Exmark 4500-466 User Manual

LAZERZ®

ADV ANTAGESERIES

MODELS

ForSerialNos.
790,000&Higher

PartNo.4500-466Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.

Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.

ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada

TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

©2009—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency ,andpromotesafe
operation.

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

3

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................14

ModelNumbers............................................14

Systems.........................................................14

Dimensions...................................................16

TorqueRequirements....................................18

ProductOverview................................................18

Operation.............................................................19

Controls........................................................19

Pre-Start........................................................22

OperatingInstructions..................................22

Transporting.................................................27

Maintenance.........................................................29

RecommendedMaintenanceSchedule(s)...........29

PeriodicMaintenance.......................................30

CheckEngineOilLevel.................................30

CheckMowerBlades.....................................31

CheckSafetyInterlockSystem.......................31

CheckRolloverProtectionsSystems(Roll

Bar)Knobs................................................32

CheckSeatBelt..............................................32

CheckforLooseHardware............................32

ServiceAirCleaner........................................32

ChangeEngineOil........................................33

CheckHydraulicOilLevel.............................33

CheckTirePressures.....................................34

CheckConditionOfBelts..............................34

LubricateGreaseFittings...............................34

LubricateBrakeHandlePivot........................35

LubricateDeckLiftPivot...............................35

CheckSparkPlugs.........................................35

ChangeHydraulicSystemFilterand

Fluid.........................................................35

WheelHub-SlottedNutTorque

Specication..............................................36

CheckEngineCoolantLevel(Kawasaki

Liquid-CooledOnly).................................37

ChangeEngineCoolant(Kawasaki

Liquid-CooledOnly).................................37

CheckSparkArrester(ifequipped).................38

ThreadLockingAdhesives.............................38

Copper-BasedAnti-seize..............................38

DielectricGrease...........................................38

Adjustments.....................................................39

DeckLeveling...............................................39

DeckRemoval...............................................41

PumpDriveBeltTension...............................41

DeckBeltTension........................................41

AdjustingtheParkingBrake...........................41

ElectricClutchAdjustment............................42

MotionControlLinkageAdjustment.............42

MotionControlDamperAdjustment.............43

MotionControlNeutralLockPivot

Adjustment...............................................43

MotionControlHandleAdjustment..............44

MotionControlFullForwardTracking

Adjustment...............................................44

CasterPivotBearingsPre-Load

Adjustment...............................................44

Cleaning...........................................................45

CleanEngineandExhaustSystem

Area..........................................................45

RemoveEngineShroudsandCleanCooling

Fins...........................................................45

CleanHydroFanCoolingGuards..................45

CleanDebrisFromMachine..........................46

CleanGrassBuild-UpUnderDeck................46

WasteDisposal..............................................46

Troubleshooting...................................................47

Schematics...........................................................49

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.

CAUTION

DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

5

Safety

DANGER

Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

•DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.

•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

6

Safety

CAUTION

Fueltankventislocatedinsidetheroll
bartube.Removingormodifyingtheroll
barcouldresultinfuelleakageandviolate
emissionsregulations.

•DoNotremoverollbar.

•DoNotweld,drill,ormodifyrollbarin
anyway.

•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.

Operation

WARNING

Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly .

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

•Removeaccumulateddebrisfrommufer
andenginearea.

•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts
withtherollbarintheraisedandlockedposition.

WARNING

Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

7

Safety

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Wheels
droppingoveredges,ditches,steepbanks,or
watercancauserollovers,whichmayresult
inseriousinjury,deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15
degrees

2.DangerZone-Useawalkbehindmowerand/orhand
trimmeronslopesgreaterthan15degrees,near
drop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandlossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem
(ROPS)

ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.

8

Safety

WARNING

Thereisnorolloverprotectionwhentheroll
barisdown.Wheelsdroppingoveredges,
ditches,steepbanks,orwatercancause
rollovers,whichmayresultinseriousinjury,
deathordrowning.

•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely
necessary.

•DoNotwearseatbeltwhentherollbar
isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance
permits.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,andelectricalwires)before
drivingunderanyobjectsandDoNotcontact
them.

•Intheeventofarollover,taketheunittoan
AuthorizedServiceDealertohavetheROPS
inspected.

•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.

•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.

•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

9

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-633922

1-403005

98-5954

103-2076

10

Safety

109-3148

107-2102

107-2112

109-7232

1.Fast3.Neutral

2.Slow

109-7330

109-7929

4.Reverse

11

Safety

1.Throttle–fast3.Choke–on

2.Throttle–slow

116-0090

109-8483

4.Choke–off

DeckDriveBeltRouting

116-0157

1.SeeOperator’smanual

116-0165

109-9361

109-9477

116-0205

12

116-0211

Safety

116-0906

ForKawasakiLiquid-CooledOnly

116-0752

1.Latch2.Unlatch

MessageDisplay

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresence

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

switch

109-7069

13

Specications

Specications

ModelNumbers

SerialNos:790,000andHigher

LZAS20BV484;LZAS20KC484;LZAS23KC524;LZAS25KC604;LZAS26LKA604;LZAS27KC524;
LZAS27KC604;LZAS29KA724

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•RPM:

–AllunitsexceptLZAS20BV484and

LZAS20KC484:FullSpeed:3750±50RPM
(PTOnotengaged)Idle:1500±100RPM

–LZAS20BV484andLZAS20KC484:Full

Speed:3750+0/-50RPM(PTOnotengaged)
Idle:1500±100RPM

FuelSystem

•Capacity:12.0gal.(45.4L)

•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.

•FuelFilter:

–Briggs&Stratton:

Briggs&StrattonP/N691035

–Kohler:

KohlerP/N2405013

–Kawasaki:

KawasakiP/N49019-7001

•FuelShut-OffValve:

AllUnits:1/4turnincrements(“ON”,“OFF”).

•Fuelleveleightsegmentdisplay—righthand
controlpanel.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

–Briggs&Stratton:16amps
–KohlerandKawasakiAir-Cooled:15amps

–KawasakiLiquid-Cooled:20amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

Allunits:

–25ampmainfuse

–25ampchargingsystemfuse

–10ampPTOfuse

–15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearforthePTO,parkbrake,
drivelevers,andoperatorpresenceinthemessage
displayontheRHcontrolpanel.

•PTOmustbedisengaged,brakeengaged,and
motioncontrolleversout(neutrallock)tostart
engine.(Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,ormotioncontrolleversare
movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or
bothleversaremovedfromneutrallockposition
whilebrakeisengaged.

CoolingSystem(Kawasaki
Liquid-CooledOnly)

•Fan:Continuousoperationwithenginerunning.

•CoolantLiquid:50/50mixofDexCool©
extendedlifeantifreezeandwater.

•CoolantCapacity:3.1quarts

14

Specications

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto
twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe
respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch
(todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•ParkingBrakeReleaseButton:Releasesparking
brake.

•DeckHeightAdjustmentLever:Setscutting
heighttodesiredposition.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

–Unlatchingposition:Deckdoesnotlatchat

thetransportposition.

•Armrests:

–Standardseat:foampaddedadjustableip-up

armrests.

–Suspensionseat:moldedadjustableip-up

armrests.

•SeatSafetySwitch:

Integratedseatswitch.Timedelayseatswitch
eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

12ccParkeraxialpistonpump

240ccParkergerolermotor

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:52oz(1.5L)perside

•HydraulicFilter:P/N116-0164

•Speeds:

–0-10mph(16.1km/hr)forward.

–0-5.5mph(8.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

Tires&Wheels

Seat

•Type:Standardseatwithhighback,extra
widefoampaddedseatcushionwithinternal
suspension,thickbolstering,armrests,integral
safetyswitch.

Optionalseataccessoriesforunitswithstandard
seats:

–Customridesuspensionsystemtoenhance

StandardSeat.Addsapproximately3inches
(7.6cm)toseatheight.

–Deluxesuspensionseatwithhighback,low

prolefoam-in-placecushion(dampened,
adjustablespringsuspension),armrests,and
integralsafetyswitch.Seatheightremainsthe
same.

–SeatIsolationSystemforreducedvibration,

toenhancerideofstandardseat,standardseat
withCustomRideSeatSuspensionorDeluxe
SuspensionSeat.Addsapproximately1inch
(2.5cm)toseatheight.

•Mounting:Adjustableforeandaftonseattracks.

Quantity

Tread

Size(72Deck)

Size(60Deck)

Size(48&52
Decks)

PlyRating

Pressure

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

–72inchDeck:(182.9cm)

•Discharge:Side

DriveFrontCaster

Pneumatic
(Air-Filled)

22

TurfMasterSmooth

24x12.00-1213x6.50-6

24x12.00-1213x5.00-6

24x9.50-1213x5.00-6

4

13psi(90kPa)

Semi-Pneumatic

15

Specications

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•BladeSpindles:Solidsteelspindleswith1.00inch
(25mm)I.D.bearings.

•DeckDrive:

Electricclutch:

–48and52inchDecks:“B”Sectionbeltwith

self-tensioningidler.

–60and72inchDecks:5VSectionbeltwith

self-tensioningidler.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport
frame.Anti-scalprollersprovidemaximumturf
protection.Deckdesignallowsforbagging,
mulchingorsidedischarge.

Dimensions

OverallWidth:

48inchDeck52inchDeck

WithoutDeck45.7inches

(116.1cm)

DeectorUp51.8inches

(131.6cm)

DeectorDown59.6inches

(151.4cm)

60inchDeck72inchDeck

WithoutDeck53.0inches

(134.6cm)

DeectorUp62.5inches

(158.8cm)

DeectorDown72.8inches

(184.9cm)

OverallLength:

45.7inches
(116.1cm)

56.3inches
(143.0cm)

64.8inches
(164.6cm)

59.1inches
(150.1cm)

73.5inches
(186.7cm)

84.9inches
(215.6cm)

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

–60inchDeck:4anti-scalprollers

–72inchDeck:4anti-scalprollers

•DeckDepth:

–48inchDeck:5.5inches(14cm)

–52inchDeck:5.5inches(14cm)

–60inchDeck:5.5inches(14cm)

–72inchDeck:5.5inches(14cm)

•CuttingHeightAdjustment:

Footactivatedleverisusedtoadjustthecutting
heightfrom1inch(2.5cm)to51/2inches(14
cm)in1/4inch(6.4mm)increments.

•MulchingKit:Optional.

48inchDeck52inchDeck

RollBar-Up79.2inches

(201.2cm)

RollBar-Down80.9inches

(205.5cm)

60inchDeck72inchDeck

RollBar-Up83.1inches

(211.1cm)

RollBar-Down84.8inches

(215.4cm)

79.2inches
(201.2cm)

80.9inches
(205.5cm)

86.1inches
(218.7cm)

87.8inches
(223.0cm)

OverallHeight:

RollBar-UpRollBar-Down

70.5inches(179.1cm)46.8inches(118.9cm)

16

Specications

TreadWidth:(CentertoCenterof
Tires,Widthwise)

48inchDeck52inchDeck

DriveWheels36.2inches

(91.9cm)

CasterWheels32.8inches

(83.3cm)

60inchDeck72inchDeck

DriveWheels41.6inches

(105.7cm)

CasterWheels39.5inches

(100.3cm)

36.2inches
(91.9cm)

32.8inches
(83.3cm)

43.6inches
(110.7cm)

47.1inches
(119.6cm)

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

48inch
Deck

48.0inches
(121.9cm)

52inch
Deck

48.0inches
(121.9cm)

60inch
Deck

50.6inches
(128.5cm)

72inch
Deck

53.6inches
(136.1cm)

CurbWeight:

20HP
Briggs&
Stratton
Units

20HP
Kohler
Units

23HP
Kohler
Units

25HP
Kohler
Units

26HP
Kawasaki
Units

27HP
Kohler
Units

29HP
Kawasaki
Units

48inch
Deck

1081lb
(490kg)

1115lb
(506kg)

—

——

——

—

———

52inch
Deck

1108lb
(503kg)

1108lb
(503kg)

60inch
Deck

——

1165lb
(528kg)

1177lb
(534kg)

1165lb
(528kg)

72inch
Deck

—

—

—

1234lb
(560kg)

AccessoryWeightTableWorksheet:

Usethetablebelowtodetermineifextraweight
isrequiredfortheunit.Identifytheaccessories
andcorrectdecksizeandplacethecorresponding
valuesintheAccessoryScorecolumn.IftheTotal
AccessoryScoremeetsthefollowing,addthe
recommendedweightkit.

Note:The72inchdeckdoesnotrequireaweightkit.

48inch

Deck

LightKit

Michigan
Seat/CRSS

Bagger

Pneumatic
Caster
Tires

MulchKit

StriperKit-300

OCD02-6-6-4

HitchKit

Sunshade
Kit

TotalAccessoryScoreRequiredWeightKit(s)

0–9

10–19

20andHigher*Two116-1173Undertoe

11

-3-3-5

*48and52inchunitsthatcomewithanundertoe
boardweightasstandard,canaddanadditionaltoe
boardweightforprimaryaccessoryweighting(scores
10-19);andfronttoeboardweightkitforsecondary
accessoryweighting(scores20andhigher).Other
unitsshouldinstallarstundertoeboardkitfor
primaryaccessoryweighting(scores10-19);anda
secondundertoeboardkitforsecondaryaccessory
weighting(scores20andhigher).

52inch

Deck

222

103

003

7

111

2

TotalAccessoryScore

65

3

60inch

Deck

Nonerequired

*116-1173Undertoe
boardmountweightkit

boardmountweightkits
orone116-1173Undertoe
boardmountweightkit
andone116-1238Front
toeboardmountweightkit

Accessory
Score

2

17

ProductOverview

*60inchunitswhichalreadyhaveanundertoeboard
mountweightasstandardrequires116-1238fronttoe
boardtopmountkitinsteadof116-1173.

TorqueRequirements

BoltLocation

BladeDriveSheave
MountingNut

BladeMountingBolt
(lubricatewithanti-seize)

Anti-ScalpRollerNyloc
NutSeeFigure19

Anti-ScalpRollerHex
CapscrewSeeFigure19

EngineMountingBolts
(Briggs&Stratton20HP)
(Kohler20-27HP)
(Kawasaki26HP
Liquid-Cooled)
(Kawasaki29HP)

WheelLugNuts

WheelMotorMounting
Bolts

Torque

140-145ft-lb(190-197
N-m)

55-60ft-lb(75-81N-m)

30-35ft-lb(41-47N-m)

50-55ft-lb(68-75N-m)

27-33ft-lb(37-45N-m)
27-33ft-lb(37-45N-m)
17-21ft-lb(23-28N-m)
27-33ft-lb(37-45N-m)

90-95ft-lb(122-129N-m)

72-77ft-lb(98-104N-m)

ProductOverview

1.RolloverProtection
System(ROPS)

2.EngineControls(right
console)

3.Seatbelt

4.Motioncontrollevers

Figure4

5.Fuelcap

6.Heightofcutadjustment

7.Parkingbrake

WheelHubSlottedNutminimum200ft-lb

(271N-m)

RolloverProtection
System(RollBar)1/2
inchMountingBolts

ClutchRetainingBolt
(securedwiththreadlocker)

HydroParkBrakeCable
Anchor1/2inchMounting
Bolt(securedwith
threadlocker)

75-80ft-lb(102-108N-m)

55-60ft-lb(75-81N-m)

67-89ft-lb(91-121N-m)

18

Operation

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof
theconsolecontroltheforwardandreversemotion
ofthemachine.

Movingtheleversforwardorbackwardturns
thewheelonthesamesideforwardorreverse
respectively.Wheelspeedisproportionaltothe
amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition
intotheT-slotlocksthemintheneutralposition
(Figure5).

Whenthemotioncontrolleversareintheneutral
position,theLCDindicatorappearsinthemessage
displayontheRHconsole(seeFigure9).

ChokeControl

Locatedonrightconsole(blacklever)(seeFigure6).

Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
rear,tothedetent,willputthechokeinthe“OFF”
position.DoNotrunawarmenginewithchokein
the“ON”position.

Figure6

RightConsole

1.Neutrallockposition
(handlesout)

2.Neutraloperateposition
(handlesin)

3.FrontofUnit

Figure5

4.Forward

5.Neutral(operate)

6.Reverse

1.WarningBuzzer(KawasakiLiquid-CooledOnly)

2.Fuses

3.Moduledisplay

4.Ignitionswitch

5.PTOengagementswitch

6.Throttle

7.Choke

8.Coolanttemperaturegauge(KawasakiLiquid-Cooled
Only)

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe
RHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive
wheels.

19

Operation

Note:TheLCDindicatorappearsinthemessage

displayontheRHconsolewhentheparkbrakeis
engaged(seeFigure9).

Pulltheleverupandrearwardtoengagethebrake.

Depressthereleasebuttonandpushdownwardto
disengagethebrake.

Figure7

1.Releasebutton2.Parkbrake

Theunitmustbetieddownandbrakeengagedwhen
transporting.

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”
and“START”.Insertkeyintoswitchandrotate
clockwisetothe“ON”position.Rotateclockwiseto
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).Allow
thekeytoreturntothe“on”positionimmediately
aftertheenginestarts.

disengagedtostartengine.(Itisnotnecessaryforthe
operatortobeintheseattostarttheengine.)

HourMeter

Locatedontherightconsoleinthemessagedisplay
(seeFigure6andFigure9).

Thehourmeterrecordsthenumberofhoursthat
theenginehasrun.

Figure9

1.LCDIndicators

2.Lowfuelindicatorlight

3.Fuellevelbardisplay

4.Lowvoltageindicatorlight

5.Hour/Voltagedisplay

Hoursarerecordedwhenthekeyisonandtheengine
isrunning(batteryvoltageis12.8Vorhigher)or
whenthekeyisonandtheoperatorisintheseat.

Thehourmeterisrecordingwhenthedecimalpoint
isashinginHour/Voltagedisplay .

Figure8

1.Off3.Start

2.On

Note:Brakemustbeengaged,motioncontrol
leversout(neutrallockposition)andPTOswitch

Hoursaredisplayedwhenthekeyisoffandwhen
themachineisrunning.

Note:Iftheignitionkeyisturnedtothe“ON”
positionforafewsecondsbeforecrankingthe
engine,thebatteryvoltagewilldisplayinthearea
wherethehoursarenormallydisplayed.

Note:TheLCDindicatorsappearwheneach
controlmeetsthe“safetostart”mode(e.g.the
indicatorturnsonwhentheoperatorisintheseat.)

20

FuelShut-OffValve

Locatedbehindandbelowtheseat.

Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate
90°toclose.

Operation

FuelGauge

Locatedontherightconsoleinthemessagedisplay
(seeFigure6andFigure9).

Thefuellevelisshownonabardisplay.Theindicator
lightappearswhenthefuellevelislow(approximately
onegallonremaininginthetank).

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating
drivecomponentsbelowtheenginedeck,
whichcouldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving
partstostopbeforeaccessingthedrivewheel
releasevalves.

WARNING

Theengineandhydraulicdriveunitscan
becomeveryhot.T ouchingahotengineor
hydraulicdriveunitscancausesevereburns.

Figure10

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure10),
rotatethehandle1/4turntotheverticalposition
untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2inFigure10),
rotatethehandle1/4turntothehorizontalposition
untilithitsagainstthestop.

Note:Thehandlemustbehorizontalandagainst
thestopforoperation.

DoNottowmachine.

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades.
Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch
isdisengaged(seeFigure9).

LowVoltageIndicator

Allowtheengineandhydraulicdriveunitsto
coolcompletelybeforeaccessingthedrive
wheelreleasevalves.

Locatedonthebackoftheunitizedhydraulicdrive
units,belowtheenginedeck.

Duringnormaloperatingconditions,thedrivewheel
releasevalvesarepositionedhorizontally.Ifthe
machinehastobepushedbyhand,thevalvesmust
beinthe“released”position(seeFigure10).

Locatedontherightconsoleinthemessagedisplay
(seeFigure6andFigure9).

Alowvoltagecondition(lessthan12.3volts)exists
whentheLCDindicatorappearsonthemessage
displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor
afewsecondsbeforecrankingtheengine,thebattery
voltagewilldisplayintheareawherethehoursare
normallydisplayed.

Note:Theindicatornormallyappearswhenthe
engineisoffandthekeyswitchisturnedtothe
“ON”position.

21

Operation

CoolantTemperatureGauge
(KawasakiLiquid-CooledOnly)

Locatedontherightconsole(seeFigure6).

Thecoolanttemperaturegaugemonitorsthe
temperatureoftheenginecoolant.Duringnormal
operatingconditionsthegaugeshouldbeinthegreen
range.Anengineoverheatingconditioniswhenthe
bardisplaygoestotheyelloworredrangeandan
alarmsounds.RefertotheWarningBuzzersection.

Figure11

1.Green

2.Yellow4.Bardisplay

3.Red

Inthenon-latchingposition,thedeckwill
automaticallyreturntothecuttingheightwhenthe
pedalislowered(seeitem3inFigure12).

Figure12

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

Pre-Start

Fillfueltank.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.

WarningBuzzer(Kawasaki
Liquid-CooledOnly)

Locatedonthesideoftherighthandconsole(see
Figure6).

Thebuzzerisawarningsignalthattheengineis
overheating.SeetheTroubleshootingsection.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe
cuttingdeck.Allowthepedaltomoverearwardto
lowerthecuttingdecktothecutheightthathasbeen
set.

TransportLock

Locatedontheheightofcutadjustmentplatestothe
rightoftheparkingbrake.

Positioninthetransportlatchingpositionto
automaticallylatchthecuttingdeckwhenraisedto
thetransportposition(seeitem1inFigure12).

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch
(13mm)belowthebottomofthellernecktoallow
forfuelexpansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem
(ROPS)

Important:Therollbarisanintegraland

effectivesafetydevice.Keeptherollbarinthe
raisedandlockedpositionwhenoperatingthe
mower.Lowertherollbartemporarilyonlywhen
absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe
tabsinterlockingasshowninFigure13tolock
therollbarintheraised,operateposition.

22

2.Applyforwardpressuretotheupperhoopofthe
rollbar.

3.Pulltheknobandrotate90°toholdinthe
unlatchedpositiontolowertherollbar.

4.Toreturntotheoperateposition,raisetheroll
bar,andthenrotateknobs90°sothatthetabs
interlockpartially.Applyforwardpressuretothe
rollbarupperhoopandobservethattheknobs
returntothecompletelylatchedposition.

Operation

Figure14

1.Engaged2.Partiallyengaged—Do
NotoperatewithROPS
inthiscondition.

Important:Alwaysusetheseatbeltwiththe
rollbarintheoperate(raised)position.Ensure
thattherearpartoftheseatissecuredwiththe
seatlatch.

Figure13

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

5.Makesuretheknobsarefullyengagedwiththe
rollbarintheraisedposition.Theupperhoopof
therollbarmayneedtobepushedforwardor
pulledrearwardtogetbothknobsfullyengaged
(seeFigure14).

OpentheFuelShut-OffValve

Thefuelshutoffvalveislocatedbehindandbelow
theseat.Rotatethevalveandalignwiththefuelline
toopen.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral
lockposition.

2.Pullupandbackontheparkingbrakeleverto
engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage”
position.

Note:Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.

4.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

5.Onacoldengine,pushthechokeleverforward
intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF”
position.

6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting

23

Operation

attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral
lockposition.

4.Engagetheparkingbrake.

5.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalve,locatedbehindand
belowtheseat,whenthemachinewillnotbein
useforafewdays,whentransporting,orwhen
theunitisparkedinsideabuilding.

DrivingtheMachine

CAUTION

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades.
Besurethatallpersonsareclearofthemowerdeck
anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe
PTOcanbeengaged.

1.Setthethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

2.PullthePTOswitchoutwardtoengagethe
blades.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

2.PushthePTOswitchintodisengagetheblades.

Machinecanspinveryrapidlybypositioning
onelevertoomuchaheadoftheother.
Operatormaylosecontrolofthemachine,
whichmaycausedamagetothemachine
orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

Important:Tobeginmovement(forwardor
backward)theoperatormustbeintheseat,the
brakelevermustbedisengaged(pusheddown)
beforethemotioncontrolleverscanbemovedin
ortheenginewillstop.

Whenthemotioncontrolleversarepositionedfully
outward(apart)intheT-slot,thedrivesystemisin
theneutrallockposition(Figure15).

Note:The“N”LCDindicatorappearswhenboth
leversareintheneutrallockposition.

Whenthemotioncontrolleversaremoveddirectly
inward(together)thedrivesystemisintheneutral
operateposition.

24

Figure15

1.Neutrallockposition
(handlesout)

2.Neutraloperateposition
(handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe
centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth
leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever
backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe
motioncontrolleversaremovedfromtheneutral
position.

4.Tostop,positionbothmotioncontrolleversin
theneutraloperateposition.

Operation

Figure16

1.FrontofUnit

2.Forward4.Reverse

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe
neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth
leversrearwardwithequalpressure.

Toturnleftorright,releasepressureonthe
motioncontrollevertowardthedesiredturn
direction.

3.Tostop,positionbothmotioncontrolleversin
theneutraloperateposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted
from1to51/2inches(2.5cmto14cm)in1/4inch
(6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Positionthetransportlockinthelatching
position.

4.Raiseandlockthedecktothe51/2inch(14cm)
transportposition(Figure17).

Thedeckisraisedbypushingthefootoperated
deckliftpedalforward.Thepedalislocatedatthe
frontrightcorneroftheoorpan.

3.Neutral

Note:Whenchangingthecuttingheight
positions,alwayscometoacompletestop
anddisengagethePTO.

25

Operation

Figure18

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

Figure17

1.Deckfootpedal3.Cutofheightdecal

2.Heightadjustmentpin4.Transportlockcontrol

5.Inserttheheightadjustmentpinintothehole
correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor
cutheights.

6.Pushthedeckliftpedal,releasethetransportlock
andallowthedecktolowertothecuttingheight.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockposition.

2.DisengagethePTO.

1.Anti-scalproller
mountingbracket

2.Cuttingheight

ForMaximumDeckFlotation,placetherollers
oneholepositionlower.Rollersshouldmaintain
1/4inch(6.4mm)clearancetotheground.Do
Notadjusttherollerstosupportthedeck.

7.Besuretherollerboltsareinstalledwiththe
springdiscwasherbetweentheheadofthebolt
andthemountingbracket(Figure19).

8.Torquethe3/8–24x2Gr8hexcapscrewto
50–55ft-lb(68–75N-m)(Figure19).

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Adjusttheanti-scalprollersbyremovingthe
bushing,springdiscwasherandbolt.

6.Placetherollersinoneofthepositionsshown
(Figure18).Rollerswillmaintain3/4inch(19
mm)clearancetothegroundtominimizegouging
androllerwearordamage.

26

1.Springdiscwasher
(conetowardsbolthead)

2.Frontrightanti-scalp
bracketshown

Figure19

3.3/8nyloc-torqueto30-35
ft-lb(41-47N-m)

4.3/8-24x2GR8torqueto
50-55ft-lb(68-75N-m)

Operation

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe
machine.Lockbrakeandblockwheels.Securely
fastenthemachinetothetrailerortruckwithstraps,
chains,cable,orropes.Besurethatthetrailerortruck
hasallnecessarylightingandmarkingasrequiredby
law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturn
signals,lights,reectivemarkings,ora
slowmovingvehicleemblem.Drivingona
streetorroadwaywithoutsuchequipment
isdangerousandcanleadtoaccidents
causingpersonalinjury.Drivingonastreet
orroadwaywithoutsuchequipmentmayalso
beaviolationofStatelawsandtheoperator
maybesubjecttotrafcticketsand/ornes.

DoNotdriveaunitonapublicstreetor
roadway.

WARNING

Loadingaunitonatrailerortruckincreases
thepossibilityofbackwardtip-over.
Backwardtip-overcouldcauseseriousinjury
ordeath.

•Useextremecautionwhenoperatinga
unitonaramp.

•Useonlyasingle,fullwidthramp;Do
Notuseindividualrampsforeachside
oftheunit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbroken
rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp
andgroundorbetweenrampandtrailer
ortruck.

•Avoidsuddenaccelerationwhiledriving
unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking
unitdownaramptoavoidtipping
backward.

LoadingaUnit

Useextremecautionwhenloadingunitsontrailersor
trucks.Onefullwidthrampthatiswideenoughto
extendbeyondthereartiresisrecommendedinstead
ofindividualrampsforeachsideoftheunit.The
lowerrearsectionofthetractorframeextendsback
betweentherearwheelsandservesasastopfor
tippingbackward.Havingafullwidthrampprovides
asurfacefortheframememberstocontactifthe
unitstartstotipbackward.Ifitisnotpossibletouse
onefullwidthramp,useenoughindividualrampsto
simulateafullwidthcontinuousramp.

Rampshouldbelongenoughsothattheangles
betweentherampandthegroundandtherampand
thetrailerortruckdonotexceed15°.Asteeperangle
maycausemowerdeckcomponentstogetcaughtas
theunitmovesfromramptotrailerortruck.Steeper
anglesmayalsocausetheunittotipbackward.If
loadingonornearaslope,positionthetraileror
trucksoitisonthedownsideoftheslopeandthe
rampextendsuptheslope.Thiswillminimizethe
rampangle.Thetrailerortruckshouldbeaslevel
aspossible.

27

Operation

Important:DoNotattempttoturntheunit

whileontheramp,youmaylosecontroland
driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp
andsuddendecelerationwhenbackingdownaramp.
Bothmaneuverscancausetheunittotipbackward.

28

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Maintenance

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,
engageparkingbrake,andpullthewire(s)
offthesparkplug(s)beforeyoudoany
maintenance.Alsopushthewire(s)aside
soitdoesnotaccidentallycontactthespark
plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

WARNING

Theenginecanbecomeveryhot.T ouching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

Beforeeachuseordaily

Every50hours

Every100hours

Every200hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkenginecoolantlevel.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrofancoolingguards.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine
Owner’sManualforadditionalinformation.)

•Lubricatethebrakehandlepivot.

•Checkthesparkplugs.

29

Maintenance

MaintenanceService

Interval

Every500hours

Every4,000hours

Yearly

MaintenanceProcedure

•Changethehydrauliclteranduid.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•

Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)

•Greasethedeckandpumpidlerpivots.

•Greasethefrontcasterpivots.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstick
andwipeoiloff.Reinsertthedipstickaccording
totheenginemanufacturer’ srecommendations.
Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow ,wipeofftheareaaroundthe
oilllcap,removecapandlltothe“FULL”
markonthedipstick.Useoilasspeciedin
EngineOwner’ sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe
oillevelbelowthe“LOW”(or“ADD”)markon
thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

batteryperformanceandlife,rechargebatteriesin
storagewhentheopencircuitvoltagedropsto12.4
volts.

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeterorwiththemessagedisplay .Iftheignition
keyisturnedtothe“on”positionforafewseconds,
thebatteryvoltagewillbedisplayedintheareawhere
thehoursarenormallydisplayed.Locatethevoltage
readingofthebatteryinthetableandchargethe
batteryfortherecommendedtimeintervaltobring
thechargeuptoafullchargeof12.6voltsorgreater.

Important:Makesurethenegativebattery
cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).

Voltage
Reading

12.6or
greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

Percent
Charge

100%

Maximum
Charger
Settings

16volts/7
amps

16volts/7
amps

16volts/7
amps

14.4volts/4
amps

Charging
Interval

No
Charging
Required

30Minutes

1Hour

2Hours

Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.T opreserveoptimum

30

Maintenance

Voltage
Reading

11.7–12.00–25%

11.7orless

Percent
Charge

0%

Maximum
Charger
Settings

14.4volts/4
amps

14.4volts/2
amps

Charging
Interval

3Hours

6Hoursor
More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin
theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure21

1.Usewrenchhereforbladeinstallation.Thisnuthas
beentorquedto140–145ft-lb(190–197N-m)

2.Torqueto55-60ft-lb(75-81N-m)Applylubricantto
threadsasneededtopreventseizing.Copper-based
anti-seizepreferable.Greaseacceptablesubstitute.

C.Applylubricanttothreadsofbladeboltto

preventseizing.Copper-basedanti-seize
preferable.Greaseacceptablesubstitute.
Installbladeboltngertight.Placewrench
onthetopspindlenutthentorquetheblade
boltsto55-60ft-lb(75-81N-m).

Figure20

1.Installbushinginbladepriortoinstallingbushingin
spindle.

B.Installbushing/bladeassemblyintospindle.

Makesurethesplinesonthebushingare
engagedinthespindlebeforetighteningthe
bolt.

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith,
parkingbrakeengaged,PTOdisengagedand
motioncontrolleversmovedoutintheneutral

31

Maintenance

lockposition.Theoperatordoesnotneedtobe
intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake
disengaged,PTOdisengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

Trytostartwithoperatorinseat,parkingbrake
engaged,PTOengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

Trytostartwithoperatorinseat,parking
brakeengaged,PTOdisengaged,andtheleft
motioncontrolleverin,startermustnotcrank,
repeatagainwiththerightleverin,thenwith
bothleversin-startermustnotcrank.

2.Checkthekillcircuits.Runengineatone-third
throttle,disengageparkingbrakeandraiseoff
ofseat(butdonotgetoffofmachine)engine
mustinitiateshutdownafterapproximately1/2
secondhaselapsed(seathastimedelaykillswitch
topreventcut-outsonroughterrain).

Runengineatone-thirdthrottle,engagePTO
andraiseoffofseat(butdonotgetoffof
machine)enginemustinitiateshutdownafter
onesecondhaselapsedifthehandlesarein.The
delaywillbe1/2secondifthehandlesareout.

Runengineatone-thirdthrottle,withbrake
disengaged,moveleversinandraiseoffseat(but
donotgetoffofmachine)enginemustinitiate
shutdownafter1/2secondhaselapsed.

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever
in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

Repeatagainmovingtherightleverin,then
movingbothleversin-enginemustinitiate
shutdownafter1/2secondhaselapsedwhether
operatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

CheckRolloverProtections
Systems(RollBar)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe
knobsareingoodworkingcondition.Makesurethe
knobsarefullyengagedwiththeROPSintheraised
position.Theupperhoopoftherollbarmayneed
tobepushedforwardorpulledrearwardtogetboth
knobsfullyengaged.

Figure22

1.Engaged2.Partiallyengaged—Do
NotoperatewithROPS
inthiscondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper
operationofretractorandbuckle.Replacebefore
operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every200hours—Service

theaircleaner.(May
needmoreoftenunder
severeconditions.See
theEngineOwner’s

32

Maintenance

Manualforadditional
information.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Loosenretainingclipsandremoveaircleaner
compartmentcover.

3.Removepaperelement.Checkthecondition
ofthepaperelement.Replaceifdirty,bentor
damaged.

4.Checktheconditionoftheinnerelement.Replace
wheneveritappearsdirty,typicallyeveryother
timethepaperelementisreplaced.Cleanthebase
aroundtheinnerelementbeforeremoving,so
dirtdoesnotgetintotheengine.

5.DoNotwashorusepressurizedairtoclean
paperelementorinnerelement.

6.Reinstallelements.Positionthecoversothatthe
rubberdustejectorispointingdownwardand
securewithretainingclips.

6.Useoilrecommendedinengineowner’smanual.
DoNotoverll.Starttheengineandcheckfor
leaks.

7.Wipeupanyspilledoilfromenginedeck
mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe
hydraulicoil.

3.Slidetheseatallthewayforwardtoaccessthe
capsontheLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand
removecap.

5.Wipethedipstickcleanandre-insertthecapback
intothehydro.Lightlytightenthecap.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours/Yearly
(whichevercomesrst)
(Mayneedmoreoften
undersevereconditions.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseislocatedonrighthandside
ofengineattherear.Placepanundermachine
tocatchoil.Removeplugfromendofdrain
hose.Allowoiltodrainandreplaceoildrainplug.
Torqueplugto20-24ft-lb.

4.Replacetheoilltereveryotheroilchange.Clean
aroundoillterandunscrewltertoremove.
Beforereinstallingnewlter,applyathincoating
ofoilonthesurfaceoftherubberseal.Turn
lterclockwiseuntilrubbersealcontactsthelter
adapterthentightenlteranadditional1/2to
3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.

6.Removethecapagainandcheckthelevelofthe
oilonthedipstick.SeeFigure23foroillevels.

Figure23

1.Full2.Add

Note:Theoillevelonthedipstickwillbe
incorrectiftheoilischeckedwhentheunitishot.

7.Ifthedipstickoillevelisatthe“add”markadd
ExmarkPremiumHydrooil.

8.Replacehydraulicreservoircapandtightenuntil
snug.DoNotovertighten.

33

Maintenance

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Semi-pneumaticcastertiresDoNotneedtobe
inated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

foamlledtiresmaycausefailurestothehydrodrive
system,frame,andothercomponents.Foamlling
tireswillvoidthewarranty.

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removeleftandrightbeltshieldsondeckandlift
upoorpantoinspectdeckdrivebelt.

3.Checkundermachinetoinspectthepumpdrive
belt.

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivots.

3.Lubricatefrontcasterpivotsonceayear.Remove
hexplugandcap.Threadgreasezerkinholeand
pumpwithgreaseuntilitoozesoutaroundtop
bearing.Removegreasezerkandthreadplugback
in.Placecapbackon.

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Note:Noadjustmentsarerequiredforbelt
tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatettingswithonetotwopumpsof
NGLIgrade#2multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

1.Deckand
PumpIdler
Pivots

2.Front
Caster
Pivots

Initial

Pumps

12

*0

Numberof

Places

2

Service

Interval

Yearly

*Yearly

Figure24

1.Sealguard2.Spacernutwithwrench
ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthe
spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly .

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

34

Maintenance

6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkP/N103-0063)mustbe
replaced.

8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontothe
axlewiththewrenchatsfacingoutward.Do
Notthreadspacernutallofthewayontotheend
oftheaxle.Leaveapproximately1/8inch(3mm)
fromtheoutersurfaceofthespacernuttothe
endoftheaxleinsidethenut.

9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
NGLIgrade#1multi-purposegrease.

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

13.T orquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully .

Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely
(morethan1or2revolutions)orhaveanyside
play.Ifthewheelspinsfreely,adjusttorqueon
spacernutuntilthereisaslightamountofdrag.
Reapplythreadlockingadhesive.

LubricateDeckLiftPivot

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype
lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe
engine.Replacewhennecessary.

ReplacementFilters

Briggs&Stratton

Kohler

Kawasaki(Air-Cooled&
Liquid-Cooled)

Note:Itisimportanttoreinstallthefuellinehoses
andsecurewithplastictiesthesameastheywere
originallyinstalledatthefactorytokeepthefuelline
awayfromcomponentsthatcouldcausefuelline
damage.

Briggs&StrattonP/N
691035

KohlerP/N2405013

Kawasaki

P/N49019-7001

ChangeHydraulicSystem
FilterandFluid

ServiceInterval:Every500hours

LubricateBrakeHandlePivot

ServiceInterval:Every200hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatebrakehandlepivotwithaspraytype
lubricantorlightoil.

Note:OnlyuseExmarkHydroFilter–PartNo.
116-0164forsummerorwinter.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

35

Maintenance

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis
importantthatnodirtorcontaminationenterthe
hydraulicsystem.

6.Usingasocket,unscrewlterstoremoveand
allowoiltodrain.

7.Beforeinstallingthenewlters,applyathincoat
ofExmarkPremiumHydrooilonthesurfaceof
thetworubberseals.

unlessitisfelttheoilhasbeencontaminatedorbeen
extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminantsintothesystem.

WheelHub-SlottedNut
TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor
taperedshaft:

1.Removeanddiscardthecotterpin.

2.Torquetheslottednutto200ft-lb(271N-m).

3.Checkdistancefrombottomofslotinnutto
insideedgeofhole.Twothreads(0.1inch)orless
shouldbeshowing.

8.Installthenewltersandtorqueto14ft-lb(19
N-m).

9.FillthehydraulicsystemasstatedinCheck
HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended.
Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro
Oil(Preferred)

Mobil115W50

10.Removethecatchpanandproperlydisposeof
hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

12.Startengineandmovethrottlecontrolaheadto
fullthrottleposition.Movethespeedcontrol
leverstothefullspeedandrunforoneminute.
Shutdownthemachine,allowthehydrostocool
andrecheckoillevel.

13.Removethejackstands.

Note:DoNotchangethehydraulicsystemoil
(exceptforwhatcanbedrainedwhenchanginglter),

ChangeInterval

500Hours

250Hours

Figure25

1.0.1inchmax2.Nomorethantwo
threads(0.1inchmax)
shouldbeshowinghere.

4.Ifmorethantwothreads(0.1inch)areshowing
removenutandinstallwasher(P/N1-523157)
betweenhubandnut.

5.Torquetheslottednutto200ft-lb(271N-m).

6.Thentightennutuntilthenextsetofslotslineup
withthecrossholeinshaft.DoNotloosennut
toaligntheslot.Ifrequired,tightentothenext
setofslots.

7.Installnewcotterpin(P/N1-806800).

Note:DoNotuseanti-seizeonwheelhub.

36

Maintenance

CheckEngineCoolantLevel
(KawasakiLiquid-Cooled
Only)

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Viewcoolantlevelinoverowbottlelocatedat
therightrearoftheenginebelowtheradiator.
Coolantlevelshouldbeattheindicatorlineon
theoverowbottle.

WARNING

Enginecoolantishotandpressurizedand
radiatorandsurroundingpartsarehot.Spray
orsteamfromhot,pressurizedliquidinthe
enginecoolingsystemandtouchingahot
radiatormaycausesevereburns.

ChangeEngineCoolant
(KawasakiLiquid-Cooled
Only)

ServiceInterval:Every4,000hours/Every4

years(whichevercomes
rst)Dex-Cool© ©
lifecoolant(orangecolor)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.Machinemust
bepositionedonlevelsurface.

2.Placeadrainpanunderthedrainplug.

3.Draincoolantwhenengineiscool.Coolantmay
bedrainedfromtheradiatorbyturningthedrain
plugcounterclockwise.

©

extended

Allowtheenginetocoolcompletelybefore
removingtheradiatorcaporservicingany
componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant
cancausepoisoning.

•Donotswallow.

•Keepoutofreachofchildrenandpets.

4.Ifthecoolantlevelislow ,removetheradiator
capandlltothebottomofthellerneck.
Unitsshouldonlybelledwitha50/50mix
ofDex-Cool©extendedlifecoolantandwater.
Dex-Cool©canbeidentiedbyitsorangecolor.

Figure26

1.Coolantdrainplug(blackhead)

2.Oildrainhose

3.Oillter

4.Sparkplug

4.Rotatethedrainplugclockwiseandremovepan.

5.Fillradiatorwitha50/50mixofwaterand
Dex-Cool©coolantasspeciedintheCheck
EngineCoolantLevelsection,allowingsome
room(approximately1/2inch(12.7mm))for
expansion.Add50/50coolantmixtooverow
bottleontherightsideoftheengineasrequired
tobringtheleveluptotheindicatorlineonthe
bottle.

37

Maintenance

WARNING

Enginecompartmentcontainsopenbelt
drives,fans,andotherrotatingcomponents
thatcancauseinjury.Fingers,hands,loose
clothing,orjewelrycangetcaughtbythe
rotatingfananddriveshaft.

•DoNotoperatemachinewithoutthe
coversinplace.

•Keepngers,hands,andclothingclearof
rotatingcomponents.

•Shutoffengine,waitformovingpartsto
stop,engageparkingbrakeandremove
key,beforeperformingmaintenance.

6.Withthecapofftheradiator,starttheengineas
statedintheOperatingInstructionsSection.

7.Operateengineuntiltheenginethermostatopens
andcoolantiscirculatingthroughtheradiator
core.Asairispurgedfromtheengineblockand
thecoolantleveldrops,addadditionalcoolantto
theradiator.

8.Whentheradiatoriscompletelyfullandno
additionalcoolantcanbeadded,continuerunning
andinstalltheradiatorcap.Makesurethatthe
capiscompletelyseatedbypressingdownrmly
whileturninguntilthecapstops.Oncethecapis
installed,theenginemaybestopped.

CheckSparkArrester

(ifequipped)

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved,
replacearrester.

4.Ifpluggingofthescreenisobserved,remove
arresterandshakelooseparticlesoutofthe
arresterandcleanscreenwithawirebrush(soak
insolventifnecessary).Reinstallarresteron
exhaustoutlet.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:

•ROPSspringpinhousing.

•Hydropumpcontrolarm,linkagebolt,and
attachmentbolt.

•Hydrocoolingfanscrew .

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof
enginecrankshaft.

Threadlockingadhesivesarerequiredforsome
hardwareonengines—seetheEnginemanual.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
location:

OnthreadsofBladeBolts.SeeCheckMower
Bladessection.

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite
gasolinevaporsevenaftertheengineis
stopped.Hotparticlesexhaustedduring
engineoperationmayigniteammable
materials.Firemayresultinpersonalinjury
orpropertydamage.

DoNotrefuelorrunengineunlessspark
arresterisinstalled.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

38

Adjustments

Note:DisengagePTO ,shutoffengine,waitfor
allmovingpartstostop,engageparkingbrake,and
removekeybeforeservicing,cleaning,ormakingany
adjustmentstotheunit.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

Maintenance

Figure27

1.Footlever3.Transportlock

2.Cutofheightpin

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper
inationpressurefortiresis13psi(90kPa).
Adjustifnecessary.

4.Positionthetransportlockinthelatching
position.

5.Pushthefootpedalallthewayforwardandthe
deckwilllatchatthe51/2inch(14cm)transport
position(Figure27).

6.Inserttheheightadjustmentpinintothe3inch
(7.6cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedeckto
lowertothecuttingheight.

8.Raisethedischargedeector.

9.Measurefromthelevelsurfacetothefronttipof
thecenterblade.Themeasurementshouldread
3inches(7.6mm).

Note:Inmostconditions,thebacktipsonthe
sidebladesshouldbeadjusted1/4inch(6.4mm)
higherthanthefront.

39

Maintenance

Figure28

1.31/4inches(8.3cm)4.3inches(7.6cm)

2.Backbladetip

3.Frontbladetip

5.Levelsurface

12.Re-measureuntilallfoursidesarethecorrect
height.Tightenallthenutsonthedeckliftarm
assemblies.

13.Lowerdischargedeector.

14.Ifthefourdecklinksdonothaveenough
adjustmenttoachieveaccuratecutheightwiththe
desiredrake,thesinglepointadjustmentcanbe
utilizedtogainmoreadjustment(seeFigure30).

10.Loosenthewhizlocknutonthesideoftheyoke
andthejamnutontop.Finetunethescrew
adjusterbyturningittoget3inch(7.6mm)
height(seeFigure29).

Toincreasetheheight,turntheadjusterscrew
clockwise;todecrease,turncounterclockwise.

Figure29

1.Whizlocknut3.Jamnut

2.Adjusterscrew4.Yoke

Figure30

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

15.T oadjustthesinglepointsystem,rstloosenthe
frontandrearheight-of-cutplatemountingbolts.

16.Ifthedeckistoolow ,tightenthesinglepoint
adjustmentboltbyrotatingitclockwise.If
thedeckistoohigh,loosenthesinglepoint
adjustmentboltbyrotatingitcounterclockwise.

Note:Loosenortightenthesinglepoint
adjustmentboltenoughtomovetheheight-of-cut
platemountingboltsatleast1/3thelengthof
theavailabletravelintheirslots.Thiswillregain
someupanddownadjustmentoneachofthe
fourdecklinks.

17.Re-tightenfrontandrearheight-of-cutplate
mountingbolts.

11.Thebacktipsofthesidebladesshouldmeasure
31/4inches(8.3cm).Finetunerearadjusters
asrequired.

Important:T orquethefrontandrear
height-of-cutplatemountingboltsto27-33
ft-lb(37-45N-m).

18.Repeatsteps9through13.

40

Maintenance

DeckRemoval

Beforeservicingorremovingthedeck,thespring
loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy.
Removingthedeckwithoutreleasingthe
storedenergycancauseseriousinjuryor
death.

DoNotattempttodisassemblethedeck
fromthefrontframewithoutlockingoutthe
storedenergy.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthe
decktotheground.

3.Placetheheightadjustmentpininthe3inch(7.6
cm)cuttingheightlocation.Thislocksthedeck
liftarmsinthelowestpositionwhenthedeckis
removed.

4.Removetheoorpanandbeltshields.

5.Insert1/2inchsocketdriverintothesquarehole
ontheidlerbracketandcarefullyrotatethedeck
idlercounterclockwisetoremovethebelt.

6.Removeandretainthehardwareonbothsidesof
thedeckasshowninFigure31.

7.Disconnectthedeckstrutandpanhardfromthe
deck.

8.Raisethefrontofthemachineandslidethedeck
leftorrighttoremove.

9.Lowerthefrontofthemachine.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move
themotioncontrolleverstotheneutrallocked
positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop,
andremovethekey.

4.Raisethebackofthemachineupandsupportthe
machinewithjackstands.

5.Removethereartiresfromthemachine.

Figure31

1.Panhardrod(rightsideonly)

2.Deckstrut

3.Reardeckliftattachmentshoulderboltandnut.

4.Frontdeckliftattachmentshoulderboltandnut.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothe
“released”position.RefertotheDriveWheel
ReleaseV alvessectioninOperation.

8.Disengagetheparkbrake.

9.Usinghandsandngersonly,pushthecaliper
leverarmtoengagethebrakepadsontherotor
untiltheleverstops.Whileholdingtheleveratthe
stoppedposition,usetheotherhandorngers
topullthecablethreadedendtightthroughthe
swivel.Spinthestandardnutagainsttheswivel
(seeFigure32).

41

Maintenance

16.Installthereartiresandtorquelugnutsto90-95
ft-lb(122-129N-m).

17.Removejackstands.

ElectricClutchAdjustment

Noadjustmentnecessary.

MotionControlLinkage
Adjustment

Locatedoneithersideofthefueltank,belowtheseat
arethepumpcontrollinkages.Rotatingthepump
linkagewitha1/2inchwrenchallowsnetuning
adjustmentssothatthemachinedoesnotmovein
neutral.Anyadjustmentsshouldbemadeforneutral

Figure32

LeftHandBrakeShown

positioningonly.

1.Cableanchor

2.Threadedrod7.Pullcablethreadedrod

3.Pushleverthisdirection8.Holdthreadedrodhere

4.Caliperleverarm9.Swivel(pivothead)

5.Standardnut(shown
againstswivel)

6.Locknut

thisdirection

Notetheorderofthestandardnutandlocknut
(nonutonthecableanchorsideoftheswivel).

10.Releaseholdonthecaliperleverandcable.The
wheelhubshouldturnbyhandinbothdirections
relativetothecaliper;somefriction/resistance
isacceptable.

11.Ifthereisnomovementbetweenthehubrotor
andthecaliperthenbackoffthestandardnutone
turnfromtheswivelandrepeatstep10(drive
releasevalvesmustbeinthe“released”position
onthehydros).

12.Ifthehubrotormovesveryfreelyrelativetothe
caliper,thentightenthestandardnutoneturn
againsttheswivelandrepeatstep10.

13.Oncestep10isachieved,holdthethreadedrod
endwithatoolandtightenthelocknutagainst
thestandardnut.DoNotallowthecabletoturn
whenthenutsaretightened.

14.Rotatethedrivewheelreleasehandletothe
“operating”position.RefertotheDriveWheel
ReleaseV alvessectioninOperation.

15.Repeatontheoppositesideofmachine.

WARNING

Enginemustberunninganddrive
wheelsmustbeturningsomotioncontrol
adjustmentcanbeperformed.Contactwith
movingpartsorhotsurfacesmaycause
personalinjury.

Keepngers,hands,andclothingclearof
rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift
pedalandremovetheheightofcutpin.Lower
decktotheground.

2.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat
safetyswitch,locatedunderthebottomcushion
oftheseat.Theswitchisapartoftheseat
assembly.

4.Temporarilyinstallajumperwireacrossthe
terminalsintheconnectorofthemainwiring
harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine.
Operatordoesnothavetobeintheseat
becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

6.Runtheunitatleast5minuteswiththedrive
leversatfullforwardspeedtobringhydraulicoil
uptooperatingtemperature.

42

Note:Themotioncontrolleverneedstobein
neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral
position.Adjustpumpcontrolrodlengths
byrotatingthedoublenutsontherodinthe
appropriatedirectionuntilthewheelsslightly
creepinreverse(Figure33).Movethemotion
controlleverstothereversepositionandwhile
applyingslightpressuretotheleverallowthe
reverseindicatorspringstobringtheleversback
toneutral.Thewheelsmuststopturningor
slightlycreepinreverse.

Maintenance

Figure34

RHMotionControlShown

1.Torquenylocnutto200in-lb(16.7ft-lb).Boltmust
protrudepastendofnylocnutaftertorque.AT-40T orx
bitwillbenecessarytoholdthestudfromturning.

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

Figure33

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire
harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral
withtheparkbrakesdisengaged.

MotionControlDamper
Adjustment

Thetopdampermountingboltcanbeadjustedto
obtainamoredesiredmotioncontrolleverresistance.
SeeFigure34formountingoptions.

MotionControlNeutralLock
PivotAdjustment

Theangednutcanbeadjustedtoobtainamore
desiredmotioncontrolleverresistance(Figure35).

Figure35

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired
feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

43

Maintenance

MotionControlHandle
Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror
lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto
thecontrolarmshaft(Figure36).

Figure36

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

1.Loosenthescrewsonacoverplate(seeFigure37).

2.Slidethecoverplatebackwardorforwardto
adjustthetraveloftheleverandtightenthe
screws.

3.Drivethemachineandcheckthefullforward
tracking.

4.Repeatsteps1through3untildesiredtracking
isobtained.

Figure37

RHMotionControlShown

1.Screw

2.Coverplate

3.Motioncontrollever

2.Movethecontrollevertothenextsetofholes.
Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol
lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor
maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever
tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe
controlleverforeoraftFigure36.Tightenboth
boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol
lever.

MotionControlFullForward
TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe
motioncontrolleversareinthefullforwardposition,
adjustthecoverplates.

CasterPivotBearings
Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut
untilwashersareatandbackoff1/4ofaturn
toproperlysetthepre-loadonthebearings.If
disassembled,makesurethespringdiscwashersare
reinstalledasshowninFigure38.

44

1.Springdiscwashers

Figure38

Maintenance

Cleaning

CleanEngineandExhaust
SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore
oftenindryordirty
conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair
intakeandexhaustsystemareacancause
engine,exhaustarea,andhydraulicsystem
tooverheatwhichcancreatearehazard.

Cleanalldebrisfromengineandexhaust
systemarea.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake
screen,aroundengineshrouding,andexhaust
systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe
engineandexhaustsystemarea

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removecoolingshroudclean-outcovers(Kohler)
orcoolingshrouds(Kawasaki)fromengineand
cleancoolingns.Alsocleandust,dirtandoil
fromexternalsurfacesofenginewhichcancause
inadequatecooling.

3.Makesurecoolingshroudclean-outcoversor
coolingshroudsarereinstalled.Operatingthe
enginewithoutcoolingshroudclean-outcovers
orcoolingshroudswillcauseenginedamagedue
tooverheating.

CleanHydroFanCooling
Guards

ServiceInterval:Beforeeachuseordaily

45

Maintenance

Removingdebrisfromthehydrofancoolingguards
willallowthehydrosystemtoruncoolerandimprove
thelifeofthehydrosystem.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Slideseatallthewayback,thenlifttheseatto
accesstheLHandRHhydrodrivearea.

3.Removeaccumulateddebrisfromthehydrofan
coolingguards.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe
machineandcuttingdeck,especiallyunderdeck
beltshields,aroundthefueltank,aroundengine
andexhaustarea.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raisedecktothetransport(51/2inch(14cm)
cuttingheight)position.Liftthefrontofunit
andsupportunitusingjackstandsorequivalent
support.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining
thebatteryisnolongeroperatingandisbeing
scrapped,takethebatterytoalocalcertiedrecycling
center.Ifnolocalrecyclingisavailablereturnthe
batterytoanycertiedbatteryreseller.

3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargedeector.

46

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.Donotattempttoserviceorreplacemajor
itemsoranyitemsthatcallforspecialtimingofadjustmentprocedures(suchasvalves,governor,etc.).Have
thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank

Enginewillnotstart,startshard,orfailsto
keeprunning

1.PTOisengaged.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock
position.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

8.Faultymodule.8.Replacemodule.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow.

4.Thethrottleandchokearenotinthe
correctposition.

5.Dirtinfuellter.5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel
system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly .

9.Electricalconnectionsarecorroded,loose
orfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.

13.Faultymodule.13.Replacemodule.

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral
lockposition.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

4.Besurethethrottlecontrolismidway
betweenthe“SLOW”and“FAST”
positions,andthechokeisinthe“ON”
positionforacoldengineorthe“OFF”
positionforawarmengine.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheseatswitchindicator.Replace
seatifneeded.

9.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

11.Clean,adjustorreplacesparkplug.

12.Checkthesparkplugwireconnection.

47

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Engineoverheats.(Coolanttemperature
gaugeisapproachingtheredzoneorwarning
buzzeremitsbeep.)

Mowerpullsleftorright(withleversfully
forward)

Machinedoesnotdrive

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesforthe
engineareplugged.

5.Dirtinfuellter.5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel
system.

1.Temperatureisincreasingoncoolant
temperaturegauge.

2.Coolantlevelislow .

3.Debrisonoraroundradiator.3.Removedebris.

4.Engineloadisexcessive.4.Reducethegroundspeed.

5.Oillevelinthecrankcaseislow.

6.Coolingnsandairpassagesforthe
engineareplugged.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating”
position.

2.Driveorpumpbeltisworn,looseor
broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling
nsandairpassages.

6.ContactanAuthorizedServiceDealer.

1.

RefertoCheckEngineCoolantLevel
sectionintheMaintenance.

2.

RefertoCheckEngineCoolantLevel
sectionintheMaintenance.

5.Addoiltothecrankcase.

6.Removetheobstructionsfromthecooling
nsandairpassages.

1.Positionhandlein“operating”position;
seeDriveWheelReleaseValvessection
inOperation.

2.Changethebelt.

4.Replacethespring.

cooldown.

Unevencuttingheight.

Abnormalvibration

Bladesdonotrotate.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley,orblade
pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Deckbeltisworn,looseorbroken.2.Installnewdeckbelt.

3.Deckbeltisoffpulley.3.Installbeltonclutchanddeckpulleys,

4.Brokenormissingidlerspring.

5.Drivebeltnotroutedcorrectly.5.Refertobeltroutingdecalondeck.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

idlers,andtensioningidlerperrouting
decalondeck.

4.Replacethespring.

48

Schematics

G008587

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

PINK

PINK

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

BLACK

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

1

A B

2 3 1 5 4

1

2

5 4 3 1 2

1

2

1

2

9 1 2 3 1 0 1 8 6 5 11 2 4 7

B

A

7 4 5 9 3 6 8 1 2

C A B

A B

26354

1

1

2

2

1

2

1

2

1

A

B

9

7

4

1 2

3

8

4

1

2
3

5

3

7

1

2

6

8

4

5

B

C

A

3

1

6

4

5

2

5

321

4

A

B

7

1

6

12

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

3

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—Air–Cooled

49

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO

CLUTCH

START RELAY

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW
TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ORANGE

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

PINK

PINK

PINK

PINK

RED

BLACK

PINK

GRAY

BLUE

BLACK

BLACK

BLACK

VIOLET

PINK

PINK

TEMP

SENDER

TERM (1)

TERM (3)

GREEN

BLACK

TERM (2)

TERM (4)

TEMPERATURE

GAUGE

ALARM

PULSE

ALARM

(+)

ORANGE

PINK

PINK

TVS

DIODE

BLACK

BROWN

2 1

1 3 2 4 5 6 7 8

1

A B

2 3 1 5 4

1

2

5 4 3 1 2

1

2

1

2

9 12 3 10 1 8 6 5 11 2 4 7

B

A

7 4 5 9 3 6 8 1 2

C A B

1

1

1

1

1

1

1

1

1

A B

26354

1

G008588

A B

5

321

4

A

B

7

1

6

12

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

2

1

2

1

2

1

A

B

1

2

9

7

4

1 2

3

8

3

7

1

2

6

8

4

5

B

C

A

4

1

2
3

5

3

1

6

4

5

2

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

3

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—Liquid–Cooled

50

ElectricalLogicSchematic—Air-Cooled

BN

BN

BU

BK

Y

W

T

PK

BN

PK

OR

GN

S R

PK PK

PK

LTGR

GY

GY

PK

V

BN V

OR

GN

OR

R

PK

R

BK

GND

PK

BK

BN

BN

BK PK

BK

GND

15A

F4

GY

R

IBA

W

V

BU

V

V

BK

+

S

-

FUEL SENDER

10A

F3

(BRAKE)

SW6

PKOR R

F2

25A

PTO

CLUTCH

BU

1

2

5

4

7

8

(PTO SWITCH)

SW2

25A

F1

(SEAT)

SW7

2

3

5

4

1

K2

(START RELAY)

TVS DIODE

U2

(NEUT_R)

SW5

B+

MAG

REG

START

FUEL

SOLINIOD

AC

STARTER

+

-

AC

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

12

B+

10

KEY_S

9

KEY_A

4

SEAT

11

BRAKE

2

NEUTRAL

3

PTO

5

FUEL

1

START_RELAY

7

MAGNETO

6

FUEL_SOLENOID

8

GROUND

HOUR METER

2

R A

I

A

4

7

1 3

6

5

A

3

SW1

1

B

B

C

B

8

24 5

(IGNITION)

4

6

5

1

KEY SW

OPTIONAL

A

CCESSORIES

2

S

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G008613

Schematics

51

Schematics

2

R A

I

3

1

2

4

A

4

7

4 1

6

5

A

3

1

6

B

C

B

B

8

2 3 5

4

5

1

2

S

SW1

(IGNITION)

KEY SW

Ignition switch terminal locations

viewed from back

OPTIONAL

ACCESSORIES

OFF = no connections

ON = BRIA

START = BRIS

BN

BN

V

BU

BK

Y

W

T

PK

BN

PK

OR

A

R

GN

S I

BK

PK PK

PK

LTGR

OR R GY

GY

PK

PK

GN

OR

PK

BU

BN V

OR OR

PK

PK

BK

PK

BK

BN

BN

BK PK

BK

GND

GY

B R

R

V

V

GN

R

W

V

BU

OS

-

+

TEMP GAUGE

BK

F2

25A

GN

GND

OR

(P)

(+)

(s)

ALARM 2 TONE

(NEUT_R)

SW5

15A

F4

10A

F3

+

S

-

FUEL SENDER

(BRAKE)

SW6

235

4

1

K2

(START RELAY)

PTO

CLUTCH

(NEUT_L)

SW4

12

B+

10

KEY_S

9

KEY_A

4

SEAT

11

BRAKE

2

NEUTRAL

3

PTO

5

FUEL

1

START_RELAY

7

MAGNETO

6

FUEL_SOLENOID

8

GROUND

HOUR METER

25A

F1

1

2

5

4

7

8

(PTO SWITCH)

SW2

(SEAT)

SW7

TVS DIODE

U2

AC-AC

+

MAG

REG

B+

START

STARTER

TEMP SW

IGNITION

MODULES

SPARK PLUG

FUEL

SOLENOID

SPARK PLUG

G008614

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

ElectricalSchematic—Liquid-Cooled

52

HydraulicDiagram

Schematics

53

General Warranty Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company,
pursuant to an agreement between them, jointly warrant on the terms and
conditions herein, that we will repair, replace or adjust any

part on these

products and found by us (in the exercise of our reasonable discretion) to

be defective in factory materials or workmanship.

This warranty may only be assigned or transferred to a second (or third)
owner by an authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.

Commercial Warranty Conditions

This warranty applies to Exmark Lazer Z and Lazer Z AS turf equipment
sold in the U.S. or Canada for a period of three years for commercial
usage.

This warranty includes the cost of parts and labor for a period of two
years and the cost of parts for one additional year. This warranty does not
cover pickup and delivery charges to and from any authorized Exmark
Service Dealer.

Consumer Warranty Conditions

This warranty applies to Exmark Lazer Z and Lazer Z AS turf equipment
sold in the U.S. or Canada for a period of five years or 750 hours
(whichever occurs first) for residential usage.

Residential usage means use of the product on the same lot as your home.
Use at more than one location is considered commercial use, and the
commercial use warranty detailed above would apply.

This warranty only includes the cost of parts and labor. For the first
warrantable service repair, Exmark will cover up to $45 for associated
pick-up and delivery charges to and from any authorized Exmark Service
Dealer. Additional transportation charges may apply, contact your Dealer
for details.

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*
* The Engine warranty is covered by the engine manufacturer. Please

refer to the engine manufacturer’s warranty statement that is included in
the literature packet.

Items and Conditions Not Covered

This warranty does not cover the following:

• Any damage or deterioration due to normal use, wear and tear, or
 exposure.

• Cost of regular maintenance service or parts, such as filters, fuel, 
 lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or required 
 replacement or repair due to normal wear, accidents, or lack of proper
 maintenance.

• Any repairs necessary due to use of parts, accessories or supplies, 
 including gasoline, oil or lubricants, incompatible with the turf 
 equipment or other than as recommended in the operator's manual or 
 other operational instructions provided by Exmark.

There are no other express warranties except for engine and special
emission system coverage.

All warranty work must be performed by an authorized Exmark Service
Dealer using Exmark approved replacement parts.

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase by an
Exmark Service Dealer before obtaining any warranty service.

Contact any Exmark Service Dealer to arrange service at their dealership.
To locate a dealer convenient to you, access our website at
www.exmark.com. U.S. or Canada customers may also call
402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s analysis or
with the assistance provided, contact us at:

 Exmark Customer Service Department
 The Exmark Warranty Company
 2101 Ashland Avenue
 Beatrice, NE 68310
 402-223-6375 or
 [e-mail]

Owner’s Responsibilities

The Exmark Lazer Z or Lazer Z AS equipment, including any defective
part, must be returned to an authorized Exmark service dealer within the
warranty period. This warranty extends only to turf equipment operated
under normal conditions. You must read the operator’s manual. You must
also properly service and maintain your Exmark product as described in
the operator’s manual. Such routine maintenance, whether performed by
a dealer or by you, is at your expense.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect
to this warranty shall be repair or replacement of defective components as
set forth herein. Neither Exmark nor Exmark Warranty Company

shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other extraordinary repair
 charges or charges relating to repairs or replacements outside of 
 normal business hours at the place of business of the authorized 
 Exmark Service Dealer.

• Rental of like or similar replacement equipment during the period of
 any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that covered by the
 terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as  
 a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.

All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.

Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the
above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.

Exmark Lazer Z and Lazer Z AS Turf Equipment

3 Year Limited Commercial Warranty

5 Year or 750 Hours Limited Consumer Warranty

G4500-434

54

Notes:

55

Notes:

56

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

575859

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT RIDING ACCESSORIES AND OP TIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

©2009ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-466Rev.B
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com