Exmark Advantage Series 4500-466, LAZER Z ADVANTAGE SERIES Operator's Manual

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LAZERZ®

ADV ANTAGESERIES

MODELS

ForSerialNos. 790,000&Higher

PartNo.4500-466Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

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

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

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

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

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

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.......................................................14

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CheckRolloverProtectionsSystems(Roll

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

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

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

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

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

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

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

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

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

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

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

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

ChangeHydraulicSystemFilterand

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

WheelHub-SlottedNutTorque

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

CheckEngineCoolantLevel(Kawasaki

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

ChangeEngineCoolant(Kawasaki

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

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

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

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

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

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

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

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

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

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

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

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

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

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

MotionControlNeutralLockPivot

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

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

MotionControlFullForwardTracking

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

CasterPivotBearingsPre-Load

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

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

CleanEngineandExhaustSystem

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

RemoveEngineShroudsandCleanCooling

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

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

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

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

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

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

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

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

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.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•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

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

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

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

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

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Safety

CAUTION

Fueltankventislocatedinsidetheroll bartube.Removingormodifyingtheroll barcouldresultinfuelleakageandviolate emissionsregulations.

•DoNotremoverollbar.

•DoNotweld,drill,ormodifyrollbarin anyway.

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

Operation

WARNING

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

•Allowengineparts,especiallythemufer, tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

•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.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

Safety

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

DANGER

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

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

3.Water

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandlossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

Safety

WARNING

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

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbar isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

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

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

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

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

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-303508

1-403005

1-633922

98-5954

103-2076

Safety

107-2102

107-2112

109-3148

109-7232

1.Fast3.Neutral

2.Slow

4.Reverse

109-7330

109-7929

Safety

109-8483

1.Throttle–fast3.Choke–on

2.Throttle–slow

4.Choke–off

109-9361

DeckDriveBeltRouting

109-9477

116-0090

116-0157

1.SeeOperator’smanual

116-0165

116-0205

Safety

116-0211

116-0752

1.Latch2.Unlatch

116-0906

ForKawasakiLiquid-CooledOnly

MessageDisplay

1.Fuel6.Hourmeter

2.Empty

7.PTO

3.Half

8.Parkingbrake

4.Full9.Neutral

5.Battery

10.Operatorpresence switch

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

109-7069

Specications

ModelNumbers

SerialNos:790,000andHigher

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

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:

–AllunitsexceptLZAS20BV484and

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

–LZAS20BV484andLZAS20KC484:Full

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

FuelSystem

•Capacity:12.0gal.(45.4L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.

•FuelFilter:

–Briggs&Stratton:

Briggs&StrattonP/N691035

–Kohler:

KohlerP/N2405013

–Kawasaki:

KawasakiP/N49019-7001

•FuelShut-OffValve:

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

•Fuelleveleightsegmentdisplay—righthand controlpanel.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

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

–KawasakiLiquid-Cooled:20amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

Allunits:

–25ampmainfuse

–25ampchargingsystemfuse

–10ampPTOfuse

–15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearforthePTO,parkbrake, drivelevers,andoperatorpresenceinthemessage displayontheRHcontrolpanel.

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

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

CoolingSystem(Kawasaki Liquid-CooledOnly)

•Fan:Continuousoperationwithenginerunning.

•CoolantLiquid:50/50mixofDexCool© extendedlifeantifreezeandwater.

•CoolantCapacity:3.1quarts

Specications

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•ParkingBrakeReleaseButton:Releasesparking brake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

–Unlatchingposition:Deckdoesnotlatchat

thetransportposition.

Seat

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

Optionalseataccessoriesforunitswithstandard seats:

–Customridesuspensionsystemtoenhance

StandardSeat.Addsapproximately3inches (7.6cm)toseatheight.

–Deluxesuspensionseatwithhighback,low

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

–SeatIsolationSystemforreducedvibration,

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

•Mounting:Adjustableforeandaftonseattracks.

•Armrests:

–Standardseat:foampaddedadjustableip-up

armrests.

–Suspensionseat:moldedadjustableip-up

armrests.

•SeatSafetySwitch:

Integratedseatswitch.Timedelayseatswitch eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

12ccParkeraxialpistonpump

240ccParkergerolermotor

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:52oz(1.5L)perside

•HydraulicFilter:P/N116-0164

•Speeds:

–0-10mph(16.1km/hr)forward.

–0-5.5mph(8.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

Pneumatic (Air-Filled)

Semi-Pneumatic

Quantity

Tread

TurfMasterSmooth

Size(72Deck)

24x12.00-1213x6.50-6

Size(60Deck)

24x12.00-1213x5.00-6

Size(48&52 Decks)

24x9.50-1213x5.00-6

PlyRating

Pressure

13psi(90kPa)

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

–72inchDeck:(182.9cm)

•Discharge:Side

Specications

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

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

•DeckDrive:

Electricclutch:

–48and52inchDecks:“B”Sectionbeltwith

self-tensioningidler.

–60and72inchDecks:5VSectionbeltwith

self-tensioningidler.

•Deck:

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

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

–60inchDeck:4anti-scalprollers

–72inchDeck:4anti-scalprollers

•DeckDepth:

–48inchDeck:5.5inches(14cm)

–52inchDeck:5.5inches(14cm)

–60inchDeck:5.5inches(14cm)

–72inchDeck:5.5inches(14cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

Dimensions

OverallWidth:

48inchDeck52inchDeck

WithoutDeck45.7inches

(116.1cm)

45.7inches (116.1cm)

DeectorUp51.8inches

(131.6cm)

56.3inches (143.0cm)

DeectorDown59.6inches

(151.4cm)

64.8inches (164.6cm)

60inchDeck72inchDeck

WithoutDeck53.0inches

(134.6cm)

59.1inches (150.1cm)

DeectorUp62.5inches

(158.8cm)

73.5inches (186.7cm)

DeectorDown72.8inches

(184.9cm)

84.9inches (215.6cm)

OverallLength:

48inchDeck52inchDeck

RollBar-Up79.2inches

(201.2cm)

79.2inches (201.2cm)

RollBar-Down80.9inches

(205.5cm)

80.9inches (205.5cm)

60inchDeck72inchDeck

RollBar-Up83.1inches

(211.1cm)

86.1inches (218.7cm)

RollBar-Down84.8inches

(215.4cm)

87.8inches (223.0cm)

OverallHeight:

RollBar-UpRollBar-Down

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

Specications

TreadWidth:(CentertoCenterof Tires,Widthwise)

48inchDeck52inchDeck

DriveWheels36.2inches

(91.9cm)

36.2inches (91.9cm)

CasterWheels32.8inches

(83.3cm)

32.8inches (83.3cm)

60inchDeck72inchDeck

DriveWheels41.6inches

(105.7cm)

43.6inches (110.7cm)

CasterWheels39.5inches

(100.3cm)

47.1inches (119.6cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

48inch Deck

52inch Deck

60inch Deck

72inch Deck

48.0inches (121.9cm)

50.6inches (128.5cm)

53.6inches (136.1cm)

CurbWeight:

48inch Deck

52inch Deck

60inch Deck

72inch Deck

20HP Briggs& Stratton Units

1081lb (490kg)

20HP Kohler Units

1115lb (506kg)

23HP Kohler Units

—

1108lb (503kg)

——

25HP Kohler Units

——

1165lb (528kg)

—

26HP Kawasaki Units

——

1177lb (534kg)

—

27HP Kohler Units

—

1108lb (503kg)

1165lb (528kg)

—

29HP Kawasaki Units

———

1234lb (560kg)

AccessoryWeightTableWorksheet:

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

Note:The72inchdeckdoesnotrequireaweightkit.

48inch

Deck

52inch

Deck

60inch

Deck

Accessory Score

LightKit

222

Michigan Seat/CRSS

103

Bagger

003

Pneumatic Caster Tires

MulchKit

-3-3-5

StriperKit-300

OCD02-6-6-4

HitchKit

111

Sunshade Kit

TotalAccessoryScore

TotalAccessoryScoreRequiredWeightKit(s)

0–9

Nonerequired

10–19

*116-1173Undertoe boardmountweightkit

20andHigher*Two116-1173Undertoe

boardmountweightkits orone116-1173Undertoe boardmountweightkit andone116-1238Front toeboardmountweightkit

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

ProductOverview

*60inchunitswhichalreadyhaveanundertoeboard mountweightasstandardrequires116-1238fronttoe boardtopmountkitinsteadof116-1173.

TorqueRequirements

BoltLocation

Torque

BladeDriveSheave MountingNut

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

BladeMountingBolt (lubricatewithanti-seize)

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

Anti-ScalpRollerNyloc NutSeeFigure19

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

Anti-ScalpRollerHex CapscrewSeeFigure19

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

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

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

WheelLugNuts

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

WheelMotorMounting Bolts

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

WheelHubSlottedNutminimum200ft-lb

(271N-m)

RolloverProtection System(RollBar)1/2 inchMountingBolts

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

ClutchRetainingBolt (securedwiththreadlocker)

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

HydroParkBrakeCable Anchor1/2inchMounting Bolt(securedwith threadlocker)

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

ProductOverview

Figure4

1.RolloverProtection System(ROPS)

5.Fuelcap

2.EngineControls(right console)

6.Heightofcutadjustment

3.Seatbelt

7.Parkingbrake

4.Motioncontrollevers

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (Figure5).

Whenthemotioncontrolleversareintheneutral position,theLCDindicatorappearsinthemessage displayontheRHconsole(seeFigure9).

Figure5

1.Neutrallockposition (handlesout)

4.Forward

2.Neutraloperateposition (handlesin)

5.Neutral(operate)

3.FrontofUnit

6.Reverse

ChokeControl

Locatedonrightconsole(blacklever)(seeFigure6).

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

Figure6

RightConsole

1.WarningBuzzer(KawasakiLiquid-CooledOnly)

2.Fuses

3.Moduledisplay

4.Ignitionswitch

5.PTOengagementswitch

6.Throttle

7.Choke

8.Coolanttemperaturegauge(KawasakiLiquid-Cooled Only)

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe RHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Operation

Note:TheLCDindicatorappearsinthemessage

displayontheRHconsolewhentheparkbrakeis engaged(seeFigure9).

Pulltheleverupandrearwardtoengagethebrake.

Depressthereleasebuttonandpushdownwardto disengagethebrake.

Figure7

1.Releasebutton2.Parkbrake

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

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

Figure8

1.Off3.Start

2.On

Note:Brakemustbeengaged,motioncontrol leversout(neutrallockposition)andPTOswitch

disengagedtostartengine.(Itisnotnecessaryforthe operatortobeintheseattostarttheengine.)

HourMeter

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Figure9

1.LCDIndicators

2.Lowfuelindicatorlight

3.Fuellevelbardisplay

4.Lowvoltageindicatorlight

5.Hour/Voltagedisplay

Hoursarerecordedwhenthekeyisonandtheengine isrunning(batteryvoltageis12.8Vorhigher)or whenthekeyisonandtheoperatorisintheseat.

Thehourmeterisrecordingwhenthedecimalpoint isashinginHour/Voltagedisplay .

Hoursaredisplayedwhenthekeyisoffandwhen themachineisrunning.

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

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

Operation

FuelShut-OffValve

Locatedbehindandbelowtheseat.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

FuelGauge

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thefuellevelisshownonabardisplay.Theindicator lightappearswhenthefuellevelislow(approximately onegallonremaininginthetank).

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck, whichcouldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

WARNING

Theengineandhydraulicdriveunitscan becomeveryhot.T ouchingahotengineor hydraulicdriveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrive wheelreleasevalves.

Locatedonthebackoftheunitizedhydraulicdrive units,belowtheenginedeck.

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

Figure10

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure10), rotatethehandle1/4turntotheverticalposition untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2inFigure10), rotatethehandle1/4turntothehorizontalposition untilithitsagainstthestop.

Note:Thehandlemustbehorizontalandagainst thestopforoperation.

DoNottowmachine.

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isdisengaged(seeFigure9).

LowVoltageIndicator

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Alowvoltagecondition(lessthan12.3volts)exists whentheLCDindicatorappearsonthemessage displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

Operation

CoolantTemperatureGauge (KawasakiLiquid-CooledOnly)

Locatedontherightconsole(seeFigure6).

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

Figure11

1.Green

3.Red

2.Yellow4.Bardisplay

WarningBuzzer(Kawasaki Liquid-CooledOnly)

Locatedonthesideoftherighthandconsole(see Figure6).

Thebuzzerisawarningsignalthattheengineis overheating.SeetheTroubleshootingsection.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

TransportLock

Locatedontheheightofcutadjustmentplatestothe rightoftheparkingbrake.

Positioninthetransportlatchingpositionto automaticallylatchthecuttingdeckwhenraisedto thetransportposition(seeitem1inFigure12).

Inthenon-latchingposition,thedeckwill automaticallyreturntothecuttingheightwhenthe pedalislowered(seeitem3inFigure12).

Figure12

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

Pre-Start

Fillfueltank.Forbestresultsuseonlyclean,fresh regulargradeunleadedgasolinewithanoctanerating of87orhigher.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

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

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Therollbarisanintegraland

effectivesafetydevice.Keeptherollbarinthe raisedandlockedpositionwhenoperatingthe mower.Lowertherollbartemporarilyonlywhen absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe tabsinterlockingasshowninFigure13tolock therollbarintheraised,operateposition.

Operation

2.Applyforwardpressuretotheupperhoopofthe rollbar.

3.Pulltheknobandrotate90°toholdinthe unlatchedpositiontolowertherollbar.

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

Figure13

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

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

Figure14

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

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

OpentheFuelShut-OffValve

Thefuelshutoffvalveislocatedbehindandbelow theseat.Rotatethevalveandalignwiththefuelline toopen.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

5.Onacoldengine,pushthechokeleverforward intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

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

Operation

attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunless thereisagrasscollectionsystemormulch kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

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

2.PullthePTOswitchoutwardtoengagethe blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

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

2.PushthePTOswitchintodisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral lockposition.

4.Engagetheparkingbrake.

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

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

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

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

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

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

Note:The“N”LCDindicatorappearswhenboth leversareintheneutrallockposition.

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Operation

Figure15

1.Neutrallockposition (handlesout)

4.Forward

2.Neutraloperateposition (handlesin)

5.Neutral(operate)

3.FrontofUnit

6.Reverse

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

Figure16

1.FrontofUnit

3.Neutral

2.Forward4.Reverse

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

Toturnleftorright,releasepressureonthe motioncontrollevertowardthedesiredturn direction.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheCuttingHeight

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

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Positionthetransportlockinthelatching position.

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

Thedeckisraisedbypushingthefootoperated deckliftpedalforward.Thepedalislocatedatthe frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Operation

Figure17

1.Deckfootpedal3.Cutofheightdecal

2.Heightadjustmentpin4.Transportlockcontrol

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor cutheights.

6.Pushthedeckliftpedal,releasethetransportlock andallowthedecktolowertothecuttingheight.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Adjusttheanti-scalprollersbyremovingthe bushing,springdiscwasherandbolt.

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

Figure18

Forcuttingheightsabove3.5inches(90mm)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(Figure19).

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

Figure19

1.Springdiscwasher (conetowardsbolthead)

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

2.Frontrightanti-scalp bracketshown

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

Operation

Transporting

TransportingaUnit

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

CAUTION

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

DoNotdriveaunitonapublicstreetor roadway.

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over. Backwardtip-overcouldcauseseriousinjury ordeath.

•Useextremecautionwhenoperatinga unitonaramp.

•Useonlyasingle,fullwidthramp;Do Notuseindividualrampsforeachside oftheunit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbroken rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp andgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledriving unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtipping backward.

LoadingaUnit

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

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

Operation

Important:DoNotattempttoturntheunit

whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

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

WARNING

Theenginecanbecomeveryhot.T ouching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkenginecoolantlevel.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrofancoolingguards.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

Every50hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

Every200hours

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

•Lubricatethebrakehandlepivot.

•Checkthesparkplugs.

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Every500hours

•Changethehydrauliclteranduid.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

Every4,000hours

•

Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)

Yearly

•Greasethedeckandpumpidlerpivots.

•Greasethefrontcasterpivots.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

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

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

CheckBatteryCharge

ServiceInterval:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.T opreserveoptimum

batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

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

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

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

12.6or greater

100%

16volts/7 amps

No Charging Required

12.4–12.675–100%

16volts/7 amps

30Minutes

12.2–12.450–75%

16volts/7 amps

1Hour

12.0–12.225–50%

14.4volts/4 amps

2Hours

Maintenance

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

11.7–12.00–25%

14.4volts/4 amps

3Hours

11.7orless

14.4volts/2 amps

6Hoursor More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure20

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Makesurethesplinesonthebushingare engagedinthespindlebeforetighteningthe bolt.

Figure21

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

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

C.Applylubricanttothreadsofbladeboltto

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

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith, parkingbrakeengaged,PTOdisengagedand motioncontrolleversmovedoutintheneutral

Maintenance

lockposition.Theoperatordoesnotneedtobe intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

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

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

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

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

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

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

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckRolloverProtections Systems(RollBar)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe knobsareingoodworkingcondition.Makesurethe knobsarefullyengagedwiththeROPSintheraised position.Theupperhoopoftherollbarmayneed tobepushedforwardorpulledrearwardtogetboth knobsfullyengaged.

Figure22

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every200hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See theEngineOwner’s

Maintenance

Manualforadditional information.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Loosenretainingclipsandremoveaircleaner compartmentcover.

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

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

5.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

6.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

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

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

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

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

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe hydraulicoil.

3.Slidetheseatallthewayforwardtoaccessthe capsontheLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand removecap.

5.Wipethedipstickcleanandre-insertthecapback intothehydro.Lightlytightenthecap.

6.Removethecapagainandcheckthelevelofthe oilonthedipstick.SeeFigure23foroillevels.

Figure23

1.Full2.Add

Note:Theoillevelonthedipstickwillbe incorrectiftheoilischeckedwhentheunitishot.

7.Ifthedipstickoillevelisatthe“add”markadd ExmarkPremiumHydrooil.

8.Replacehydraulicreservoircapandtightenuntil snug.DoNotovertighten.

Maintenance

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Semi-pneumaticcastertiresDoNotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

3.Checkundermachinetoinspectthepumpdrive belt.

Note:Noadjustmentsarerequiredforbelt tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Deckand PumpIdler Pivots

Yearly

2.Front Caster Pivots

*Yearly

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

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

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure24

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

Maintenance

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

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

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

9.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

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

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .

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

LubricateBrakeHandlePivot

ServiceInterval:Every200hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebrakehandlepivotwithaspraytype lubricantorlightoil.

LubricateDeckLiftPivot

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’s Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ReplacementFilters

Briggs&Stratton

Briggs&StrattonP/N 691035

Kohler

KohlerP/N2405013

Kawasaki(Air-Cooled& Liquid-Cooled)

Kawasaki

P/N49019-7001

Note:Itisimportanttoreinstallthefuellinehoses andsecurewithplastictiesthesameastheywere originallyinstalledatthefactorytokeepthefuelline awayfromcomponentsthatcouldcausefuelline damage.

ChangeHydraulicSystem FilterandFluid

ServiceInterval:Every500hours

Note:OnlyuseExmarkHydroFilter–PartNo.

116-0164forsummerorwinter.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

Maintenance

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem.

6.Usingasocket,unscrewlterstoremoveand allowoiltodrain.

7.Beforeinstallingthenewlters,applyathincoat ofExmarkPremiumHydrooilonthesurfaceof thetworubberseals.

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

9.FillthehydraulicsystemasstatedinCheck HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ChangeInterval

ExmarkPremiumHydro Oil(Preferred)

500Hours

Mobil115W50

250Hours

10.Removethecatchpanandproperlydisposeof hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

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

13.Removethejackstands.

Note:DoNotchangethehydraulicsystemoil (exceptforwhatcanbedrainedwhenchanginglter),

unlessitisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor taperedshaft:

1.Removeanddiscardthecotterpin.

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

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

Figure25

1.0.1inchmax2.Nomorethantwo threads(0.1inchmax) shouldbeshowinghere.

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

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

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

7.Installnewcotterpin(P/N1-806800).

Note:DoNotuseanti-seizeonwheelhub.

Maintenance

CheckEngineCoolantLevel (KawasakiLiquid-Cooled Only)

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Spray orsteamfromhot,pressurizedliquidinthe enginecoolingsystemandtouchingahot radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant cancausepoisoning.

•Donotswallow.

•Keepoutofreachofchildrenandpets.

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

ChangeEngineCoolant (KawasakiLiquid-Cooled Only)

ServiceInterval:Every4,000hours/Every4

years(whichevercomes rst)Dex-Cool© ©

extended

lifecoolant(orangecolor)

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

2.Placeadrainpanunderthedrainplug.

3.Draincoolantwhenengineiscool.Coolantmay bedrainedfromtheradiatorbyturningthedrain plugcounterclockwise.

Figure26

1.Coolantdrainplug(blackhead)

2.Oildrainhose

3.Oillter

4.Sparkplug

4.Rotatethedrainplugclockwiseandremovepan.

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

Maintenance

WARNING

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

•DoNotoperatemachinewithoutthe coversinplace.

•Keepngers,hands,andclothingclearof rotatingcomponents.

•Shutoffengine,waitformovingpartsto stop,engageparkingbrakeandremove key,beforeperformingmaintenance.

6.Withthecapofftheradiator,starttheengineas statedintheOperatingInstructionsSection.

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

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

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

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

DoNotrefuelorrunengineunlessspark arresterisinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

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

ThreadLockingAdhesives

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

•ROPSspringpinhousing.

•Hydropumpcontrolarm,linkagebolt,and attachmentbolt.

•Hydrocoolingfanscrew .

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof enginecrankshaft.

Threadlockingadhesivesarerequiredforsome hardwareonengines—seetheEnginemanual.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Maintenance

Adjustments

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

4.Positionthetransportlockinthelatching position.

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

Figure27

1.Footlever3.Transportlock

2.Cutofheightpin

6.Inserttheheightadjustmentpinintothe3inch (7.6cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargedeector.

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

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

Maintenance

Figure28

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

2.Backbladetip

5.Levelsurface

3.Frontbladetip

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

Toincreasetheheight,turntheadjusterscrew clockwise;todecrease,turncounterclockwise.

Figure29

1.Whizlocknut3.Jamnut

2.Adjusterscrew4.Yoke

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

12.Re-measureuntilallfoursidesarethecorrect height.Tightenallthenutsonthedeckliftarm assemblies.

13.Lowerdischargedeector.

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

Figure30

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

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

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

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

17.Re-tightenfrontandrearheight-of-cutplate mountingbolts.

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

18.Repeatsteps9through13.

Maintenance

DeckRemoval

Beforeservicingorremovingthedeck,thespring loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthe storedenergycancauseseriousinjuryor death.

DoNotattempttodisassemblethedeck fromthefrontframewithoutlockingoutthe storedenergy.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthe decktotheground.

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

4.Removetheoorpanandbeltshields.

5.Insert1/2inchsocketdriverintothesquarehole ontheidlerbracketandcarefullyrotatethedeck idlercounterclockwisetoremovethebelt.

6.Removeandretainthehardwareonbothsidesof thedeckasshowninFigure31.

Figure31

1.Panhardrod(rightsideonly)

2.Deckstrut

3.Reardeckliftattachmentshoulderboltandnut.

4.Frontdeckliftattachmentshoulderboltandnut.

7.Disconnectthedeckstrutandpanhardfromthe deck.

8.Raisethefrontofthemachineandslidethedeck leftorrighttoremove.

9.Lowerthefrontofthemachine.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey.

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

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

8.Disengagetheparkbrake.

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

Maintenance

Figure32

LeftHandBrakeShown

1.Cableanchor

6.Locknut

2.Threadedrod7.Pullcablethreadedrod thisdirection

3.Pushleverthisdirection8.Holdthreadedrodhere

4.Caliperleverarm9.Swivel(pivothead)

5.Standardnut(shown

againstswivel)

Notetheorderofthestandardnutandlocknut (nonutonthecableanchorsideoftheswivel).

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

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

12.Ifthehubrotormovesveryfreelyrelativetothe caliper,thentightenthestandardnutoneturn againsttheswivelandrepeatstep10.

13.Oncestep10isachieved,holdthethreadedrod endwithatoolandtightenthelocknutagainst thestandardnut.DoNotallowthecabletoturn whenthenutsaretightened.

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

15.Repeatontheoppositesideofmachine.

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

17.Removejackstands.

ElectricClutchAdjustment

Noadjustmentnecessary.

MotionControlLinkage Adjustment

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

WARNING

Enginemustberunninganddrive wheelsmustbeturningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift pedalandremovetheheightofcutpin.Lower decktotheground.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.Theswitchisapartoftheseat assembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

6.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulicoil uptooperatingtemperature.

Maintenance

Note:Themotioncontrolleverneedstobein

neutralwhilemakinganynecessaryadjustments.

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

Figure33

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure34formountingoptions.

Figure34

RHMotionControlShown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

MotionControlNeutralLock PivotAdjustment

Theangednutcanbeadjustedtoobtainamore desiredmotioncontrolleverresistance(Figure35).

Figure35

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

Maintenance

MotionControlHandle Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(Figure36).

Figure36

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraftFigure36.Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

MotionControlFullForward TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthecoverplates.

1.Loosenthescrewsonacoverplate(seeFigure37).

2.Slidethecoverplatebackwardorforwardto adjustthetraveloftheleverandtightenthe screws.

3.Drivethemachineandcheckthefullforward tracking.

4.Repeatsteps1through3untildesiredtracking isobtained.

Figure37

RHMotionControlShown

1.Screw

3.Motioncontrollever

2.Coverplate

CasterPivotBearings Pre-LoadAdjustment

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

Maintenance

Figure38

1.Springdiscwashers

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancause engine,exhaustarea,andhydraulicsystem tooverheatwhichcancreatearehazard.

Cleanalldebrisfromengineandexhaust systemarea.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

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

CleanHydroFanCooling Guards

ServiceInterval:Beforeeachuseordaily

Maintenance

Removingdebrisfromthehydrofancoolingguards willallowthehydrosystemtoruncoolerandimprove thelifeofthehydrosystem.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Slideseatallthewayback,thenlifttheseatto accesstheLHandRHhydrodrivearea.

3.Removeaccumulateddebrisfromthehydrofan coolingguards.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

3.Ensurethedriveleversareintheneutral lockposition.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose orfaulty.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

Starterdoesnotcrank

8.Faultymodule.8.Replacemodule.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow.

3.Addoiltothecrankcase.

4.Thethrottleandchokearenotinthe correctposition.

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

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

6.Dirt,water,orstalefuelisinthefuel system.

6.ContactanAuthorizedServiceDealer.

7.Aircleanerisdirty.

7.Cleanorreplacetheaircleanerelement.

8.Seatswitchisnotfunctioningproperly .

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Electricalconnectionsarecorroded,loose orfaulty.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

11.Clean,adjustorreplacesparkplug.

12.Sparkplugwireisnotconnected.

12.Checkthesparkplugwireconnection.

Enginewillnotstart,startshard,orfailsto keeprunning

13.Faultymodule.13.Replacemodule.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow.

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe engineareplugged.

4.Removetheobstructionsfromthecooling nsandairpassages.

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

Enginelosespower

6.Dirt,water,orstalefuelisinthefuel system.

6.ContactanAuthorizedServiceDealer.

1.Temperatureisincreasingoncoolant temperaturegauge.

RefertoCheckEngineCoolantLevel sectionintheMaintenance.

2.Coolantlevelislow .

RefertoCheckEngineCoolantLevel sectionintheMaintenance.

3.Debrisonoraroundradiator.3.Removedebris.

4.Engineloadisexcessive.4.Reducethegroundspeed.

5.Oillevelinthecrankcaseislow.

5.Addoiltothecrankcase.

Engineoverheats.(Coolanttemperature gaugeisapproachingtheredzoneorwarning buzzeremitsbeep.)

6.Coolingnsandairpassagesforthe engineareplugged.

6.Removetheobstructionsfromthecooling nsandairpassages.

Mowerpullsleftorright(withleversfully forward)

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating” position.

1.Positionhandlein“operating”position; seeDriveWheelReleaseValvessection inOperation.

2.Driveorpumpbeltisworn,looseor broken.

2.Changethebelt.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

4.Replacethespring.

Machinedoesnotdrive

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

cooldown.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

front-to-rear.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

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

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley,orblade pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

Abnormalvibration

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Deckbeltisworn,looseorbroken.2.Installnewdeckbelt.

3.Deckbeltisoffpulley.3.Installbeltonclutchanddeckpulleys,

idlers,andtensioningidlerperrouting decalondeck.

4.Brokenormissingidlerspring.

4.Replacethespring.

Bladesdonotrotate.

5.Drivebeltnotroutedcorrectly.5.Refertobeltroutingdecalondeck.

Schematics

ElectricalDiagram—Air–Cooled

G008587

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

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

7 4 5 9 3 6 8 1 2

C A B

A B

26354

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—Liquid–Cooled

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO

CLUTCH

START RELAY

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

BLUE

BLACK

VIOLET

PINK

TEMP

SENDER

TERM (1)

TERM (3)

GREEN

BLACK

TERM (2)

TERM (4)

TEMPERATURE

GAUGE

ALARM

PULSE

ALARM

(+)

ORANGE

PINK

TVS

DIODE

BLACK

BROWN

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

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

7 4 5 9 3 6 8 1 2

C A B

A B

26354

G008588

A B

321

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

1 2

2 3

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalLogicSchematic—Air-Cooled

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

REG

START

FUEL

SOLINIOD

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G008613

Schematics

ElectricalSchematic—Liquid-Cooled

R A

4 1

2 3 5

SW1

(IGNITION)

KEY SW

Ignition switch terminal locations

viewed from back

OPTIONAL

ACCESSORIES

OFF = no connections

ON = BRIA

START = BRIS

S I

PK PK

LTGR

OR R GY

BN V

OR OR

BK PK

GND

B R

TEMP GAUGE

25A

GND

(P)

(+)

(s)

ALARM 2 TONE

(NEUT_R)

SW5

15A

10A

FUEL SENDER

(BRAKE)

SW6

235

(START RELAY)

PTO

CLUTCH

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

25A

(PTO SWITCH)

SW2

(SEAT)

SW7

TVS DIODE

AC-AC

MAG

REG

B+

START

STARTER

TEMP SW

IGNITION

MODULES

SPARK PLUG

FUEL

SOLENOID

SPARK PLUG

G008614

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

Schematics

HydraulicDiagram

General Warranty Conditions and Products Covered

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

part on these

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

be defective in factory materials or workmanship.

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

Commercial Warranty Conditions

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

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

Consumer Warranty Conditions

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

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

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

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

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

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

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

 Exmark Customer Service Department  The Exmark Warranty Company  2101 Ashland Avenue  Beatrice, NE 68310  402-223-6375 or  service@exmark.com

Owner’s Responsibilities

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

General Conditions

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

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

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Lazer Z and Lazer Z AS Turf Equipment

3 Year Limited Commercial Warranty

5 Year or 750 Hours Limited Consumer Warranty

G4500-434

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

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-FRONT RIDING ACCESSORIES AND OP TIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

PartNo.4500-466Rev.B (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Advantage Series 4500-466, LAZER Z ADVANTAGE SERIES Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual