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Exmark 790 manual

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Table of contents for the manual

  • Page 1

    For Serial Nos. 790,000 & Higher Part No. 4500-485 R ev. C LAZER Z ® MODELS ADVANTAGE SERIES MODELS[...]

  • Page 2

    - 1 -[...]

  • Page 3

    -2- REA D OPERA T OR’S M A NUA L BEFORE OPERA TING OR SERVICING EXMA RK EQUIPMENT. TA BLE OF CONTENTS Description Page Brake Handle Assemb ly ................................................ 25 Caster Wheel Assembly ........................................... 18- 19 Controls Group .............................................................. 22 [...]

  • Page 4

    48” DECK GROUP -3- Item Part No. Descrip tion Qty. 1 109-9027 Asm , Deck W / Decals 484 ..... ..... .... ..... .. 1 2 103-6401 Blade-Notc hed.. .... ..... ..... ..... .... ..... ..... ... 3 O 103-6391 Blade, Mulching ..... .... ..... ..... ..... ..... ..... .. 3 103-6386 Blade, Low Lift .... .... ..... ..... ..... ..... ..... .... . 3 103-6381 Bl[...]

  • Page 5

    48” DECK W /DECALS ASSEMBLY – 109-9027 -4- Item Part No. Descript ion Qty. 2 1-303508 Decal-W arning, Discharge . .... ..... ..... .... .. 1 3 1-403005 Decal-Danger ... ..... ..... .... ..... ..... ..... .... ..... 2 4 1-633922 Decal, Antisc alp .. .... ..... ..... ..... .... ..... ..... .. 1 5 98-5954 Decal-Cover, Missi ng ... ..... .... .....[...]

  • Page 6

    CUTT ER HOUSING ASSEMBLY – 109-9017 -5- Item Pa rt No . D escrip tion Qty . 1 103-1330 Guard, Bearing Top ... ..... ..... ..... ..... ..... ... 1 2 103-2535 Spacer, Guard B ottom ..... .... ..... ..... ..... ... 1 3 103-2802 W asher, Spri ng Disc 3/4 ...... ..... ..... ..... ... 1 4 103-2982 Key, Machine 1/ 4 x 3/16 x 3/4 .... ..... .... ... 1 5 [...]

  • Page 7

    52” DECK GROUP -6- Item Part No. Descrip tion Qty. 1 109-9012 Asm , Deck W / Decals 524 ..... ..... .... ..... . 1 2 1-603299 Roller, Sc alp, Anti ... ..... ..... .... ..... ..... ..... . 3 3 98-5975 W asher, Spri ng Disc 3/8 . ..... .... ..... ..... ... 3 4 116-0133 Extension-Spri ng .... ..... .... ..... ..... ..... ..... . 1 5 109-9851 Axle, A[...]

  • Page 8

    52” DECK W /DECALS ASSEMBLY – 109-9012 -7- Item Part No. Descript ion Qty. 2 1-303508 Decal, W arni ng Discharge ... ..... ..... .... .... 1 3 1-403005 Dec al, Danger . ..... .... ..... ..... ..... .... ..... ..... . 2 4 1-633922 Dec al, A ntiscal p .. ..... .... ..... ..... ..... .... ..... .. 1 5 98-5954 Decal, Cover Mis sing ... .... ..... .[...]

  • Page 9

    CUTT ER HOUSING ASSEMBLY – 109-9018 -8- Item Part No. Descript ion Qty. 1 103-8353 Housing, Cut ter .... .... ..... ..... ..... .... ..... ..... . 1 2 103-2535 Spacer, Guard B ottom ..... .... ..... ..... ..... ... 1 3 Q 103-9086 Kit, Splined Spindl e .... ..... .... ..... ..... ..... .... 1 4 103-2982 Key, Machine 1/ 4 x 3/16 x 3/4 .... .....[...]

  • Page 10

    60” DECK GROUP -9- Item Part No. Descrip tion Qty. 1 109-9013 Asm , Deck W / Decals 604 ..... ..... .... ..... . 1 3 103-6403 Blade, Notc hed .... .... ..... ..... ..... ..... .... .... 3 O 103-6393 Blade, Mulc hing ...... ..... ..... .... ..... ..... ..... . 3 103-6388 Blade, Low Lift .... .... ..... ..... ..... ..... ..... .... . 3 103-6383 Bla[...]

  • Page 11

    60” DECK W /DECALS ASSEMBLY – 109-9013 -10- Item Part No. Descript ion Qty. 2 1-303508 Decal, W arni ng, Discharge .. ..... ..... .... .... 1 3 1-403005 Dec al, Danger . ..... .... ..... ..... ..... .... ..... ..... . 2 4 1-633922 Dec al, A ntiscal p .. ..... .... ..... ..... ..... .... ..... .. 1 5 116-0025 Decal, Ul tracut 60 Seri es 4 ... ..[...]

  • Page 12

    CUTT ER HOUSING ASSEMBLY – 109-9019 -11- Item Part No. Descript ion Qty. 1 103-1330 Guard, Bearing Top ... ..... ..... ..... ..... ..... ... 1 2 103-2535 Spacer, Guard B ottom . ..... ..... ..... ..... .... .. 1 3 103-2802 W asher, Spri ng Disc 3/4 ... ..... ..... .... ..... .. 1 4 103-2982 Key, Machine 1/ 4 x 3/16 x 3/4 .... ..... .... ... 1 5 ?[...]

  • Page 13

    72” DECK GROUP -12- Item Part No. Descrip tion Qty. 1 109-9014 Asm , Deck W / Decals 724 ..... ..... .... ..... .. 1 2 98-5975 W asher, Spri ng Disc 3/8 . ..... .... ..... ..... ... 1 3 116-0133 Extension-Spri ng .... ..... .... ..... ..... ..... ..... . 1 4 109-9851 Axle, Anti -Scalp Roller ... ..... .... ..... ..... .... 4 5 103-6404 Blade, Not[...]

  • Page 14

    72” DECK W /DECALS ASSEMBLY – 109-9014 -13- Item Part No. Descript ion Qty. 2 1-303508 Decal-W arning, Discharge . .... ..... ..... .... .. 1 3 1-403005 Dec al-Danger ... .... ..... ..... .... ..... ..... ..... .... . 2 4 1-633922 Dec al, A ntiscal p .. ..... .... ..... ..... ..... .... ..... .. 1 5 98-5954 Decal-Cover, Missi ng ... ..... .... [...]

  • Page 15

    CUTT ER HOUSING ASSEMBLY – 116-0911 -14- Item Part No. Descript ion Qty. 1 103-1330 Guard, Bearing Top ... ..... ..... ..... ..... ..... ... 1 2 103-2535 Spacer, Guard B ottom . ..... ..... ..... ..... .... .. 1 3 103-2802 W asher, Spri ng Disc 3/4 ... ..... ..... .... ..... .. 1 4 103-2982 Key, Machine 1/ 4 x 3/16 x 3/4 .... ..... .... ... 1 5 ?[...]

  • Page 16

    DECK IDLER ASSEMBLY – 109-2883 -15- Item Part No. Descript ion Qty. 1 43-0940 Spacer-Hub, Blower . ..... ..... ..... .... ..... ..... . 1 2 103-2916 Guard, Top. ..... ..... ..... ..... ..... ..... ..... ..... .... 1 3 103-3504 B earing, S pherical. ..... ..... ..... .... ..... ..... .... 2 4 103-3505 Seal, Double Li p..... ..... .... ..... ..... [...]

  • Page 17

    MAINFRAME GROUP -16- Item Part No. Descript ion Qty. 1 109-7345 Frame, Main 48/52 W /Decals. ..... ..... ..... . . 1 109-7347 Frame, Main 60 W/ Decals ..... ..... ..... ..... . . 1 109-7349 Frame, Main 72 W/ Decals ..... ..... ..... ..... . . 1 1:2 109-9477 Decal, W arni ng Spring Load . .... ..... ..... ... . 2 1:3 107-2112 Decal, W arning .. ....[...]

  • Page 18

    ROPS ASSEMBLY – 116-0230 -17- Item Part No. Descript ion Qty. 3 109-6653 S pacer . .... ..... ..... ..... ..... ..... .... ..... ..... ..... .. 2 4 116-0019 Asm , Rops Upper W /Dec al . ..... .... ..... ..... 1 4:2 107-2102 Decal, W arning, Folding Rops ..... ..... ..... 1 5 109-5337 B umper, Rops ..... ..... ..... .... ..... ..... ..... .... .. [...]

  • Page 19

    CASTER W HEEL ASSEMBLY – 48” & 52” -18- Item Part No. Des cription Qty. 1 1-543509 Cone, Bearing Tapered Roll er .... ..... ... 2 2 1-543511 Seal, Grease .. ..... ..... ..... ..... .... ..... ..... .. 1 3 116-1092-01 Wld, Caster Fork ... ..... ..... .... ..... ..... ..... 1 4 1-633508 W asher, Spri ng Disc ... ..... ..... ..... .... .....[...]

  • Page 20

    CASTER W HEEL ASSEMBLY – 60” & 72” -19- Item Part No. Des cription Qty. 1 1-543509 Cone, Bearing Tapered Roll er .... ..... ... 2 2 1-543511 Seal, Grease .. ..... ..... ..... ..... .... ..... ..... .. 1 3 1-633508 W asher, Spri ng Disc ... ..... ..... ..... .... ..... 3 4 103-1474-01 Fork-Cast er .. .... ..... ..... ..... ..... ..... ....[...]

  • Page 21

    DECK SUPPORT GROUP -20- Item Part No. Descript ion Qty. 1 109-7952 Asm , Deck St rut .... ..... .... ..... ..... .... ..... ..... 2 1:2 109-5009 Bushing-S uspension, Rubber.. ..... ..... ..... 2 1:3 109-5010 Spacer ... .... ..... ..... ..... ..... ..... .... ..... ..... ..... 2 2 109-5013 Asm , Panhard Rod.. ..... ..... ..... .... ..... ..... .. 1 [...]

  • Page 22

    HEIGHT OF CUT ASSEMBLY – 109-7438 -21- Item Part No. Descript ion Qty. 1 62-1330 Bolt-S houlder ...... ..... ..... ..... .... ..... ..... ..... . 1 2 109-7130 Grom met ... ..... ..... ..... ..... ..... .... ..... ..... ..... . 1 3 104-8301 Nut, Nyloc 3/8-16 Flg ... .... ..... ..... ..... ..... .. 1 4 109-7124 S pring, E x tension .... ..... .... [...]

  • Page 23

    CONTROLS GROUP -22- Item Part No. Descript ion Qty. 1 109-8484 Console, P anel W / Decal W /Decal (A ll Units E xcept 26HP Kaw) ... 1 109-9454 Console, P anel W /Decal (26HP K aw) .... 1 1:2 109-8483 Decal, Control P anel ..... ..... ..... ..... .... ..... . 1 1:3 109-7330 Decal, Fuse... ..... ..... .... ..... ..... ..... ..... ..... .. 1 2 109-816[...]

  • Page 24

    MOTION CONTROL GROUP -23- Item Part No. Descript ion Qty. 1 116-0880 Asm , Mot Ctrl/ Bushing RH .. ..... ..... .... ..... 1 1:2 109-8054 Bushing, Flanged .. ..... ..... ..... ..... ..... ..... ... 4 2 116-0881 Asm , Mot Ctrl/ Bushing LH ... ..... .... ..... ..... 1 2:2 109-8054 Bushing, Flanged .. ..... ..... ..... ..... ..... ..... ... 4 3 V 116-0[...]

  • Page 25

    PARK BRAKE GROUP -24- Item Part No. Descript ion Qty. 1 117-0383 A sm, Brake Handle ... .... ..... ..... ..... ..... .... . 1 2 3230-2 Bolt, Carriage 5/16-18 x 1 ... .... ..... ..... ..... 2 3 104-8300 Nut, Nyloc 5/16-18 Flg . ..... ..... ..... .... ..... .. 2 4 60-1730 Pin-Clevis .... ..... .... ..... ..... .... ..... .... ..... ..... . 2 5 3272-1[...]

  • Page 26

    BRAKE HANDLE ASSEMBLY – 117-0383 -25- Item Part No. Descript ion Qty. 1 99-5107 Nut, Loc k 1/2-13 ..... .... ..... ..... ..... .... ..... ... 1 2 117-0380 S pacer . .... ..... ..... ..... ..... ..... .... ..... ..... ..... .. 1 3 115-3580 Arm, Brake LH . ..... ..... ..... ..... .... ..... ..... .... 1 4 117-0376 Spring Torsi on RH .... .... .....[...]

  • Page 27

    SEAT GROUP -26- Item Part No. Descript ion Qty. 1 116-0852 S eat, E xmark .. ..... .... ..... ..... ..... .... ..... ..... . 1 4 109-9036 Mount, Seat W /Decal s .... ..... .... ..... ..... .... 1 8 104-8300 Nut, Nyloc 5/16-18 Flg . ..... ..... ..... .... ..... .. 8 11 116-0192-03 Plate, Seat Support . .... ..... ..... ..... .... ..... ... 1 Item Pa[...]

  • Page 28

    SEAT W /T RACKS ASSEMBLY – 116-0037 -27- Item Part No. Descript ion Qty. 1 109-9801 S et, S eat Track ..... .... ..... ..... ..... ..... ..... .... 1 2 109-9813 Set, A rm Rest Pads .... ..... .... ..... ..... ..... ... 1 3 109-9804 Kit, Arm Rest Set ... .... ..... ..... ..... .... ..... .... 1 4 109-9805 Kit, Seat Belt W / Long Buckle ...... ....[...]

  • Page 29

    FUEL TANK GROUP -28- Item Part No. Descript ion Qty. 1 109-9357 Asm , Fuel Tank... ..... ..... ..... ..... ..... ..... ..... 1 109-9656 Asm , Fuel Tank W /O S ender .. ..... ..... ..... 1 6 32128-33 Nut, W hizloc k 1/4-20 .. ..... ..... ..... .... ..... .... 2 11 109-2365 Bum per-Rubber (W /Stud) .. ..... ..... ..... .... . 2 Item Part No. Descript[...]

  • Page 30

    FUEL TANK ASSEMBLY – 109-9357 & 109-9656 -29- Item Part No. Descript ion Qty. 2 46-6560 Bushing ... ..... .... ..... ..... ..... .... ..... ..... ..... .... 4 3 109-9364 Fitting, Fuel W /Line And Sc reen . ..... ..... . 1 4 9107944 Screw-Pan . ..... ..... ..... .... ..... ..... ..... ..... .... . 5 5 3253-17 W asher, Lock 3/16 ...... ..... ..[...]

  • Page 31

    ENGINE GROUP – 20HP BRIGGS & STRAT TON -30- Item Part No. Descript ion Qty. 2 116-0993 Sheave, W /Hub .... ..... ..... .... ..... ..... .... ..... . 1 3 1-807259 Key, Machine 1/ 4 x 1/4 x 1 .. ..... .... ..... ..... 1 4 109-8138-01 Anchor, Clut ch .... ..... .... ..... ..... .... ..... ..... .. 1 5 109-9155 Clutch ............................[...]

  • Page 32

    ENGINE GROUP – 20-27HP KOHLER -31- Item Part No. Descript ion Qty. 2 109-9905 Sheave, W /Hub 23, 25 and 27 HP .. ..... ... 1 116-0993 Sheave, W /Hub 20 HP ... ..... .... ..... ..... .... . 1 3 109-9282 Clutch, CMS-200 23,25 and 27 HP . ..... . 1 109-9155 Clutch, CMS-175 20 HP . .... ..... .... ..... ..... . 1 4 109-6919 W as her, Clut ch .... ...[...]

  • Page 33

    ENGINE GROUP – 29HP KAW ASAKI -32- Item Part No. Descript ion Qty. 2 109-9905 Sheave, W /Hub .... ..... ..... .... ..... ..... .... ..... . 1 3 109-9282 Clutch, CMS-200 W /Spot Brak e. ..... ..... .. 1 4 109-6919 W asher, Clut ch .... ..... .... ..... ..... .... ..... ..... . 1 5 1-603610 W asher, Spri ng Disc 7/16 .. .... ..... ..... ..... . 2 6[...]

  • Page 34

    ENGINE GROUP – 26HP KAW ASAKI LIQUID-COOLED -33- Item Part No. Descript ion Qty. 2 109-9905 Sheave, W /Hub .... ..... ..... .... ..... ..... .... ..... . 1 3 109-9282 Clutch, CMS-200 W /Spot Brak e. ..... ..... .. 1 4 109-6919 W asher, Clut ch .... ..... .... ..... ..... .... ..... ..... . 1 5 1-603610 W asher, Spri ng Disc 7/16 .. .... ..... ...[...]

  • Page 35

    HYDRAULIC GROUP -34- Item Part No. Descript ion Qty. 1 109-2182 Asm , Pum p Idler ... ..... ..... ..... ..... .... ..... .... 1 2 109-6658 Nut, Nyloc 3/8-16 Flg ... .... ..... ..... ..... ..... .. 1 3 116-1322 Asm , Hydro LH 12CC W /Ch eck (48 ” & 52 ”) .............................. 1 116-1324 Asm , Hydro LH 12CC W /Shock ( 60” & 72?[...]

  • Page 36

    PUMP IDLER ASSEMBLY – 109-2182 -35- Item Part No. Descript ion Qty. 2 43-0940 Spacer-Hub, B lower .... ..... ..... .... ..... ..... ... 1 3 103-3504 Bearing, S pherical. ..... ..... ..... .... ..... ..... .... 2 4 103-3505 Seal, Double Li p..... ..... .... ..... ..... ..... ..... ... 1 5 103-3506 Seal, S ingle Lip ..... ..... ..... ..... .... ...[...]

  • Page 37

    ELECTRICAL GROUP -36- Item Part No. Descript ion Qty. 2 V 115-3869 Harness -W ire, Main (Liquid-Cooled) ... ... 1 115-2796 Harness-W ire, Main (Air-Cooled) .. ..... .... 1 2:1 103-3895 Diode-TVS .. ..... ..... ..... ..... ..... ..... ..... ..... ... 1 2:2 218-578 Fuse-10 Am p ... ..... ..... ..... ..... .... ..... ..... .... 1 2:3 109355 Fuse-15 Am[...]

  • Page 38

    DECAL GROUP -37- Item Part No. Descript ion Qty. 1 109-7069 Dec al, Cons ole ..... ..... ..... ..... .... ..... ..... .... 1 2 109-9477 Decal, W arni ng Spring Load . .... ..... ..... ... 2 3 107-2102 Dec al, ROP S Folding ... ..... .... ..... ..... ..... .. 1 4 98-5954 Decal, Danger ... ..... .... ..... ..... ..... .... ..... .... 2 5 1-403005 Dec[...]

  • Page 39

    AIR-COOLED ELECTRICAL DIAGRAM -38-[...]

  • Page 40

    LIQUID-COOLED ELECTRICAL DIAGRAM -39- PTO SWITCH SEA T SWITCH IGNITION SWITCH FUSE BLOCK REGULA T OR GROUND PTO CLUTCH ST AR T RELA Y ST AR T RED HOUR METER/MODULE L T . GREEN YELLOW TA N BRO WN WHITE ORANGE GRA Y VIOLET BLUE GREEN RED BLACK ORANGE ORANGE MA G PINK FUEL SOLENOID BRO WN BRO WN VIOLET ENGINE FUEL SENDER B+ BRO WN PINK PINK PINK PINK [...]

  • Page 41

    AIR-COOLED ELECTRICAL LOGIC SCHEMATIC -40-[...]

  • Page 42

    LIQUID-COOLED ELECTRICAL LOGIC SCHEMATIC -41- 2 R A I 3 1 2 4 A 4 7 4 1 6 5 A 3 1 6 B C B B 8 23 5 4 5 1 2 S SW1 (IGNITION) KEY SW Ignition switch terminal locations viewed from back OPTIONAL ACCESSORIES OFF = no connections ON = BRIA ST ART = BRIS BN BN V BU BK Y W T PK BN PK OR A R GN S I BK PK PK PK L TGR OR R GY GY PK PK GN OR PK BU BN V OR OR [...]

  • Page 43

    -42-[...]

  • Page 44

    © 2009 Exmark Mf g. Co., Inc. Part No. 4500-485 Rev . C Industrial Par k Box 808 (402) 223-6300 Beatrice, NE 68310 Fax (402) 223-5489 A ll Rights Reserved Printed In USA[...]