Service Kits  
Part No.  
Description  
Qty.  
Part No.  
Description  
Qty.  
103-9762  
103-9763  
103-9764  
103-9765  
103-4242  
103-7447  
Kit, Seal .......................................................1  
Handle, Actuating.........................................1  
Clip, Retaining..............................................1  
Nut, Hex Toplock 1-20UNEF-2B ..................1  
Asm, Wheel Hub W/Studs ...........................1  
Stud, Wheel 1/2-20 x 1/2..............................4  
103-7441  
103-7443  
94-6922  
Bearing, Input Shaft..................................... 1  
Kit, Cylinder Block 12CC.............................. 1  
Bearing, Thrust............................................ 1  
Kit, Overhaul Seal........................................ 1  
105-6184  
14  
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HYDRAULIC GROUP  
15  
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HOPPER GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
1-543963  
1-633068  
Bumper, Rubber.....................................2  
Spacer ...................................................2  
21 103-8325  
22 321-2  
Clip, Retainer-13mm.............................. 2  
Screw, HH 1/4-20 x 1/2.......................... 4  
Screw, HH 3/8-16 x 1............................. 2  
Bolt, Carriage 1/4-20 x 1........................ 4  
Bolt, Carriage 1/4-50 x 1 1/2.................. 6  
Nut, Retainer ......................................... 4  
Washer, 3/8 SAE................................... 6  
Washer, 5/16 Std................................... 4  
Nut, Nyloc 3/8-16................................... 6  
Nut, Nyloc 1/4-20................................... 29  
Screw, Truss HD 1/4-20 x 1................... 30  
Nut, Whizlock 5/16-18 ........................... 4  
Nut, Whizlock 1/4-20 ............................. 39  
Clip, Loom 1/2 ....................................... 1  
Nut, Hex M10-1.5 Flg............................. 2  
Screw, Shoulder 3/8-16 x 1.295............. 2  
Shock, Gas Compression...................... 1  
Kit, Damper W/Clips .............................. 2  
Kit, Damper W/Clips .............................. 1  
103-5045-03 Brace, Side............................................2  
23 323-6  
4 109-4086  
Asm, Hopper Frame...............................1  
Stud, Ball 13mm ....................................2  
24 3229-2  
5
6
7
8
9
103-5426  
25 3229-4  
103-5736-03 Channel, Screen (RH)............................1  
103-5746 Shock, Gas Tension...............................2  
26 107069  
27 3256-24  
28 3256-3  
103-5749-03 Panel, Hinge (LH) ..................................1  
103-5751-03 Panel, Hinge (RH)..................................1  
29 3296-39  
30 3296-42  
31 32105-32  
32 32128-20  
33 32128-33  
34 1-513762  
35 33005-00  
36 614672  
37 103-5425  
38 109-0715  
39 109-0716  
10 103-5752  
Stud, Ball 10mm ....................................4  
11 103-5772-03 Brace, Top.............................................1  
12 103-5774-03 Channel, Screen (LH) ............................1  
13103-9457  
14 103-6022-03 Channel, Hopper Frame.........................1  
15 103-6025 Shield, Trailing.......................................1  
16 103-7035-03 Channel, Screen Front...........................1  
Asm, Hopper..........................................1  
17 109-4019  
18 103-7824  
19 103-7825  
20 103-8324  
Guard, Damper......................................2  
Insulation, Foam Pad Rear ....................1  
Insulation, Foam Pad Front....................1  
Clip, Retainer-10mm..............................4  
Reference page 20 for remainder of items included in hopper assembly  
Includes items: 1, 18, 19, 32 and frame weldment.  

16  
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HOPPER GROUP  
17  
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HOPPER GROUP (cont.)  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-303435  
109-3854  
1-513762  
1-543296  
1-303335  
109-3955  
Washer, Spring Disk 1/4 ........................3  
Kit, Fill Sensor Wire ...............................1  
Clip, Loom 1/2........................................4  
Grommet................................................1  
Tie, Plastic.............................................1  
Door, 9.5 Bushel Hopper........................1  
25 103-8444  
26 103-8680  
27 103-8789  
28 109-3853  
29 103-9456  
30 321-2  
Decal, Pinch Point ................................. 2  
Deflector, Discharge Chute.................... 1  
Flag, Fill Sensor..................................... 2  
Motor ..................................................... 1  
Asm, Door Hopper................................. 1  
Screw, HH 1/4-20 x 1/2.......................... 19  
Screw, HH 5/16-18 x 7/8........................ 4  
Screw, HH 1/4-28 x 3/4.......................... 3  
Asm, Hopper.......................................... 1  
Bolt, Carriage 5/16-18 x 3/4 ................... 6  
Screw, PPH #10-24 x 1 3/4.................... 2  
Washer, 1/4 Std..................................... 17  
Screw, PPH #6-32 x 5/8......................... 2  
Washer, 5/16 SAE................................. 4  
Screw, Truss HD #10-24 X 1/2 .............. 2  
Screw, Wing 1/4-20 x 3/4....................... 3  
Nut, Nyloc #10-24.................................. 4  
Nut, Nyloc 1/4-20................................... 5  
Nut, Nyloc #6-32 Thin............................ 2  
Screw, Truss HD 1/4-20 x 1................... 6  
Nut, Retainer-Panel 1/4-20 .................... 5  
Nut, Whizlock 5/16-18............................ 8  
Nut, Whizlock 1/4-20 ............................. 27  
Screw, Truss HD 1/4-20 x 1/2................ 4  
103-5745-03 Panel, Hopper Screen............................1  
31 322-4  
109-4253  
109-4254  
Asm, Door Pivot W/Decal (LH)...............1  
Wld, Door Pivot W/Decal (RH)...............1  
Decal, Exmark Logo...............................1  
Wld, Switch Mount.................................1  
32 329-4  
33 103-9457  
34 3230-23  
35 3250-48  
36 3256-2  
10 103-6024  
11 109-3648  
12 103-6067-03 Bracket, Motor (LH)................................1  
13 103-6068-03 Bracket, Motor (RH)...............................1  
14 103-7048-03 Panel, Screen Extend ............................1  
15 109-4153-03 Wld, Door Support .................................1  
16 103-7085-03 Plate, Switch..........................................1  
17 103-7098-03 Handle, Screen (LH) ..............................1  
18 103-7099-03 Handle, Screen (RH)..............................1  
19 109-3650-03 Wld, Diffuser..........................................1  
37 9107622  
38 3256-23  
39 32122-30  
40 109-1063  
41 3296-2  
42 3296-42  
43 3296-9  
20 103-9466  
21 109-0717  
22 321-4  
Asm, Fill Sensor.....................................1  
Asm, Hopper Screen..............................1  
Screw, HH 1/4-20 x 3/4..........................5  
44 32105-32  
45 107069  
46 32128-20  
47 32128-33  
48 32122-42  
23 103-8203-03 Guide, Screen........................................2  
24 1-613235 Washer..................................................2  
Reference page 18 for remainder of items included in hopper assembly.  
18  
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HOPPER GROUP (cont.)  
19  
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ELECTRICAL GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-513051  
1-513152  
1-513180  
1-513374  
1-513747  
Switch, N.O...........................................  
Switch, N.C. ..........................................  
Plate, Switch .........................................  
Meter, Hour...........................................  
Decal, Battery .......................................  
1
1
1
1
1
1
1
1
1
2
2
4
3
1
1
3
7
1
2
1
2
22 109-4736  
23 103-2106  
1-603511  
Asm, Switch W/Nut...............................  
Key, Exmark Logo.................................  
Key, Ignition..........................................  
Bolt, Hold Down....................................  
Fuse, 30 Amp .......................................  
Asm, Battery Hold Down W/Decal ........  
Fuse, 20 Amp .......................................  
Cable, Battery (+)..................................  
Cable, Ground (-)..................................  
Harness, Wiring....................................  
Harness, Hopper Wire ..........................  
Screw, HH 1/4-20 x 3/4.........................  
Asm, Hopper Switch Actuator ...............  
Tie, Cable 5 1/2 (Small) ........................  
Screw, HH 5/16-18 x 7 1/2....................  
Nut, Hex 5/16-18...................................  
Washer, 1/4 Std....................................  
Screw, HH Machine 10-24 x 5/8............  
Screw, PPH #10-24 x 5/8......................  
Nut, Nyloc #10-24 .................................  
Nut, Nyloc 5/16-18 ................................  
1
1
1
2
1
1
2
1
1
1
1
7
1
1
1
1
5
2
8
4
1
24 103-1312  
25 1-816003  
26 103-9470  
27 1-816001  
28 103-8354  
29 103-8355  
30) 109-4270  
31) 103-8800  
32 321-4  
1-522424-03 Wld, Mount Seat Spring ........................  
1-523415  
109-2407  
1-543393  
Spring ...................................................  
Insulator, Battery...................................  
Insulator, Solenoid ................................  
Wingnut, Nyloc 1/4-20...........................  
Switch, N.C. ..........................................  
Plate, Tapped........................................  
Clip, Loom 5/8.......................................  
Asm, Positive Battery Cable..................  
Indicator, Red Led.................................  
Relay, 12VDC 40 Amp..........................  
Nut, Whizlock 1/4-20.............................  
Nut, Ignition...........................................  
Bolt, Carriage #10-24 x 1/2....................  
Module, Seat Delay...............................  
Alarm, Dual Tone 12VDC......................  
10 1-543792  
11 1-633111  
12 1-633181  
13 1-643312  
14109-2923  
15 1-643267  
16 1-643275  
17 32128-33  
18 103-0498  
19 1-807513  
20 100-6186  
21 103-0205  
33 103-8528  
34 1-303287  
35 322-50  
36 3217-6  
37 3256-2  
38 3290-134  
39 3290-500  
40 3296-2  
41 3296-29  
X
Use dielectric grease on all wiring harness connectors.  
Assembly includes items #8, #9, and #28.  
20  
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ELECTRICAL GROUP  
21  
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ELECTRICAL DIAGRAM  
22  
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ELECTRICAL LOGIC SCHEMATIC  
23  
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DECALS GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
103-8451  
109-7318  
103-9274  
98-5954  
Decal, Ignition/Speed Control ................1  
Decal, Danger........................................2  
Decal, Belt Routing................................1  
Decal, Missing Cover.............................2  
Decal, Relay ..........................................1  
Decal, Clutch Adjustment.......................1  
Decal, Hydraulic Tank............................1  
Decal, Warning......................................2  
Decal, Battery........................................1  
10 65-2690  
11 103-8425  
12 103-8444  
13 103-8495  
14 109-4273  
15 103-6024  
16 116-1175  
17 109-4638  
103-9502  
Decal, Hot Surface ................................ 2  
Decal, Driveline ..................................... 1  
Decal, Pinch Point ................................. 2  
Decal, Pinch Point ................................. 2  
Decal, Wheel Motor Release ................. 1  
Decal, Exmark Logo .............................. 1  
Decal, Service Aid Navigator ................. 1  
Decal, Instrument Panel ........................ 1  
Kit, Decal  
103-8611  
103-9034  
116-0404  
98-4361  
1-513747  
24  
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25  
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© 2009 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-368 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed In USA.  
All Rights Reserved  
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