Hydro Cut Series Walk-Behind Mowers

Parts Manual HP Product Mfg. No. Description 92 Hydro Cut, HP Kawasaki, 2 inch (CE) Hydro Cut Series Walk-Behind Mowers Rev. 0/200

Table Of Contents PRODUCT COMPONENTS PAGES Engine Deck & Handle Bars Group... Engine, PTO & Deck Drive Idler Group... Transaxle, Mount & Drive Idler Group... Transaxle SERVICE PARTS... Controls Group... 2 Electrical Group... Fuel Tank Group... Fuel Tank Supply Group... Wheel & Tire Group... 20 Decals - Brand, Model, Safety & Instruction... 22 2 inch Mower Deck - Frame, Caster & Shield... 2 2 inch Mower Deck - Height Adjustment... 2 2 inch Mower Deck - Housing, Arbors & Blades... 2 Torque Specification Chart... Inside Back Cover

Engine Deck & Handle Bars Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 2 7 See Motion Control, Parking Brake and Operator Presence Group 22 9 2 See Motion Control, Parking Brake and Operator Presence Group See Fuel Tank & Mount Group 7 7 20 9 2

Engine Deck & Handle Bars Group REF NO PART NO. QTY. DESCRIPTION 0220 SWITCH, PTO 2 022222 SWITCH RETAINER RING 020 NUT, Hex, /-2 00 CABLE, Choke Control 020 2 CAPSCREW, Hex Head, /-20 x / 022 SWITCH, Ignition, Complete (Includes Ref 7-9) 7 02279 KEY, Ignition, Molded (set of 2) 022790 COVER 9 02279 PLASTIC NUT 0729 CABLE, Throttle Control 02 2 FOAM GRIP 2 0209 2 NUT, Hex Nylon Lock, /-20 0790 HANDLE BAR ASSEMBLY, (Orange) 0279 2 SCREW, Phillips Head, #-2 x /2 0279 SWITCH, NC 02029 2 NUT, Hex, #-2 7 0220 BODY CLIP, /- 077 REAR SHIELD, (Orange) 9 020 CAPSCREW, Hex Head, /- x / 20 02 WASHER, / 2 020 ENGINE DECK ASSEMBLY, (Orange) 22 07 THROTTLE STOP PLATE Footnotes

Engine, PTO & Deck Drive Idler Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI002 2 27 2 Muffler Clamp & Hardware 9 2 2 9 9 20 22 2 2 20 2 2 9 See Transaxle, Mount & Drive Idler Group 7 7 9 2

Engine, PTO & Deck Drive Idler Group REF NO PART NO. QTY. DESCRIPTION * ENGINE, HP Kawasaki, Model FHV 027 FUEL FILTER 02 OIL FILTER (90-207) * PRE-CLEANER (-70) * AIR FILTER (-707) * MUFFLER (9070-7002) * EXHAUST MANIFOLD (0-700) * MANIFOLD HEAT SHIELD (27-7022) * 2 EXHAUST MANIFOLD GASKET (0-702) * RECOIL ASSEMBLY, Complete (90-700) 2 0279 GROMMET 02 SPRING, Extension 0202 CAPSCREW, Hex Head, /- x -/2 029 NUT, Hex Serrated Flange, /- 0207B 2 BUSHING, Brass 7 07 DECK DRIVE IDLER ARM, (Orange) 020 WASHER, / 9 020 C-CLIP 029 IDLER PULLEY 02 WASHER, /2 2 02020 CAPSCREW, Hex Head, /2-20 x 2-/2 0209 NUT, Hex Nylon Lock, /2-20 072 CRANKSHAFT BOLT, 7/ x 2-/ 022 CLUTCH RETAINER 77 ELECTRIC CLUTCH 7 0007 KEY, / Sq. x 2 020 CAPSCREW, Hex Head, /- x 2-/ 9 02 7 WASHER, / 20 020 2 CAPSCREW, Hex Head, /- x / 2 027 CLAMP 22 0227 NUT, Hex Serrated Flange, /- 2 007 HOSE, -/2 inch (oil drain) 2 0292 CLAMP, # Hose 2 0207 NUT, Hex Nylon Lock, /- 2 02 CARRIAGE BOLT, /- x -/ 27 029 MUFFLER GUARD 2 0290 BRACKET Footnotes * See your local Kawasaki engine dealer for parts & service. 7

Transaxle, Mount & Drive Idler Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 2 2 2 22 7 20 9 2 7 7 2 Idler Pulley 9 9 Transaxle Pulley Engine Pulley

Transaxle, Mount & Drive Idler Group REF NO PART NO. QTY. DESCRIPTION 0209 NUT, Hex Nylon Lock, /- 2 0207 7 NUT, Hex Nylon Lock, /- 02 2 WASHER, / 072 TRANSAXLE BRACE, (Orange) 0209 2 CAPSCREW, Hex Head, Self-Tapping, /- x / 020 CAPSCREW, Hex Head, /- x / 7 02 SKID PLATE, (Orange) 02297 HYDRO RETURN SPRING 9 0202 CAPSCREW, Hex Head, /- x 02290 HYDROSTATIC TRANSAXLE 020 BELT, Drive 2 02007 SPRING, Extension 020 2 NUT, Hex Side Lock, /- 0202 CAPSCREW, Hex Head, /- x 02 2 WASHER, Fender, / 077 SPACER 7 0207B 2 BUSHING, Brass 0777 TRANSAXLE IDLER ARM, (Orange) 9 027 IDLER PULLEY ASSEMBLY 20 02 WASHER, / 2 020 CAPSCREW, Hex Head, /- x 2 22 079 TRANSAXLE DRIVE PULLEY Footnotes 9

Transaxle SERVICE PARTS NOTE: Unless noted otherwise, use the standard hardware torque specification chart. 02290

Transaxle SERVICE PARTS REF NO PART NO. QTY. DESCRIPTION 02290. SEALANT 9 022902 SHAFT, INPUT 02290 RING - RETAINING 02290 SPACER 2 02290 RING - RETAINING 02290 BALL BEARING 2 022907 2 OUTBOARD SLEEVE BEARING 02290 AXLE SHAFT - RH 022909 AXLE SHAFT - LH 02290 SPRING - HELICAL COMPRESSION 02290 WASHER 7 022902 7. 20W-0 OIL 02297 HYDRO RETURN SPRING 9 02290 FAN,, BLADE 2 02290 EXPANSION TANK KIT 02290 FAN/PULLEY KIT (includes Ref. 9) Footnotes

Controls Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 2 9 7 2 9 7 9 20 2 2 2 22 2 7 2 2 27 2 2 2 2 27 2 2 2 0 29 2 2 2

Controls Group REF NO PART NO. QTY. DESCRIPTION 097 OPERATOR PRESENCE HANDLE - RH, (Orange) 2 0290 2 VINYL GRIP 020 2 NUT, Hex, /- 07 2 ADJUSTER LINKAGE 09 2 SHOULDER SPACER 0772 SWITCH ROD 7 027 BRAKE ROD 02007 COLLAR, Set, / 9 07 2 THUMB CONTROL LEVER, Complete, (Orange), (Includes Ref No. ) 02 2 FOAM GRIP 0 PIVOT CONTROL - RH, (Orange) 2 022 7 PIN, Clevis, / x 020979 CLEVIS, Plastic, /-2 0220 PIN, Cotter 020 NUT, Hex, /-2 072 2 THUMB CONTROL ROD 7 020 2 NUT, Hex Side Lock, /- 022 NUT, Hex Serrated Flange, /-20 9 0 PIVOT CONTROL - LH, (Orange) 20 097 OPERATOR PRESENCE HANDLE - LH, (Orange) 2 020 CAPSCREW, Hex Head, /-20 x / 22 0222 2 SHOULDER BOLT, /2 x 2 022 2 NUT, Hex Serrated Flange, /- 2 02 WASHER, / 2 020 CAPSCREW, Hex Head, /- x / 2 0207 NUT, Hex Nylon Lock, /- 27 029 2 BEARING, Flange 2 0202 CAPSCREW, Hex Head, /- x 29 092 SPRING, Extension 0 02 BRAKE LINKAGE ROD 0772 DUMP VALVE ROD 2 022 2 COLLAR, Set, / 0770 LINK STUD 0797 CONTROL SHAFT ASSEMBLY, (Orange) 020 CAPSCREW, Hex Head, TFL, /- x -/ 0227 2 NUT, Hex Serrated Flange, /- Footnotes

Electrical Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 UNDER CONTROL PANEL 2 7 Operator Presence Switch UNDER ENGINE DECK To Electric Clutch To Alternator To Engine Magneto To Engine Mount Bolt

Electrical Group REF NO PART NO. QTY. DESCRIPTION 07772 WIRE HARNESS 2 0220 SWITCH, PTO 022 SWITCH, Ignition, Complete (Includes Ref No. -) 02279 KEY, Ignition, Molded (set of 2) 022790 COVER 02279 PLASTIC NUT 7 0279 SWITCH, NC Footnotes

Fuel Tank Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 2 7

Fuel Tank Group REF NO PART NO. QTY. DESCRIPTION 022 FUEL TANK CAP 2 09 FUEL TANK 020 CAPSCREW, Hex Head, /- x / 02 WASHER, / 020 CAPSCREW, Hex Head, /- x -/ 02 FUEL TANK MOUNT - LH, (Orange) 7 022 NUT, Hex Serrated Flange, /- 0 FUEL TANK MOUNT - RH, (Orange) Footnotes 7

Fuel Tank Supply Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 7 9 Connect to Fuel Pump 2 9 Tank Components

Fuel Tank Supply Group REF NO PART NO. QTY. DESCRIPTION 020 CLAMP, Hose 2 007 HOSE, 7 inch (supplied with engine) 027 FUEL FILTER 009 2 HOSE, 9-/2 inch 00 2 WIRE LOOM, inch 022 VALVE, FUel Shut-Off 7 020 ELBOW FITTING 7200 GROMMET 9 0209 2 HOSE CLAMP 009220 HOSE, 20 inch 0207 SCREEN FITTING Footnotes 9

Wheel & Tire Group NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI007 2 7 20

Wheel & Tire Group REF NO PART NO. QTY. DESCRIPTION 009 2 KEY, / 2 020792S 2 DRIVE HUB 02 2 WHEEL & TIRE ASSEMBLY, x. x, Complete (Includes Ref & ) 022 2 TIRE,. x. x 02 2 WHEEL ASSEMBLY, x. 0220 SHIM 7 020 2 C-CLIP 0200 LUG NUT Footnotes 2

9 Decals - Brand, Model, Safety & Instruction NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI009 2 9 D B C A 7 9 2 2 22

Decals - Brand, Model, Safety & Instruction REF NO PART NO. QTY. DESCRIPTION 097 DECAL, Control Panel 2 02 DECAL, Warning Machine Climb 02 DECAL, Warning Explosive Fuel 09 DECAL, Deck Height, Pulley Position 022 DECAL, ICC 0777 DECAL, Cut Height Adjust 7 722 DECAL, Simplicity, Blue & Silver, Icon 02 DECAL, Stripe, Blue and Grey 9 707 DECAL, Hot 70277 DECAL, Danger, Chute In Place, Hand Under Deck * MODEL/SERIAL TAG (Not serviced) 2 * DECAL, I.D. Plate Footnotes * Not a service part. 2

2 inch Mower Deck - Frame, Caster & Shield NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI00 2 2 2 0 2 29 9 7 7 2 29 2 27 27 7 2 2 22 2 20 2 2 9 2

2 inch Mower Deck - Frame, Caster & Shield REF NO PART NO. QTY. DESCRIPTION 0 SHIELD INSERT, (Orange) 2 02299 SCREW, Allen Head, /-20 x /2 00 GUARD, Mower Deck 0 2 SHIELD MOUNT BRACKET, (Orange) 0220 BODY CLIP, /- 029 LOCKWASHER, / 7 020 CAPSCREW, Hex Head, /-20 x / 020 CAPSCREW, Hex Head, /- x 9 022 NUT, Hex Serrated Flange, /- 02020 CAPSCREW, Hex Head, /- x 2-/2 02 WASHER, / 2 0229 KNOB 07 FRAME RAIL - LH, (Orange) 02209 2 PLASTIC CAP 09 CROSS TUBE, (Orange) 099 CASTER MOUNT FRAME, Complete, (Orange) (Includes Ref. No. 7 & 2) 7 02009 2 GREASE FITTING, /-2 0207 2 CAPSCREW, Hex Head, /2- x -/2 9 07 2 AXLE, Caster 20 02S 2 WHEEL & TIRE ASSEMBLY, Silver, 9 x. x, Complete (Includes Ref. No. 2-2) 2 02 2 TIRE, Front, 9 x. x 22 022 2 TUBE, for 9 x. x Tire 2 02S 2 HUB & BEARING ASSEMBLY, Complete, Silver (Includes Ref. No. 2 & 2) 2 022 2 BEARING, Roller ( per tire) 2 02 RETAINER, Bearing (2 per tire) 2 020 2 NUT, Hex Nylon Lock, /2-27 072 2 CASTER YOKE, (Orange) (Use with Ref. No., Part No. 099) 2 0202 BUSHING, Flange 29 0209 NUT, Hex Nylon Lock, /- 0 0 2 COLLAR, Split, / 0227 2 VINYL CAP 2 079 FRAME RAIL - RH, (Orange) Footnotes 2

2 inch Mower Deck - Height Adjustment NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI002 2 2 2 2 7 7 2 2 2 2 9 2 22 7 2 22 9 20 2

2 inch Mower Deck - Height Adjustment REF NO PART NO. QTY. DESCRIPTION 022 WASHER, inch 2 072 DECK LIFT PIVOT - REAR, (Orange) 02 SHOULDER BOLT, /- x /2 x / 07 HEIGHT ADJUST ROD 02 LINKAGE ADJUSTER 020 NUT, Hex Side Lock, /- 7 0220 PIN, Cotter 020 NUT, Hex Top Lock, /- 9 0 COLLAR, Set, / 02 WASHER, / 022 SPRING, Compression 2 077 DECK ADJUST LINK, (Orange) 020 CAPSCREW, Hex Head, /- x 029 NUT, Hex Serrated Flange, /- 020 2 CAPSCREW, Hex Head, /- x -/ 09 2 SPACER 7 09 2 COLLAR, Double Split, inch 022 7 NUT, Hex Serrated Flange, /- 9 0777 CUT HEIGHT INDICATOR 20 020 NUT, Hex, /- 2 07 DECK LIFT PIVOT, Front, (Orange) 22 020 CAPSCREW, Hex Head, /- x / 2 09 2 HANGER PLATE, (Orange) 2 02009 GREASE FITTING, /-2 2 0 WASHER, Nylon, / Footnotes 27

2 inch Mower Deck - Housing, Arbors & Blades NOTE: Unless noted otherwise, use the standard hardware torque specification chart. FI000 PTO Clutch Pulley Idler Pulley Spindle Pulley 2 Torque Lock Nuts to -90 Ft. Lbs. (-22 Nm) 2 7 22 2 2 2 9 2 2 7 2 Torque Capscrews to 70 Ft. Lbs. (9 Nm) 9 20 2

2 inch Mower Deck - Housing, Arbors & Blades REF NO PART NO. QTY. DESCRIPTION 0229 BELT, Arbor 2 029 2 NUT, Hex Nylon Lock, /- 02 2 WASHER, Spring, / 0007 2 KEY, / Square x 07 2 SPINDLE PULLEY 0772 SPACER 7 020 CAPSCREW, Hex Head, /- x 07777 BELT GUIDE, (Orange) 9 022 NUT, Hex Serrated Flange, /- 0207 NUT, Hex Nylon Lock, /- 070 2 SPINDLE ASSEMBLY, Complete (Includes Ref. No. 2-) 2 0 BEARING, Ball 0 2 SPACER, Bearing 0 2 SPINDLE HOUSING 0 2 TRASH SHIELD 0702 2 SPINDLE SHAFT 7 02 CAPSCREW, Hex Flange Head, /- x -/ 020 2 MOWER BLADE, -/ 9 029 2 WASHER, USS, / 20 0220 2 CAPSCREW, Hex Head, /- x -/ 2 077 MOWER DECK HOUSING, (Orange) 22 09 CHUTE PIVOT ROD 2 0772 DISCHARGE CHUTE, (Orange) 2 729 2 SPRING, Torsion 2 0 SPRING SPACER Footnotes 29

Hardware Identification & Torque Specifications Common Hardware Types Hex Head Capscrew Washer Torque Specification Chart FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%) Carriage Bolt Lockwasher Hex Nut Standard Hardware Sizing When a washer or nut is identified as /2, this is the Nominal size, meaning the inside diameter is /2 inch; if a second number is present it represent the threads per inch When bolt or capscrew is identified as /2 - x 2, this means the Nominal size, or body diameter is /2 inch; the second number represents the threads per inch ( in this example, and the final number is the body length of the bolt or screw (in this example 2 inches long). The guides and ruler furnished below are designed to help you select the appropriate hardware and tools. 0 / /2 / / /2 / 2 / /2 / / /2 / Screw, /2 x 2 Body Diameter Body Length Nut, /2 Inside Diameter Hardware Grade No Marks SAE Grade 2 SAE Grade SAE Grade Size Of in/lbs in/lbs in/lbs Hardware ft/lbs Nm. ft/lbs Nm. ft/lbs Nm. -2 9 2. 0.. - 20 2...9-2 27..9 0. -2. 9. 7.7 /-20 7..9 2. /-2 7.. 9.0 /-.0 7 2. 2.0 /-2 2. 9 2. 27.0 /- 20 27.2 0 0..2 /-2 2. 7. 0.0 7/- 0 0. 0.0 70 9.2 7/-20 7. 7. 0. /2-0.0 7 2.0 9. /2-20 7. 90 22. 20.2 9/-2. 9. 0 20.0 9/- 7 2.0 20.2 70 2.2 /- 90 22. 0 20.0 220 299.2 /- 0 0 2. 20 2. /- 0 27. 20. 2.0 /- 0 2. 00 0.0 20 7.2 7/-9 0 90. 00.0 00.0 7/- 2. 0 9. 0 97. - 220 299.2 0 7. 900,2.0-2 20 2. 0 70.,000,0.0 NOTES. These torque values are to be used for all hardware excluding: locknuts, self-tapping screws, thread forming screws, sheet metal screws and socket head setscrews. 2. Recommended seating torque values for locknuts: a. for prevailing torque locknuts - use % of grade torques. b. for flange whizlock nuts and screws - use % of grade torques.. Unless otherwise noted on assembly drawings, all torque values must meet this specification. Wrench & Fastener Size Guide / / / 7/ DIA. /2 DIA. / Bolt or Nut Wrench 7/ / Bolt or Nut Wrench /2 / Bolt or Nut Wrench 9/ 7/ Bolt or Nut Wrench (Bolt) / Wrench (Nut) / /2 Bolt or Nut Wrench /