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
7ꢀ Kohler
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
13ꢁ 103-1963
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
13ꢂ 103-9457
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
ꢂ
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
14ꢁ 109-2923
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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