Exmark 4500-501 User Manual

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LAZERZ®XS

DIESELMODELS

ForSerialNos. 790,000&Higher

PartNo.4500-501Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Dieselengineexhaustandsomeofits constituentsareknowntotheStateof Californiatocausecancer,birthdefects, andotherreproductiveharm.

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.

Contactusatwww.Exmark.com.

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.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

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

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

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

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

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

Specications.......................................................16

ModelNumbers............................................16

Systems.........................................................16

Dimensions...................................................18

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

ProductOverview................................................19

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

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

Pre-Start........................................................21

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

Transporting.................................................26

Maintenance.........................................................28

RecommendedMaintenanceSchedule(s)...........28

PeriodicMaintenance.......................................29

CheckEngineOilLevel.................................29

CheckBatteryCharge....................................29

CheckMowerBlades.....................................30

CheckSafetyInterlockSystem.......................30

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................31

CheckSeatBelt..............................................31

CheckforLooseHardware............................31

ServiceAirCleaner........................................31

ChangeEngineOil........................................32

CheckHydraulicOilLevel.............................32

CheckTirePressures.....................................32

CheckConditionOfBelts..............................32

LubricateGreaseFittings...............................33

LubricateCasterWheelHubs........................33

LubricateBrakeHandlePivot........................34

LubricateBrakeRodBushings.......................34

LubricateMotionControlBronze

Bushings...................................................34

DrainFuelFilter/WaterSeparator..................34

ChangeFuelFilter/WaterSeparator...............35

ChangeHydraulicSystemFilter.....................35

WheelHub-SlottedNutTorque

Specication..............................................35

CheckEngineCoolantLevel..........................36

ChangeEngineCoolant.................................36

ThreadLockingAdhesives.............................37

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................37

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

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

Adjustments.....................................................38

DeckLeveling...............................................38

PumpDriveBeltTension...............................39

MuleDriveBeltTensionAdjustment.............39

DeckBeltTension........................................40

AlternatorBeltTension.................................40

BeltGuideAdjustment..................................40

BrakeLinkAdjustment..................................40

BrakeAdjustment..........................................41

ElectricClutchAdjustment............................41

ReverseIndicatorAdjustment........................41

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

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

CasterPivotBearingsPre-Load

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

ClutchShim..................................................43

Cleaning...........................................................46

CleanEngineCoolingSystem........................46

RemoveAccumulatedDebrisfromEngine

.................................................................46

CleaningoftheRadiator................................46

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

CleanGrassBuild-UpUnderDeck................47

WasteDisposal..............................................47

Troubleshooting...................................................48

Schematics...........................................................51

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.

Safety

DANGER

Incertainconditionsdieselfuelisextremely ammableandvaporsareexplosive.

Areorexplosionfromdieselfuelcanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anydieselfuelthatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Adddieselfueltothefueltankuntilthe levelis1/4to1/2inch(6–13mm)below thebottomofthellerneck.Thisempty spaceinthetankallowsdieselfuelto expand.

•Neversmokewhenhandlingdieselfuel, andstayawayfromanopenameor wheredieselfuelfumesmaybeignited byspark.

•Storedieselfuelinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Dieselfuelisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleanddiesel tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•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.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

Safety

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

•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.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•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.

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.

•DoNotmowslopesgreaterthan15 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

Safety

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

WARNING

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

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 resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbar isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

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

•Keepengine,enginearea,andpumpdrivebelt compartmentfreefromaccumulationofgrass, leaves,excessivegreaseoroil,andotherdebris whichcanaccumulateintheseareas.These materialscanbecomecombustibleandmayresult inare.

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

Safety

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•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.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Makesureallhydraulicuidhoses andlinesareingoodconditionand allhydraulicconnectionsandttings aretightbeforeapplyingpressureto hydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponents canresultinsystemfailure,fuelleakageand possibleexplosion.

Useonlyapprovedfuellinesandclampsfor highpressuresystems.

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.

1-633706

1-403005

1-513742

98-5954

1-513748

Safety

103-2076

103-0223

103-0261

103-7218

103-1798

107-2102

Safety

107-2112

109-1399

109-0872

109-2219

109-1214

109-2263

109-1215

Safety

109-2264

109-2478

109-2951

109-3148

Safety

116-0997

109-6855

109-7949

19426-87881

116-0127

19426-87903

116-0404

Safety

107-9866

1.Fast

2.Slow

3.Neutral4.Reverse

Specications

ModelNumbers

SerialNos:790,000andHigher

LXS25KD605;LXS25KD665;LXS25KD725

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3850±50RPM(NoLoad) Idle:1400RPM

FuelSystem

•Capacity:15.5gal.(58.6L)

•TypeofFuel:Dieselfuel,40cetaneorhigheror biodieseluptoB20(20%biodiesel,80%petro diesel).

•FuelFilter:In-line113Micron ExmarkP/N112-7836.

•FuelShut-OffValve:1/4turnincrements (“OFF”,righttank,lefttank,)

•Fuelgaugeinlefthandfueltank.

ElectricalSystem

•ChargingSystem:ExternalAlternator

•ChargingCapacity:60amps

•BatteryType:BCIGroup26

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:One20ampbladetype;One30ampblade type

SafetyInterlockSystem

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

CoolingSystem

•Fan:Electricwithcontinuousoperationwith enginerunning.

•CoolantLiquid:50/50mixofDexCool© extendedlifeantifreezeandwater.

•CoolantCapacity:4quarts

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftAssistLever:Footpedalthatassists inraisingthedeck.

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

Seat

•Type:Deluxesuspensionseathighback,low prolefoam-in-placecushion(dampened, adjustablespringsuspension)andarmrests, adjustablebackangle.

Specications

•Mounting:Hingedtotiltupforaccessto hydraulicpumps,batteryandothercomponents. Heldintiltedpositionwithscissor—typelinks. Adjustableforeandaftseattrack.

•Armrests:Moldedadjustableip-uparmrests.

•SeatSafetySwitch:Incorporatedintothe SafetyInterlockSystem.Timedelayseatswitch eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearPW variabledisplacementpistonpumps.

•WheelMotors:TwoParker/Rosswith11/4inch taperedshafts.

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:5.5qt.(5.2L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–0-12.0mph(19.3km/hr)forward.

•Discharge:Side

•BladeSize:(3ea.)

–60inchDeck:20.75inches(52.7cm)

–66inchDeck:22.75inches(57.8cm)

–72inchDeck:24.75inches(62.9cm)

•BladeSpindles:Solidsteelspindleswith1.18inch (30mm)I.D .bearings.

•DeckDrive:

–Electricclutchmountedonhorizontalengine

shaft.“B”Sectionbelt(withself-tensioning idler)fromelectricclutchtotransfershaft mountedondeck.

–Bladesaredrivenbyone“B”Sectionbelt

(w/self-tensioningidler)fromtransfershaft ondecktobladespindles.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport frame.Sixanti-scalprollersprovidemaximum turfprotection.Deckdesignallowsforbagging, mulchingorsidedischarge.

–0-8.0mph(12.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

Pneumatic (Air-Filled)

DeckSize

Quantity

TreadSize

Size26x12.00-1213x6.50-6

PlyRating

Pressure

60,66,&72

“Multi-Trac C/S”

10psi(69kPa)

Semi-Pneumatic

AllDecks

Smooth

CuttingDeck

•CuttingWidth:

•DeckDepth:

–60inchDeck:6.0inches(15.2cm)

–66inchDeck:6.0inches(15.2cm)

–72inchDeck:6.0inches(15.2cm)

•CuttingHeightAdjustment:

Anextra-longcushionedleverisusedtoadjust thecuttingheightfrom1inch(2.5cm)to5inches (12.7cm)in1/4inch(6.4mm)increments.The cuttingheightadjustmenthandlehasatransport positionandalladjustmentscanbemadewhile theoperatorremainsseated.Unitsalsohavea footoperateddeckliftassistlevertoaidinraising thedeck.

•MulchingKit:Optional.

–60inch(152.4cm)

–66inch(167.6cm)

–72inch(182.9cm)

Specications

Dimensions

OverallWidth:

Without Deck

Deector Up

Deector Down

OverallLength:

RollBarUp

RollBarDown

60inch Deck

53.5inches (135.9cm)

61.4inches (156.0cm)

72.8inches (184.9cm)

60inch Deck

81.9inches (208.0cm)

92.5inches (235.0cm)

66inch Deck

57.3inches (145.5cm)

68.0inches (172.7cm)

79.4inches (201.7cm)

66inch Deck

83.4inches (211.8cm)

94.0inches (238.8cm)

72inch Deck

61.5inches (156.2cm)

74.3inches (188.7cm)

85.8inches (217.9cm)

72inch Deck

85.8inches (217.9cm)

96.4inches (244.9cm)

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

CutterHousingSpindle Nut

BladeMountingBolt (lubricatewithanti-seize)

EngineDeck/FrontFrame MountBolts

Anti-ScalpRollerNyloc NutSeeFigure10

Anti-ScalpRollerHex CapscrewSeeFigure10

EngineMountingBolts

WheelLugNuts

WheelMotorMounting Bolts

WheelHubSlottedNutminimum125ft-lb

Torque

90-110ft-lb(122-149N-m)

160-185ft-lb(217-251 N-m)

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

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

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

15-20ft-lb(20-27N-m)

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

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

(169N-m)

OverallHeight:

RollBar-UpRollBar-Down

72.7inches(184.7cm)53.8inches(136.7cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

Drive Wheels

Caster Wheels

60inch Deck

41.9inches (106.4cm)

37.3inches (94.7cm)

66inch Deck

45.9inches (116.6cm)

42.3inches (107.4cm)

72inch Deck

45.9inches (116.6cm)

47.3inches (120.1cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

60inchDeck66inchDeck72inchDeck

56.0inches (142.2cm)

57.6inches (146.3cm)

60.2inches (152.9cm)

RolloverProtectionSystem (RollBar)MountingBolts

DeckDriveJackshaftNut

ClutchRetainingBolt (securedwiththreadlocker)

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

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

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

CurbWeight:

60inchDeck66inchDeck72inchDeck

1545lb(701kg)1595lb(723kg)1645lb(746kg)

Operation

ProductOverview

1.MotionControlLever5.Controls

2.ParkingBrakeLever

3.Height-of-CutLever

4.FuelCap(BothSides)

Figure4

6.SeatBelt

7.RollBar

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideofthe consolecontroltheforwardandreversemotionof themachine.Theleverscontroltheowofhydraulic oilfromthehydrostaticpumptothedrivewheel motorforeachside.

Movingtheleversforwardorbackwardturnsthe wheelonthesamesideforwardorinreverse.Wheel speedisproportionaltotheamounttheleveris moved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (Figure6).

ThrottleControl

Locatedonrightfueltank.

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonleftsideofunit,justtothefrontofthe console.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightfueltank.

Theignitionswitchisusedtostartandstopthe engine.Theswitchhasthreepositions“OFF”,“ON”

Operation

and“START”.Insertkeyintoswitchandrotate clockwisetothe“ON”position.Rotateclockwiseto thenextpositiontoengagethestarter(keymustbe heldagainstspringpressureinthisposition).

Note:Brakemustbeengaged,motioncontrollevers out(neutrallockposition)andPTOswitch“OFF”to startengine.(Itisnotnecessaryfortheoperatorto beintheseattostarttheengine.)

HourMeter

Locatedontherightfueltank.

Thehourmeterisconnectedtoapressureswitch installedintheengineblockanditrecordsthe numberofhoursthattheenginehasrun.Ifthe ignitionswitchisleftonwithoutenginerunning, hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locateddirectlybelowtherightsideofconsole,next tothecubby.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Thevalvehasthreepositions,eachpositionmade in1/4turnincrements.

FuelFlowValveHandlePosition

“Off”Right

RightTank

LeftTankLeft

Down

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe pushedwithouttheenginerunning.Unhookseat latchandtiltseatuptogainaccesstopumps.

Witha5/8inchwrench,turnbothvalvesoneturn counterclockwisetoreleasedrivesystem.Turn clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

TrackingAdjustmentKnob

LocatedundertheseatontheLHpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso thatthemachinetracksstraightwiththedrivelevers inthefullforwardposition.

Stopmachineandwaitforallmovingpartstostop. Engageparkbrake.Unhookseatlatchandtiltseat forwardtogainaccesstothetrackingknob.Rotate theknobclockwise(asviewedfromtherearofthe machine)tocausethemachinetotrackmoretothe rightandcounterclockwisetocausethemachine totrackmoretotheleft.Adjustinquarter-turn incrementsuntilthemachinetracksstraight.Check thatthemachinedoesnotcreepwheninneutralwith theparkbrakedisengaged.

Important:DoNotrotatetheknobtoofar,as thismaycausethemachinetocreepinneutral. RefertotheMotionControlLinkageAdjustment sectioninMaintenance.

PTOEngagementSwitch

Locatedonrightfueltank.

Switchmustbepulledouttothe“ROTATE” positiontoengagetheblades.Switchispushedinto the“STOP”positiontostoptheblades.

FuelGauge

Locatedontheleftfueltank.

Thefuelgaugemonitorstheamountoffuelintheleft tankonly.Usethefuelfromtherightfueltankrst. Whentherightfueltankisempty,switchtotheleft fueltank.Fuelgaugewillmonitortheremainingfuel.

DriveWheelReleaseValves

Locatedonthetoprightfrontcornerofhydrostatic pumps.

CoolantTemperatureGauge

Locatedatthefrontoftheleftfueltank.

Thecoolanttemperaturegaugemonitorsthe temperatureoftheenginecoolant.Anengine overheatingconditionisindicatedbytheredarea onthegaugeandanalarmwillsound.Refertothe WarningBuzzerintheTroubleshootingsection.

Voltmeter

LocatednexttotheCoolantTemperatureGaugeat thefrontoftheleftfueltank.

Operation

Thevoltmetermeasurethevoltageoutputofthe alternator.Bothhighandlowvoltageswillpotentially damagethebattery.

GlowPlugSwitchandLight

Locatedontherightfueltank.

Depressandholdtheswitchtoheattheglowplugs. Theglowpluglightcomesonwhentheglowplug switchisdepressed.Theglowpluglightindicatesthe glowplugsarepreheatingthecombustionchamber.

LowOilPressureLight

Locatedontherightfueltank.

Lightwillcomeonwhenengineoilpressureislow orlost.

WarningBuzzer

Locatedbehindtheseatundertheairdeectoron theelectricalpanel.

Thebuzzerisawarningsignalthattheengine isoverheatingortheoilpressureislow .Seethe Troubleshootingsection.

Useofsummergradedieselfuelabove20°F(-7°C) willcontributetowardlongerlifeofthepump components.

Important:DoNotusekeroseneorgasoline insteadofdieselfuel.Failuretoobservethis cautionwilldamagetheengine.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuel ofuptoB20(20%biodiesel,80%petrodiesel).The petrodieselportionshouldbeloworultralowsulfur.

Observethefollowingprecautions:

•Thebiodieselportionofthefuelmeet specicationASTMD6751orEN14214.

•Theblendedfuelcompositionshouldmeet ASTMD975orEN590.

•Paintedsurfacesmaybedamagedbybiodiesel blends.

•UseB5(biodieselcontendof5%)orlesserblend incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuel astheymaybedegradeovertime.

Pre-Start

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

DeterminingFuel

Theenginerunsonclean,freshdieselfuelwith aminimumoctaneratingof40.Purchasefuelin quantitiesthatcanbeusedwithin30daystoensure fuelfreshness.

Usesummergradedieselfuel(No.2-D)at temperaturesabove20°F(-7°C)andwintergrade dieselfuel(No.1-DorNo.1-D/2-Dblend)below 20°F(-7°C).Useofwintergradedieselfuelatlower temperaturesprovideslowerashpointandpour pointcharacteristics,thereforeeasingstartabilityand lesseningchancesofchemicalseparationofthefuel duetolowertemperatures(waxappearance,which maypluglters).

•Fuellterpluggingmaybeexpectedforatime afterconvertingtobiodieselblends.

•Contactyourdistributorifyouwishformore informationonbiodiesel.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundeachfueltankcapandremovethe cap.Addfueltobothfueltanks,untilthelevelis 1/4to1/2inch(6to13mm)belowthebottom ofthellerneck.Thisspaceinthetankallows thefueltoexpand.DoNotllthefueltanks completelyfull.

3.Installfueltankcapssecurely.Wipeupanyfuel thatmayhavespilled.

4.Ifpossible,llthefueltankaftereachuse.This willminimizepossiblebuildupofcondensation insidethefueltank.

Operation

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand installthetwopinsandsecurethemwiththe hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.Ensurethatthe rearpartoftheseatissecuredwiththeseat latch.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushinonthePTOswitchtothe“STOP” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

4.Onawarmengine,placethethrottleinthe “SLOW”position.

5.Onacoldengine,(below14°F(-10°C)),placethe throttleinthe“MIDWAY”position.

Note:DoNotusefuelleftoverfromsummer.

6.Turnignitionswitchtothe“ON”position. Depresstheglowplugswitchandtheglowplug lightwillturnon.Holdswitchasrequiredby chartbelow.Turntheignitionswitchtothe “START”position.Releasetheignitionswitchas soonastheenginestarts.

GlowPlugChart

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

TurnthevalvetotheLHorRHtank.

AmbientTemperature

Above50°F(10°C)

50°F(10°C)to23°F(-5°C)

Below23°F(-5°C)

Limitofcontinuoususe

HoldGlowPlugsOn

NONEED

Approximately5seconds

Approximately10seconds

20seconds

Theglowpluglight,locatedneartheglow plugswitch,willilluminatewhentheswitchis depressed.Theglowpluglightindicatestheglow plugsarepreheatingthecombustionchamber.

Important:DoNotcranktheengine continuouslyformorethentensecondsata time.Iftheenginedoesnotstart,allowa30 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotorand/orfuel solenoid.

7.Movethethrottletothe“SLOW”(ifin “MIDWAY”)andlettheenginewarmupafew minutesbeforemovingthethrottletothe“FAST” position.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

Operation

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunless thereisagrasscollectionsystemormulch kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

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

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE” position.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral lockposition.

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

WhenleversarecenteredintheT-slotthedrive systemisintheneutralposition.Withleversmoved outintheT-slotthedrivesystemisintheneutrallock position(Figure6).

4.Engagetheparkingbrake.

Operation

Figure6

1.HandlesOut(Neutral Lock)

2.HandlesIn(Neutral)

3.FrontofUnit

4.Forward

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralunlockedposition.

3.Tomoveforwardinastraightlineapplyequal forwardpressuretobothlevers.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedawayfrom neutral.

4.Tostop,pullthemotioncontrolleversbackto theneutralposition.

5.Neutral

6.Reverse

7.NeutralLock

Figure7

1.HandlesOut(Neutral Lock)

2.HandlesIn(Neutral)

3.FrontofUnit

4.Forward

5.Reverse

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe centertotheneutralunlockedposition.

2.Tomoverearwardinastraightlineapplyingequal pressurepullbothmotioncontrolleversrearward.

Toturnleftorright,releasepressureonthe motioncontrollevertowardthedirectiondesired.

3.Tostop,pushthemotioncontrolleverstothe neutralposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from1to5inches(2.54cmto12.7cm)in1/4inch (6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Raisethedeckheightlevertothetransport position(alsothe5inch(12.7cm)cuttingheight position)(Figure8).

Thedeckcanberaisedbypullingthedecklever upand/orbypushingdownonthefootoperated

Operation

deckliftassistleverlocatedatthefrontright corneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure8

1.Leverintransportand5inch(12.7cm)cuttingheight position

4.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheightand installthehairpincotterpin.

Seethedecalonthesideofthedeckliftplatefor cutheights.

5.Movethedeckheightleveroutofthetransport position(or5inch(12.7cm)cuttingheight)and downontotheheightadjustmentpintomowat selectedheight.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

6.Placetherollersinoneofthepositionsshown (Figure9).Rollerswillmaintain3/4inch(19mm) clearancetothegroundtominimizegougingand rollerwearordamage.

Figure9

Forcuttingheightsabove4.0inches(102mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Besuretherollerboltsareinstalledwiththe springdiscwasherbetweentheheadofthebolt andthemountingbracket.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

8.Torquethe3/8–24x2Gr8hexcapscrewto 50–55ft-lb(68–75N-m)(Figure10).

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingtheboltandspring discwasher.

Operation

Figure10

1.Springdiscwasher (conetowardsbolthead)

2.Frontrightanti-scalp bracketshown

9.Ifthe3/8nylocnuthasbeenremoved, re-installandtorqueto30–35ft-lb(41–47N-m) (Figure10).

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

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

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.

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.

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.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Operation

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitchand engageparkingbrake,beforeyoudoany maintenance.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Aftertherst250hours

Beforeeachuseordaily

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkenginecoolantlevel.

•Cleantheenginecoolingsystem.

•Removeaccumulateddebrisfromengine.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

WARNING

Theenginecanbecomeveryhot.Touching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Every40hours

Every50hours

Every100hours

Every160hours

Every200hours

Every400hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheheightadjustmentshaftbearings.

•Greasethereardeckstruts.

•Drainfuellter/waterseparator.

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

•Cleantheenginecoolingsystem.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

•Greasethebrakebrackets.

•Replacethefuellter/waterseparator(moreoftenindirtyordustyconditions).

Maintenance

MaintenanceService

Interval

Every500hours

Every600hours

Every4,000hours

Monthly

Yearly

PeriodicMaintenance

CheckEngineOilLevel

MaintenanceProcedure

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Replacetheaircleanerelements.(Mayneedmoreoftenundersevereconditions.Seethe EngineOwner’sManualforadditionalinformation.)

•

Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)

•Checkthebatterycharge.

•Changetheengineoilifoperatedlessthan100hours.

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

•Greasethemuledrivebeltidlerarm.

•Greasethepumpdrivebeltidlerarm.

•Lubricatethecasterwheelhubs.

CheckBatteryCharge

ServiceInterval:Monthly

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Raiseradiatortogainaccesstodipstick.

CAUTION

Iftheradiatorproprodisnotsecurely positionedinthenotchtheradiatormayfall. Fallingradiatorcouldcauseseriousinjury.

Besuretheproprodisengagedsecurelyin thenotchatthefarrightsideoftheslot.

4.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.Removethedipstick andreadtheoillevel.

5.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.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.Topreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebattery inthetablebelowandchargethebatteryforthe recommendedtimeintervaltobringthechargeupto afullchargeof12.6voltsorgreater.

Important:Makesurethenegativebattery cablesaredisconnectedandthebatterycharger

Maintenance

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%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure12

1.Usewrenchherefor bladeinstallation.This nuthasbeentorquedto 90–110ft-lb(122–149 N-m)

2.T orqueto55-60ft-lb (75-81N-m)Apply lubricanttothreads asneededtoprevent seizing.Copper-based anti-seizepreferable. Greaseacceptable substitute.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based anti-seizepreferable.Greaseacceptable substitute.Installbladeboltngertight.Place wrenchonthetopspindlenutthentorquethe bladeboltsto55-60ft-lb(75-81N-m).

2.Liftdeckandsecureinraisedpositionasstated intheCleanGrassBuild-UpUnderDeck procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure11

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

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

Maintenance

motioncontrolleversmovedoutintheneutral 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 1/2secondhaselapsed.

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

Again,runengineatone-thirdthrottle,brake engaged,andmoveleftmotioncontrolleverin

-enginemustinitiateshutdown.

Repeatagainmovingtherightleverin,then movingbothleversin-enginemustinitiate shutdownwhetheroperatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckRolloverProtections Systems(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

Makesurelatchpinandhairpinarefullyinstalled andlanyardisingoodcondition.

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:Every50hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See theEngineOwner’s Manualforadditional information.)

Every600hours—Replace theaircleanerelements. (Mayneedmoreoften undersevereconditions. SeetheEngineOwner’s Manualforadditional information.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhooktwoairltercanisterlatchestogain accesstotheaircleanerelement.

3.Removeaircleanercanistercoverandremove outerelement.

4.Checktheconditionofthepaperelement. Replaceifdirty,bentordamaged.

Maintenance

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

6.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

Yearlyifoperatedless than100hours.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.UseExmark PremiumHydrooil.Replacehydraulicreservoir capandtightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.

2.Drainoilwhileengineiswarmfromoperation.

3.Fastendeckbeltspanstogetherwithmechanics wireortiewraptopreventoilfromdrainingonto belt.

4.Placepanundermachinetocatchoil.Remove theoildrainplug.Allowoiltodrainandreplace oildrainplug.

5.Replacetheoilltereveryotheroilchange.Clean aroundoillterandunscrewltertoremove. Beforereinstallingnewlter,applyathincoating ofoilonthesurfaceoftherubberseal.Turn lterclockwiseuntilrubbersealcontactsthelter adapterthentightenlteranadditional1fullturn.

6.Unlatchradiatorandliftituptoaccessoilll. Cleanaroundoilllcapandremovecap.Fill tospeciedcapacityandreplacecap.Useoil recommendedinengineowner’smanual.DoNot overll.

7.Removewireortiewrapfrombeltspans

8.Starttheengineatidlefor5minutes.Stopengine andwaitthreeminutes,thenchecktheoillevel. Ifrequired,addoiltobringleveltothe“FULL” markonthedipstick.DoNotoverll.

9.Checkforleaks,includingaroundtheoillter.

10.Wipeupanyspilledoil.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto10psi(69kPa).

4.Semi-pneumaticcastertiresdonotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.Removethe airdetectorpanelonfrontsideoftheengine compartmenttocheckpumpdrivebeltand alternatorbelt.

3.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

4.Checkundermachinetoinspectthemule drivebelt.RefertoMuleDriveBeltTension AdjustmentsectioninAdjustments.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.Front Casterwheel hubs

2.Front Caster Pivots

3.Height Adjustment Shaft Bearings

4.Deck DriveBelt IdlerArm

5.Brake Brackets

6.Mule DriveBelt IdlerArm

7.Pump DriveBelt IdlerArm

8.Deck RearStruts

*Seestep3forspeciallubricationinstructionson thefrontcasterpivotsandtheLubricateCaster WheelHubssectionforspeciallubrication instructionsonthefrontcasterswheelhubs.

Initial

Pumps

Numberof

Places

540Hours

Service

Interval

*Yearly

Yearly

200Hours

Yearly

40Hours

Maintenance

Number6(MuleDriveBeltIdlerArm)Located

UnderEngineFrame

Number7(PumpDriveBeltIdlerArm)Located

UnderEngineFrame

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

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure13

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

Maintenance

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

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.Torquethenutto75-80in-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.

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandlepivot withaspraytypelubricantorlightoil.

LubricateBrakeRod Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake rodshaftwithaspraytypelubricantoralightoil (bushingsarelocatedtotheinsideoftheange bearings).

LubricateMotionControl BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings securingthemotioncontrolarmshaftswitha lightoiloraspraytypelubricant.

DrainFuelFilter/Water Separator

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Placeadrainpanunderthefuellterandloosen thedrainplugapproximately1turn.

3.Watershoulddrain.

4.Whenfuelbeginstoowfromthelter,tighten thedrainplug.

Important:Waterorothercontaminantsinfuel canseverelydamagefuelpumpand/ortheother enginecomponents.

Maintenance

ChangeFuelFilter/Water Separator

ServiceInterval:Every400hours/Yearly

(whichevercomesrst) (moreoftenindirtyor dustyconditions).

DANGER

Useofimpropercomponentscanresultin systemfailure,fuelleakageandpossible explosion.

•EnsurethatanAuthorizedServiceDealer replacethefuellterandanycomponents forthefuelsystem.

•Useonlyapprovedfuellines,hoseclamps andfuelltersforhighpressuresystems.

ChangeInlineFuelFilter

ServiceInterval:Asrequired

Aninlinefuellterisinstalledbetweenthefueltank andthefuelpump.Replacewhennecessary.

Important:Beforereinstallingnewlter,ll itwithExmarkPremiumHydrooilandapply athincoatofoilonthesurfaceoftherubber seal.

Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.

5.FillreservoirasstatedinCheckHydraulicOil Levelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

7.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol leverstothefullspeedandrunforseveral minutes.Shutdownmachineandrecheckoil level.

ChangeInterval

500Hours

250Hours

ReplacementFilters

ExmarkP/N112-7836

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearlyif usingMobil115W50)

Note:UseonlyExmarkP/N103-2146.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raiseseat.

3.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

4.Unscrewltertoremoveandallowoiltodrain fromreservoir.

Note:DoNotchangehydraulicsystemoil(except forwhatcanbedrainedwhenchanginglter),unless itisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor taperedshaft:

1.Torquetheslottednutto125ft-lb(169N-m).

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

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

Maintenance

4.Torquetheslottednutto125ft-lb(169N-m).

5.Thentightennutuntilthenextsetofslotslineup withthecrossholeinshaft.

6.Replacecotterpin.

Note:DoNotuseanti-seizeonwheelhub.

CheckEngineCoolantLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Viewcoolantlevelinoverowbottleontheleft sideoftheenginecompartment.Coolantlevel shouldbeattheindicatorlineontheoverow bottle.

4.Ifthecoolantlevelislow,openhoodorraise radiator,removethecaptotheoverowbottle andlltotheindicatorline.Unitsshouldonlybe lledwitha50/50mixofDex-Cool©extended lifecoolantandwater.Dex-Cool©canbe identiedbyitsorangecolor.

ChangeEngineCoolant

ServiceInterval:Every4,000hours/Every4

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

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

2.Unhookseatlatch,tiltseatupandtilthood forwardtogainaccesstothecoolingarea.Do Notraiseradiator,asitmaynotfullydraininthat position.

extended

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Spray orsteamfromhot,pressurizedliquidinthe enginecoolingsystemandtouchingahot radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Spray orsteamfromhot,pressurizedliquidinthe enginecoolingsystemandtouchingahot radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant cancausepoisoning.

•DoNotswallow.

•Keepoutofreachofchildrenandpets.

CAUTION

Enginecoolantistoxic.Swallowingcoolant cancausepoisoning.

•DoNotswallow.

•Keepoutofreachofchildrenandpets.

3.Draincoolantwhenengineiscool.Coolantmay bedrainedfromtheradiatorbyremovingthe drainplugintherightrearcorner.Theengine blockmaybedrainedbyremovingtherear radiatorhoseand/orbyopeningthedraincock ontheright-handsideoftheengineblock(see Figure14).

Maintenance

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

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

FuelTank—Mounting

Figure14

1.Oildipstick

4.Reinstallalldrainplugsandhosesandtighten draincock.

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

2.Draincock

WARNING

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

HardwareSpecications

ServiceInterval:Asrequired

Wheninstallingthenutsonthefueltankstuds,fully tightenthenylocnutandbackoff1/2turn.This allowsfornormalfueltankexpansionandcontraction withchangesintemperatureandfuellevels.

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol arms.

•Sheaveretainingboltintheendofengine crankshaft.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

•Boltsretainingstubshafttoengineywheel.

•DoNotoperatemachinewithoutthe coversinplace.

•Keepngers,hands,andclothingclearof rotatingcomponents.

•Shutoffengine,waitformovingpartsto stop,engageparkingbrakeandremove key,beforeperformingmaintenance.

6.Withthecapofftheradiator,tilthoodclosedand puttheseatdown.Starttheengineasstatedin theOperatingInstructionsSection.Returnthe seatupandhoodforwardtotheopenposition.

Adhesivessuchas“LoctiteRC/609orRC/680”or “Fel-ProPro-LockRetainingIorRetainingII”are usedonthefollowing:

Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

Maintenance

•Undertopcutterhousingbearingguard.

•Betweenthejackshaftandbearingsandthe jackshaftandsheaves.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing locations:

OnthreadsofBladeBoltsSeeCheckMowerBlades section.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Adjustments

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

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checktirepressureindrivetires.Properination pressurefortiresis10psi(69kPa).Adjustif necessary.

4.Setanti-scalprollerstotopholesorremovethem completelyforthisadjustment.

5.Raisethedecktothe5inch(12.7cm)height position(alsotransportposition)andtakeallforce offofthetwolargedeckliftspringsbyloosening thenutsatthefrontofeachspring(Figure15).

6.Lowerthedecktothe1inch(2.54cm)height position.Forcetheleftreardecksupportarm downwardabout1/4inch(6.4mm)togetthe decktorestatthe1inchheightposition.Place lockingpliersbetweentherearswivelandspring stoptoholdthedeckinthisposition(Figure15).

7.Placea3/4inch(19mm)thickblockofwood undereachofthetworearanti-scalproller bracketsandplaceoneunderoneofthefront centeranti-scalprollerbrackets.

8.Loosenthetwotopchainboltsinslotsintherear deckliftarms.Loosenjamnutsandbackoffthe socketheadadjustingscrewsonthebottomof thearmsuntilthechainsarejustloose.Turnthe socketheadadjustingscrewsinuntilslackistaken outofeachchain.Tightenthejamnuts.Tighten thechainboltsinthedeckliftarmsmakingsure theydon’tmovewhiletightening.

9.Loosenthefournutswhichsecurethefront swivels(twoperside)untilthefrontchainsare looseandfrontofdeckissupportedbythe3/4 inch(19mm)block.DoNotloosenthefront chainhardware.

10.Onleftside,adjustfrontswivelusingthelocking nutbehindtheswiveluntilthefrontchainistight andallslackisremovedfromlinkage.DoNotlift frontofdeckoff3/4inch(19mm)block.Secure

Maintenance

frontswivelusinglockingnutinfrontofswivel. Repeatforrightside.

11.Recheckthatthe3/4inch(19mm)blockstjust snuglyunderthebracketsandthatthetensionon allthechainsisapproximatelyequal.Makesure allchainattachmentboltsaretight.Reposition anti-scalprollersandtightensecurely.

Figure15

1.Applydownwardpressurehere

2.Placelockingpliersheretoholdspring

3.13–1/2inches(34.3cm)forcutheightsat2inchesor aboveor14inches(35.6cm)forcutheightsbelow2 inches

4.Removeforceondeckspringsbylooseningnutshere

5.Swivel

6.Frontofunit

7.Socketheadadjustingscrew

8.Jamnut

sideenginedecksupport,ispositionedbetween thecentersofthetwoalignmentholesinthe leftsupportplate(Figure16andFigure17).It isnecessarytoadjustthebelttensionwhenthe centeroftheboltheadisatorbelowthecenter ofthebottomalignmenthole.

3.Whenadjustmentisnecessary,loosentheidler pulleyontheright-handsidesoitcanmoveup anddownintheslot.

Placeawrenchonthe3/8inchnutinthecenter ofthespringloadedpulleyandapplyupward pressuretorelievetensiononthespring(a1/2 inchdrivebreakerbarand9/16inchsocketworks best).

Repositiontheadjustingpulleytothebottomof theslot.

Note:Wheninstallinganewbelt,itisnecessary torepositiontherightadjustingpulleyupwardin theslotinordertopositionthecenterofthespring loadedpulleybetweenthealignmentholes.

12.Raisedeckliftlevertothe5inch(12.7cm) cuttingheightposition(Figure8).Adjustspring compressionuntilproperdistanceisobtained betweenthetwolargewashers(Figure15). Adjustmentismadebyturningthenutatthe frontofeachspring(clockwisewillshortenthe spring,counterclockwisewilllengthenthespring). Lockinpositionwithjamnuts.

Note:Whenaboveadjustmentshavebeenmade, thefrontofthedeckwillbeslightlylowerthanthe rearofthedeck.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

MuleDriveBeltTension Adjustment

Self-tensioningidler,adjustasfollows:

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktomakesurethecenterofthebolthead inthecenterofthespringloadedpulley,onleft

1.Frontofunit

Figure16

2.Alignmentholes

Maintenance

1.Springidlerpulley

2.Frontofunit

Figure17

3.Rightsideidlerpulley (adjustable)

be1/8inch(3.2mm)awayfromthebelt,with bolt-endofguidenearendofslot(Figure18).

4.Ifadjustmentisnecessary,loosentheboltsecuring thebeltguideandmakeproperadjustment. Tightenhardware.

Figure18

1.Endofslot

2.Beltguide

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AlternatorBeltTension

Stopengine,waitforallmovingpartstostopand removekey.Engageparkingbrake.

Tiltseatandremoveairdeectorpanel

Totightenalternatorbelt,loosenbothupperand loweralternatormountingbolts.Rotatealternator out,awayfromengineandretightenhardwareto secureinplace.

Whenproperlytensioned,thealternatorbeltwill deect1/4to3/8inch(7-9mm)whileapplying22 poundsofforcetothebeltmidwaybetweenfanand alternator.

BeltGuideAdjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

BrakeLinkAdjustment

Checktomakesurebrakeisadjustedproperly.

1.Disengagebrakelever(leverdown).

2.Measurethelengthofthespring.Measurement shouldbe213/16inches(7.1cm)between washers.(Figure19).

3.Ifadjustmentisnecessary,adjustthenylocnut atthebottomofthespringtoachieve213/16 inches(7.1cm).

2.Removethebeltshieldontherightsideofmower deck.

3.Notebeltguideboltedtodeckneartheshield supportstudandright-handpulley .Guideshould

Figure19

1.Leverdown (disengaged)

2.Leverup(engaged)

3.Nylocnutbelowtrunnion roller

4.Nylocnutbelowspring

5.1/8to3/16inch(3.2to

4.8mm)

6.Removepintoadjust rodlengthforadditional brakeadjustment

7.Trunnionroller

8.Springretainerbracket

9.213/16inches(7.1cm)

10.Jamnutabovetrunnion roller

BrakeAdjustment

1.Checkforbrakelink213/16inches(7.1cm) measurementasdescribedintheBrakeLink Adjustmentsection.

Maintenance

ElectricClutchAdjustment

Noadjustmentnecessary.

ReverseIndicator Adjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatforward.

3.Beginwitheithertheleftorrightmotioncontrol lever.Movelevertotheneutralpositionandpull leverbackuntiltheclevispin(onarmbelowpivot shaft)contactstheendoftheslot(justbeginning toputpressureonspring).(Figure20).

4.Checkwhereleverisrelativetonotchinconsole (shouldbecenteredallowinglevertopivot outwardtotheneutrallockposition).

5.Ifadjustmentisneeded,loosenthenutagainstthe yokeandwhileapplyingslightrearwardpressure onthemotioncontrollever,turntheheadofthe adjustmentboltintheappropriatedirectionuntil leveriscentered(keepingrearwardpressureon theleverwillkeepthepinattheendoftheslot andallowtheadjustmentbolttomovethelever totheappropriateposition).Tightenlocknut.

6.Repeatonoppositesideofunit.

2.Engagethebrakelever(leverup).Thespace betweenthebrakespringbracketandthenyloc nutunderthespringshouldmeasure1/8inchto 3/16inch(3.2–4.8mm).

3.Ifadjustmentisnecessary,loosenjamnutabove thetrunnionroller.Adjustthenylocnutunder thetrunnionrolleruntildistancelistedabove existsbetweenthespringretainerbracketandthe adjacentnylocnut.Tightenthejamnutabove thetrunnionroller.

4.Ifthecorrectgapcannolongerbeachieved becausethereisnoclearancebetweenthenyloc nutbelowthespringandthejamnutabove thetrunnionortherearenothreadsleftonthe bottomnylocnut,thelengthofthebrakerodcan beadjusted.Removeapinfromayokeateither endofthebrakerodandlengthen(orshorten)the brakeroduntilthecorrectgapcanbeachievedby followingsteps2and3.

Figure20

1.Turnbolthere4.Yoke

2.Levercenteredinnotch5.Loosenhere

3.Endofslot

6.Reverseindicator

Maintenance

MotionControlLinkage Adjustment

WARNING

Enginemustberunninganddrive wheelsmustbeturningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

1.Thisadjustmentmustbemadewiththedrive wheelsturning.Firstraisetherearofmachine upandsupportwithjackstands(orequivalent support)justhighenoughtoallowthedrive wheelstorotatefreely.

2.Unhookseatlatchandtiltseatforward.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locateddirectlytotheleftoftheseat switchassemblybesidethehydraulicoilreservoir.

Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

4.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulic systemoiluptooperatingtemperature.

5.Loosenlocknutsfromtheballjointsateachend ofthepumpcontrollinkage(Figure21).

Figure21

Right-HandSideofUnit

1.Turnheretoadjust

6.Startengine.Brakemustbeengagedand motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

7.Thereverseindicatorspringmustbecorrect beforethefollowingadjustmentscanbemade. SeetheReverseIndicatorAdjustmentsection.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

Theleftrodassemblycontrolstheleftwheeland therightrodassemblycontrolstherightwheel.

8.Bringthemotioncontrolleverintotheneutral position.AdjustRHpumpcontrolrodlength byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(Figure21).Movethemotion controllevertothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringtobringtheleversbackto neutral.Thewheelmuststopturningorslightly creepinreverse.Whenadjustmentiscomplete, tightenlocknutsontoballjoints.

9.BringtheLHmotioncontrolleverintothe neutralposition.AdjusttheLHpumpcontrolrod lengthbyrotatingthetrackingadjustmentknobin theappropriatedirectionuntilthewheelsslightly creepinreverse.Movethemotioncontrollever tothereversepositionandwhileapplyingslight pressuretotheleverallowthereverseindicator springtobringtheleversbacktoneutral.The

2.Loosenhere(right-hand thread)

Maintenance

wheelmuststopturningorslightlycreepin reverse(Figure22).

Figure22

Left-HandSideofUnit

1.TurnLHtrackingadjustmentknob.(DoNotloosenany nutsonLHside)

10.Shutoffunit.Removejumperwirefromwire harnessconnectorandplugconnectorintoseat switch.

CasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennyloc nutuntilwashersareatandbackoff1/4ofa turntoproperlysetthepre-loadonthebearings. Ifdisassembled,makesurethespringwashersare reinstalledasshowninFigure24.

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure23formountingoptions.

Figure23

1.Motioncontrolbracket

2.Leastresistance(softestfeel)

3.Mediumresistance(mediumfeel)

4.Mostresistance(rmestfeel)

5.T orquenylocnutto200in-lb(16.7ft-lb).Boltmust protrudepastendofnylocnutaftertorque.

6.Damper

7.Dampermustmovefreelyonbolt.

Figure24

1.Springdiscwashers

ClutchShim

Somelatermodelyearunitshavebeenbuiltwith clutchesthatcontainabrakeshim.Whentheclutch brakehasworntothepointwheretheclutchno longerengagesconsistently ,theshimcanberemoved toextendtheclutchlife.

Maintenance

Figure25

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

A.Loosenbothbrakemountingboltsone-half

toonefullturnasshownbelow .

Note:DoNotremovethebrakepolefrom theeldshell/armature.Thebrakepolehas worntomatchthearmatureandneedsto continuetomatchaftertheshimisremoved toensureproperbraketorque.

RemovingtheShim:

1.Stopengine,waitforallmovingpartstostop, andremovekey.Engageparkingbrake.Allow themachinetocoolcompletelybeforestarting theseinstructions.

2.Usingapneumaticline,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers.

Figure26

Figure27

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

Figure28

1.Shim

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature. Ifthegapisgreaterthan.04inch(1mm),proceed withthefollowingsteps:

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13

N-m)+/-0.5ft-lb(0.7N-m).

E.Usinga0.010inchthickfeelergauge,verify

thatagapispresentbetweentherotorand armaturefaceonbothsidesofthebrakepole

Maintenance

asshown.(Duetothewaytherotorand armaturefaceswear(peaksandvalleys)itis sometimesdifculttomeasurethetruegap.)

Figure29

1.Feelergauge

doesnotengageproperly,referencethe Troubleshootingsection.

Figure30

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstepF.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengage

withthePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly .Iftheclutch

Maintenance

Cleaning

CleanEngineCooling System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundtheenginecooling airintakeandinsideofthepumpdrive beltcompartmentanddamagedormissing rubberbafescancausetheengineand hydraulicsystemtooverheatwhichcan createarehazard.

•Cleanalldebrisfrominsideofpumpdrive beltcompartmentdaily.

•Cleandebrisfromradiatorscreenand coredaily.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfrominsideofpumpdrivebelt compartment.

3.Wipedebrisfromscreeninenginecover.

2.Removeairdeectorpanelfrombehindseat.

3.Cleanaroundywheel,cylinderhead,injectors, andinjectorpump.

4.Reinstalltheairdeectorpanel.

Important:DoNotusewatertocleanengine. Uselowpressurecompressedair.SeeEngine Owner’sManual.

CleaningoftheRadiator

ServiceInterval:Every50hours(Maybe

requiredmoreoftenindry ordirtyconditions.)

1.Stopengine,waitforallrotatingpartstostopand removekey.Engageparkingbrake.

2.Allowenginetocool.

3.Rotateseatandenginecoverforward.

4.Whileholdingfanup,removethefourscrews attachingthefantotheshroud.Disconnectand removethefan.

5.Usingcompressedair,blowoutdebrisstuck betweenthensoftheentireradiator,bothfrom thetopdownandfromthebottomup.

6.Ifdebrisremains,itmaybenecessarytousewater fromalowpressurehose.Iftheradiatorisclean, proceedtostep8.

4.Rotateenginecoverforwardandwipedebris fromradiatorcoreasrequired.

5.Cleandebrisfromradiatornswithcompressed air.

Important:Ifdebrisoraircannotbeblown throughtheradiator,seeCleaningofthe Radiatorsection.

6.Inspectsealsinenginecoverandreplaceif necessary.

RemoveAccumulatedDebris fromEngine

ServiceInterval:Beforeeachuseordaily

Enginepartsshouldbekeptcleantoreducetherisk ofoverheatingandignitionofaccumulateddebris.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

7.Covertheenginewithapieceofcardboard,ora plasticsheet.Squirtwaterdownthroughthens. Blowthroughwithlowpressureairfromboth directions.Ifdebrisremains,repeatuntilclean.

8.Re-assemblethefantotheradiator.Reconnect thefan.

9.Starttheenginetoensurethefanisfunctioning properly.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Maintenance

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisedecktothetransport(5inch(12.7cm) cuttingheight)position.Liftthefrontofunit andsupportunitusingjackstandsorequivalent support.

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank.

Enginewillnotstart,startshard,orfailsto keeprunning.

1.PTOisengaged.

2.Parkingbrakeisnotset.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow .

4.Thethrottleisnotinthecorrectposition.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Electricalconnectionsarecorroded,loose orfaulty.

9.Relayorswitchisdefective.9.ContactanAuthorizedServiceDealer.

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral lockposition.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

4.Besurethethrottlecontrolismidway betweenthe“SLOW”and“FAST” positions.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

Enginelosespower.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.V entholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Engineoverheats.

Mowerpullsleftorright(withleversfully forward).

Machinedoesnotdrive.

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Dirtyairlter.

4.Coolantlevelislow .

5.Debrisonoraroundradiator.5.Removedebris.

6.W aterpumporalternatorbeltisworn, loose,orbroken.

1.Trackingneedsadjustment.1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

3.Reverseindicatorandmotioncontrol linkageneedadjustment.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

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.

2.Addoiltothecrankcase.

3.Cleanorreplacetheaircleanerelement.

4.Addcoolant.

6.ContactanAuthorizedServiceDealer.

3.Adjustthereverseindicatorandthe motioncontrollinkage.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration.

Bladesdonotrotate.

Warningbuzzeremitscontinuousbeep.(See alsoEngineoverheats).

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.

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley .2.Checkbeltfordamage;replaceif

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

5.Brokenormissingidlerspring.

1.T emperatureisincreasingoncoolant temperaturegauge.

2.Coolantlevelislow .

3.Debrisonoraroundradiator.3.Removedebris.

4.W aterpumporalternatorbeltisworn, looseorbroken.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

necessary.Installdrivebeltandcheckbelt guideforcorrectposition.

pulley,idlerarmandspringforcorrect positionandfunction.

5.Replacethespring.

1.Turnunitoffandallowengineandengine componentstocool.

2.Addcoolant.

4.ContactAuthorizedServiceDealer.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Warningbuzzeremitsintermittentbeep.

Clutchwillnotengage.

1.Oillevelislow .1.Checkoillevel.

2.Oilleakingfromengine.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply .4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

2.ContactAuthorizedServiceDealer.

1.Replacefuse.Checkcoilresistance, batterycharge,chargingsystem,and wiringconnectionsandreplaceif necessary.

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Replaceclutch.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Schematics

RED

BLACK

YELLOW/BLACK

PINK

YELLOW/RED

ORANGE

BLACK

YELLOW/BLACK

BLACK

PINK

5 43

2 1

RED

GROUND

ORANGE

BROWN/BLACK

PINK/BLACK

BLACK

RED

BROWN/BLACK

YELLOW/BLACK

YELLOW

BLACK

ORANGE/BLACK

DK. GREEN DK. GREEN

DK. GREEN VIOLET

LT. BLUE LT. BLUE

LT. GREEN

GRAY

TAN

LT. BLUE

BLACK

BROWN

GRAY

ORANGE

GRAY

ORANGE

GRAY

BLACK

PINK/BLACK

WHITE

BLACK/GREEN

YELLOW/RED

BLACK/GREEN

BLACK/WHITE

DK. BLUE

BLACK

YELLOW/BLACK

VIOLET

PINK

BLACK

PINK

YELLOW/BLACK

RED

ORANGE

RED

BLACK

GROUND

STARTER;

BATTERY (POS)

DIODE

GLOW SWITCH

ENGINE

A B

B A

SEAT DELAY

MODULE CONTROL

SEAT DELAY

MODULE INPUT

SEAT

SWITCH

PTO

CLUTCH

PTO

SWITCH

20 AMP FUSE

(IGN. SWITCH)

STARTER

SOLENOID

SIGNAL

GLOW

RELAY

START

RELAY

BRAKE

SWITCH

LH MOTION

CONTROL

RH MOTION

CONTROL

IGNITION

SWITCH

HOUR

METER

RED

ORANGE

YELLOW

TAN

ORANGE/BLACK

LT. BLUE

LT.GREEN

DK. GREEN

LT. BLUE

VIOLET

BLACK

RED RED

ORANGE/BLACK

ORANGE

BROWN/BLACK

YELLOW/BLACK YELLOW/BLACK

PINK/BLACK

SEAT DELAY

MODULE DIODE

GRAY

BLACK

OIL

SWITCH

OIL

PRESSURE

RELAY

ALTERNATOR

RELAY

FUEL

SOLENOID

ALTERNATOR

CONNECTOR

ALT "B"

TERMINAL

GLOW

PLUG

RAIL

TEMP.

SWITCH

DUAL

TONE

ALARM

TEMP AND

GLOW LED

30 AMP FUSE

(FAN)

40 AMP FUSE

(GL

OW)

BROWN/BLACK

YELLOW/BLACK

VIOLET

PINK

BLACK/WHITE

BLACK

DK. BLUE

RED

BLACK/WHITE

PINK

YELLOW/BLACK

PINK

BLACK

RED/BLACK

BLACK

RED

YELLOW/BLACK

PINK/BLACK

YELLOW/BLACK

TEMP

SENDER

6 5 4 7

3 2 1 8

B A

2 1

54321

4 1 7 2 5 6 3 8 9

A B C

54321

3241

35412

321

543215432

1A 1B 2A 2B

12345678

2 1

FUEL

PUMP

STARTER

MOTOR

BLACK

TEMP GAUGE

AND VOLTMETER

FAN

RELAY

OPEN WITH

BRAKE

ENGAGED

CLOSED WITH

BRAKE

ENG

AGED

BOTH MOTION CONTROL

SWITCHES ARE CLOSED WITH

CONTROL LEVERS IN NEUTRAL

LOCK POSITION

SWITCH IN: ORANGE TO PINK/BLACK

SWITCH OUT: ORANGE TO GRAY

SWITCH IS CLOSED

WITH OPER

ATOR

IN THE SEAT

NOTE:

CONNECTORS VIEWED FROM TERMINAL END

G010235

TERMINAL A

TERMINAL B

TERMINAL Y

TERMINAL X

TERMINAL S

TERMINAL I

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, AUX HYD, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, AUX HYD, PTO SWITCH

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

B + I + A

2. RUN

1. OFF

POSITION

3. START

Schematics

ElectricalDiagram

Schematics

ElectricalLogicSchematic

HydraulicDiagram

Schematics

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 for a period of two years.

This warranty applies to Exmark commercial turf equipment sold in the U.S. or Canada. 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.

 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.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized   Exmark Service Dealer.

• 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  service@exmark.com

Owner’s Responsibilities

The Exmark turf 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 Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

Notes:

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

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-F RONT RIDING AC CESSORIES A ND OPTIONS

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.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-501Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark 4500-501 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual