Exmark FrontRunner Air-Cooled User Manual

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Page 1

LAZERZ®XS

AIR-COOLEDMODELS

ForSerialNos. 790,000&Higher

PartNo.4500-376Rev.A

Page 2

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

Page 3

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.

Page 4

Contents

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

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

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

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

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

Specications.......................................................15

ModelNumbers............................................15

Systems.........................................................15

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

TorqueRequirements....................................17

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

Operation.............................................................18

Controls........................................................18

Pre-Start........................................................19

OperatingInstructions..................................20

Transporting.................................................24

Maintenance.........................................................26

RecommendedMaintenanceSchedule(s)...........26

PeriodicMaintenance.......................................27

CheckEngineOilLevel.................................27

CheckBatteryCharge....................................27

CheckMowerBlades.....................................28

CheckSafetyInterlockSystem.......................28

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................29

CheckSeatBelt..............................................29

CheckforLooseHardware............................29

ServiceAirCleaner........................................29

ChangeEngineOil........................................30

CheckHydraulicOilLevel.............................30

CheckTirePressures.....................................30

CheckConditionOfBelts..............................30

LubricateGreaseFittings...............................30

LubricateCasterWheelHubs........................31

LubricateBrakeHandlePivot........................32

LubricateBrakeRodBushings.......................32

LubricateMotionControlBronze

Bushings...................................................32

CheckSparkPlugs.........................................32

ChangeHydraulicSystemFilter.....................33

WheelHub-SlottedNutTorque

Specication..............................................33

ThreadLockingAdhesives.............................33

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................34

Copper-BasedAnti-seize..............................34

DielectricGrease...........................................34

Adjustments.....................................................34

DeckLeveling...............................................34

PumpDriveBeltTension...............................35

MuleDriveBeltTensionAdjustment.............35

DeckBeltTension........................................36

BeltGuideAdjustment..................................36

BrakeLinkAdjustment..................................36

BrakeAdjustment..........................................36

ElectricClutchAdjustment............................37

ReverseIndicatorAdjustment........................37

MotionControlLinkageAdjustment.............37

MotionControlDamperAdjustment.............38

CasterPivotBearingsPre-Load

Adjustment...............................................39

Cleaning...........................................................39

CleanEngineCoolingSystem........................39

RemoveAccumulatedDebrisfromEngine

.................................................................39

CleanGrassBuild-UpUnderDeck................40

WasteDisposal..............................................40

Troubleshooting...................................................41

Schematics...........................................................43

Page 5

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER, WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

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

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

CAUTION:Blacklettering/Y ellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Page 6

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.

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

Page 7

Safety

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.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

Page 8

Safety

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.

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

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

Figure3

1.SafeZone-Usethe mowerhereonslopes lessthan15degrees

2.DangerZone-Useawalk behindmowerand/or handtrimmeronslopes greaterthan15degrees, neardrop-offsandwater.

3.Water

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

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

Page 9

Safety

drivingunderanyobjectsandDoNotcontact them.

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

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

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

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Makesureallhydraulicuidhoses andlinesareingoodconditionand allhydraulicconnectionsandttings aretightbeforeapplyingpressureto hydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.

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

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

Page 10

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-633706

1-403005

1-513742

98-5954

103-0262

1-513748

Page 11

Safety

103-6700

103-1798

103-7218

103-2076

103-7616

103-4930

103-5881

Page 12

Safety

109-0872

107-2102

107-2112

109-1214

109-1215

Page 13

Safety

116-0127

109-1399

116-0404

109-2219

116-0997

109-3148

109-7949

Page 14

Safety

107-9866

1.Fast

2.Slow

3.Neutral4.Reverse

Page 15

Specications

ModelNumbers

SerialNos:790,000andHigher

LXS35BV605;LXS35BV665;LXS35BV725

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3750±50RPM(NoLoad) Idle:1500RPM

FuelSystem

•Capacity:15.5gal.(58.6L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.

•FuelFilter:In-line30MicronBriggsP/N695327.

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

•Fuelgaugeinlefthandfueltank.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:20amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Two20ampbladetype

•SafetyInterlockSystem:

–PTOmustbedisengaged,brakeengaged,

andmotioncontrolleversout(neutrallock) tostartengine.(Itisnotnecessaryforthe operatortobeintheseattostarttheengine.)

–OperatormustbeinseatwhenPTOis

engaged,brakeisdisengaged,ormotion controlleversaremovedinorenginewillstop.

–Enginewillstopifeithertheleft,theright,

orbothleversaremovedfromneutrallock positionwhilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftAssistLever:Footpedalthatassists inraisingthedeck.

Seat

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

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

•Armrests:Moldedadjustableip-uparmrests.

•SeatSafetySwitch:Incorporatedintothe SafetyInterlockSystem.Timedelayseatswitch eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearvariable displacementpistonpumps.

•WheelMotors:TwoHydroGearwith11/4inch taperedshafts.

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:5.5qt.(5.2L)

Page 16

Specications

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–0-12.0mph(19.3km/hr)forward.

–0-8.0mph(12.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

Pneumatic (Air-Filled)

DeckSize

Quantity

TreadSize

Size26x12.00-1213x6.50-6

PlyRating

Pressure

60,66,&72

“Multi-Trac C/S”

10psi(69kPa)

Semi-Pneumatic

AllDecks

Smooth

CuttingDeck

•CuttingWidth:

–60inch(152.4cm)

–66inch(167.6cm)

–72inch(182.9cm)

•DeckDrive:

–Electricclutchmountedonhorizontalengine

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

–Bladesaredrivenbyone“B”Sectionbelt

(w/self-tensioningidler)fromtransfershaft ondecktobladespindles.

•Deck:

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

•DeckDepth:

–60inchDeck:6.0inches(15.2cm)

–66inchDeck:6.0inches(15.2cm)

–72inchDeck:6.0inches(15.2cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

•Discharge:Side

•BladeSize:(3ea.)

–60inchDeck:20.75inches(52.7cm)

–66inchDeck:22.75inches(57.8cm)

–72inchDeck:24.75inches(62.9cm)

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

Dimensions

OverallWidth:

Without Deck

Deector Up

Deector Down

60inch Deck

53.5inches (135.9cm)

61.4inches (156.0cm)

72.8inches (184.9cm)

66inch Deck

57.3inches (145.5cm)

68.0inches (172.7cm)

79.4inches (201.7cm)

72inch Deck

61.5inches (156.2cm)

74.3inches (188.7cm)

85.8inches (217.9cm)

Page 17

Specications

OverallLength:

RollBarUp

RollBarDown

60inch Deck

81.9inches (208.0cm)

92.5inches (235.0cm)

66inch Deck

83.4inches (211.8cm)

94.0inches (238.8cm)

72inch Deck

85.8inches (217.9cm)

96.4inches (244.9cm)

OverallHeight:

RollBar-UpRollBar-Down

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

TreadWidth:(CentertoCenterof Tires,Widthwise)

Drive Wheels

Caster Wheels

60inch Deck

41.9inches (106.4cm)

37.3inches (94.7cm)

66inch Deck

45.9inches (116.6cm)

42.3inches (107.4cm)

72inch Deck

45.9inches (116.6cm)

47.3inches (120.1cm)

BoltLocation

Anti-ScalpRollerNyloc NutSeeFigure10

Anti-ScalpRollerHex CapscrewSeeFigure10

EngineMountingBolts

WheelLugNuts

WheelMotorMounting Bolts

WheelHubSlottedNutminimum125ft-lb(169

RolloverProtectionSystem (RollBar)MountingBolts

DeckDriveJackshaftNut

ClutchRetainingBolt (securedwiththreadlocker)

Torque

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

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

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

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

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

N-m)

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

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

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

WheelBase:(CenterofCasterTireto CenterofDriveTire)

60inchDeck66inchDeck72inchDeck

56.0inches (142.2cm)

57.6inches (146.3cm)

60.2inches (152.9cm)

CurbWeight:

60inchDeck66inchDeck72inchDeck

1510lb(685kg)1560lb(708kg)1610lb(730kg)

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

CutterHousingSpindle Nut

BladeMountingBolt (lubricatewithanti-seize)

Torque

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

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

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

EngineDeck/FrontFrame MountBolts

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

Page 18

Operation

ProductOverview

1.MotionControlLever5.Controls

2.ParkingBrakeLever

3.Height-of-CutLever

4.FuelCap(BothSides)

Figure4

6.SeatBelt

7.RollBar

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideofthe consolecontroltheforwardandreversemotionof themachine.Theleverscontroltheowofhydraulic oilfromthehydrostaticpumptothedrivewheel motorforeachside.

Movingtheleversforwardorbackwardturnsthe wheelonthesamesideforwardorinreverse.Wheel speedisproportionaltotheamounttheleveris moved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (Figure6).

ChokeControl

Locatedonrightfueltank.

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

ThrottleControl

Locatedonrightfueltank.

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonleftsideofunit,justtothefrontofthe console.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Page 19

Operation

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightfueltank.

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

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

HourMeter

Locatedontherightfueltank.

Thehourmeterisconnectedtoapressureswitch installedintheengineblockanditrecordsthe numberofhoursthattheenginehasrun.Ifthe ignitionswitchisleftonwithoutenginerunning, hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locateddirectlybelowtherightsideofconsole,next tothecubby .

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

DriveWheelReleaseValves

Locatedonthetoprightfrontcornerofhydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe pushedwithouttheenginerunning.Unhookseat latchandtiltseatuptogainaccesstopumps.

Witha5/8inchwrench,turnbothvalvesoneturn counter-clockwisetoreleasedrivesystem.Turn clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

TrackingAdjustmentKnob

LocatedundertheseatontheLHpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso thatthemachinetracksstraightwiththedrivelevers inthefullforwardposition.

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

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Thevalvehasthreepositions,eachpositionmade in1/4turnincrements.

FuelFlowValveHandlePosition

“Off”

RightTankRight

LeftTankLeft

Down

FuelGauge

Locatedontheleftfueltank.

Important:DoNotrotatetheknobtoofar,as thismaycausethemachinetocreepinneutral. RefertotheMotionControlLinkageAdjustment sectioninMaintenance.

PTOEngagementSwitch

Locatedonrightfueltank.

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

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh regulargradeunleadedgasolinewithanoctanerating

Page 20

Operation

of87orhigher.Regulargradeleadedgasolinemay alsobeused;however,combustionchamberand cylinderheadwillrequiremorefrequentservice.See EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

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

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand installthetwopinsandsecurethemwiththe hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.Ensurethatthe rearpartoftheseatissecuredwiththeseat latch.

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

TurnthevalvetotheLHorRHtank.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushinonthePTOswitchtothe“STOP” 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

Page 21

Operation

time.Iftheenginedoesnotstart,allowa60 secondcool-downperiodbetweenstarting 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.

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-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE” position.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position todisengagetheblades.

•Slowthemachinedownbeforemaking sharpturns.

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

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

Page 22

Operation

Figure6

1.HandlesOut(Neutral Lock)

2.HandlesIn(Neutral)

3.FrontofUnit

4.Forward

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralunlockedposition.

3.Tomoveforwardinastraightlineapplyequal forwardpressuretobothlevers.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedawayfrom neutral.

4.Tostop,pullthemotioncontrolleversbackto theneutralposition.

5.Neutral

6.Reverse

7.NeutralLock

Figure7

1.HandlesOut(Neutral Lock)

2.HandlesIn(Neutral)

3.FrontofUnit

4.Forward

5.Reverse

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe centertotheneutralunlockedposition.

2.Tomoverearwardinastraightlineapplyingequal pressurepullbothmotioncontrolleversrearward.

Toturnleftorright,releasepressureonthe motioncontrollevertowardthedirectiondesired.

3.Tostop,pushthemotioncontrolleverstothe neutralposition.

AdjustingtheCuttingHeight

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

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

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

Thedeckcanberaisedbypullingthedecklever upand/orbypushingdownonthefootoperated

Page 23

Operation

deckliftassistleverlocatedatthefrontright corneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure8

1.Leverintransportand5inch(12.7cm)cuttingheight position

4.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheightand installthehairpincotterpin.

Seethedecalonthesideofthedeckliftplatefor cutheights.

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

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

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

Figure9

Forcuttingheightsabove4.0inches(102mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Besuretherollerboltsareinstalledwiththe springdiscwasherbetweentheheadofthebolt andthemountingbracket.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

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

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingtheboltandspring discwasher.

Page 24

Operation

Figure10

1.Springdiscwasher (conetowardsbolthead)

2.Frontrightanti-scalp bracketshown

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

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

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

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over. Backwardtip-overcouldcauseseriousinjury ordeath.

•Useextremecautionwhenoperatinga unitonaramp.

•Useonlyasingle,fullwidthramp;Do Notuseindividualrampsforeachside oftheunit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbroken rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp andgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledriving unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtipping backward.

Transporting

TransportingaUnit

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

CAUTION

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

DoNotdriveaunitonapublicstreetor roadway.

LoadingaUnit

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

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

Page 25

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Operation

Page 26

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

WARNING

Theenginecanbecomeveryhot.Touching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Aftertherst250hours

Beforeeachuseordaily

Every40hours

Every50hours

Every100hours

Every160hours

Every200hours

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheenginecoolingsystem.

•Removeaccumulateddebrisfromengine.

•Cleanthegrassbuild-upfromunderthedeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheheightadjustmentshaftbearings.

•Greasethereardeckstruts.

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

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

•Checkthesparkplugs.

•Greasethebrakebrackets.

Page 27

Maintenance

MaintenanceService

Interval

Every500hours

Every600hours

Monthly

Yearly

MaintenanceProcedure

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

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

•Checkthebatterycharge.

•Changetheengineoilifoperatedlessthan100hours.

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

•Greasethemuledrivebeltidlerarm.

•Greasethepumpdrivebeltidlerarm.

•Lubricatethecasterwheelhubs.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

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

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:Monthly

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

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

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

Page 28

Maintenance

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

Figure12

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

2.Torqueto55-60ft-lb (75-81N-m)Apply lubricanttothreads asneededtoprevent seizing.Copper-based anti-seizepreferable. Greaseacceptable substitute.

C.Applylubricanttothreadsofbladeboltas

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

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure11

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith, parkingbrakeengaged,PTOdisengagedand

Page 29

Maintenance

motioncontrolleversmovedoutintheneutral lockposition.Theoperatordoesnotneedtobe

intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

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

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

Runengineatone-thirdthrottle,engagePTO andraiseoffofseat(butdonotgetoffof machine)enginemustinitiateshutdownafter 1/2secondhaselapsed.

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

Again,runengineatone-thirdthrottle,brake engaged,andmoveleftmotioncontrolleverin

-enginemustinitiateshutdown.

Repeatagainmovingtherightleverin,then movingbothleversin-enginemustinitiate shutdownwhetheroperatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckRolloverProtections Systems(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

Makesurelatchpinandhairpinarefullyinstalled andlanyardisingoodcondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

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

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatuptogainaccess totheaircleaner.

3.Loosenretainingclipsandremoveaircleaner compartmentcover.

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

5.Checktheconditionoftheinnerelement.Replace wheneveritappearsdirty,typicallyeveryother timethepaperelementisreplaced.Cleanthebase

Page 30

Maintenance

aroundtheinnerelementbeforeremoving,so dirtdoesnotgetintotheengine.

6.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

Yearlyifoperatedless than100hours.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseislocatedonrighthandside ofengine.Placepanundermachinetocatchoil. Removeplugfromendofdrainhose.Allowoil todrainandreplaceoildrainplug.Torqueplug to20-24ft-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.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

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

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto10psi(69kPa).

4.Semi-pneumaticcastertiresdonotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.Lifttherubber aponfrontsideoftheenginetocheckpump drivebelt.

3.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

4.Checkundermachinetoinspectthemuledrive belt.SeeMuleDriveBeltTensionAdjustment section.

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

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Page 31

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Maintenance

Fitting

Locations

1.Front Casterwheel hubs

2.Front Caster Pivots

3.Height Adjustment Shaft Bearings

4.Deck DriveBelt IdlerArm

5.Brake Brackets

6.Mule DriveBelt IdlerArm

7.Pump DriveBelt IdlerArm

8.Deck RearStruts

Initial

Pumps

Numberof

Places

540Hours

*Seestep3forspeciallubricationinstructionson thefrontcasterpivotsandtheLubricateCaster WheelHubssectionforspeciallubrication instructionsonthefrontcasterswheelhubs.

Service

Interval

200Hours

40Hours

*Yearly

Number6(MuleDriveBeltIdlerArm)Located

UnderEngineFrame

Yearly

Number7(PumpDriveBeltIdlerArm)Located

UnderEngineFrame

3.Lubricatefrontcasterpivotsonceayear.Remove hexplugandcap.Threadgreasezerkinholeand

Yearly

pumpwithgreaseuntilitoozesoutaroundtop bearing.Removegreasezerkandthreadplugback in.Placecapbackon.

Yearly

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure13

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

Page 32

Maintenance

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkPN103-0063)mustbe replaced.

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

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandlepivot withaspraytypelubricantorlightoil.

LubricateBrakeRod Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake rodshaftwithaspraytypelubricantoralightoil (bushingsarelocatedtotheinsideoftheange bearings).

LubricateMotionControl

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.

BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings securingthemotioncontrolarmshaftswitha lightoiloraspraytypelubricant.

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’s Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltanksandthe engine.Replacewhennecessary.

ReplacementFilters

Briggs&Stratton

Briggs&StrattonP/N 695327

Page 33

Maintenance

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

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

Note:UseonlyExmarkPartNo.103-2146.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raiseseat.

3.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

4.Unscrewltertoremoveandallowoiltodrain fromreservoir.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor taperedshaft:

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

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

3.Ifmorethantwothreads(0.1inch)areshowing removenutandinstallwasher(PN1-523157) betweenhubandnut.

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

5.Thentightennutuntilthenextsetofslotslineup withthecrossholeinshaft.

6.Replacecotterpin.

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

5.FillreservoirasstatedinCheckHydraulicOil Levelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

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

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

ChangeInterval

500Hours

250Hours

Note:DoNotuseanti-seizeonwheelhub.

FuelTank—Mounting HardwareSpecications

ServiceInterval:Asrequired

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

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol arms.

•Sheaveretainingboltintheendofengine crankshaft.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

Page 34

Maintenance

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

Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthejackshaftandbearingsandthe jackshaftandsheaves.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Adjustments

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

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

4.Setanti-scalprollerstotopholesorremovethem completelyforthisadjustment.

5.Raisethedecktothe5inch(12.7cm)height position(alsotransportposition)andtakeallforce offofthetwolargedeckliftspringsbyloosening thenutsatthefrontofeachspring(Figure14).

6.Lowerthedecktothe1inch(2.54cm)height position.Forcetheleftreardecksupportarm downwardabout1/4inch(6.4mm)togetthe decktorestatthe1inchheightposition.Place lockingpliersbetweentherearswivelandspring stoptoholdthedeckinthisposition(Figure14).

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

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

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

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

Page 35

Maintenance

frontswivelusinglockingnutinfrontofswivel. Repeatforrightside.

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

Figure14

1.Applydownwardpressurehere

2.Placelockingpliersheretoholdspring

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

4.Removeforceondeckspringsbylooseningnutshere

5.Swivel

6.Frontofunit

7.Socketheadadjustingscrew

8.Jamnut

sideenginedecksupport,ispositionedbetween thecentersofthetwoalignmentholesinthe leftsupportplate(Figure15andFigure16).It isnecessarytoadjustthebelttensionwhenthe centeroftheboltheadisatorbelowthecenter ofthebottomalignmenthole.

3.Whenadjustmentisnecessary,loosentheidler pulleyontheright-handsidesoitcanmoveup anddownintheslot.

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

Repositiontheadjustingpulleytothebottomof theslot.

Note:Wheninstallinganewbelt,itisnecessary torepositiontherightadjustingpulleyupwardin theslotinordertopositionthecenterofthespring loadedpulleybetweenthealignmentholes.

12.Raisedeckliftlevertothe5inch(12.7cm) cuttingheightposition(Figure8).Adjustspring compressionuntilproperdistanceisobtained betweenthetwolargewashers(Figure14). Adjustmentismadebyturningthenutatthefront ofeachspring(clockwisewillshortenthespring, counter-clockwisewilllengthenthespring).Lock inpositionwithjamnuts.

Note:Whenaboveadjustmentshavebeenmade, thefrontofthedeckwillbeslightlylowerthanthe rearofthedeck.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

MuleDriveBeltTension Adjustment

Self-tensioningidler,adjustasfollows:

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktomakesurethecenterofthebolthead inthecenterofthespringloadedpulley,onleft

1.Frontofunit

Figure15

2.Alignmentholes

Page 36

Maintenance

1.Springidlerpulley

2.Frontofunit

BrakeLinkAdjustment

Checktomakesurebrakeisadjustedproperly.

1.Disengagebrakelever(leverdown).

2.Measurethelengthofthespring.Measurement shouldbe213/16inches(7.1cm)between washers.(Figure18).

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

Figure16

3.Rightsideidlerpulley (adjustable)

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

BeltGuideAdjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethebeltshieldontherightsideofmower deck.

3.Notebeltguideboltedtodeckneartheshield supportstudandright-handpulley.Guideshould be1/8inch(3.2mm)awayfromthebelt,with bolt-endofguidenearendofslot(Figure17).

4.Ifadjustmentisnecessary,loosentheboltsecuring thebeltguideandmakeproperadjustment. Tightenhardware.

Figure18

1.Leverdown (disengaged)

2.Leverup(engaged)

3.Nylocnutbelowtrunnion roller

4.Nylocnutbelowspring

5.1/8to3/16inch(3.2to

4.8mm)

6.Removepinadjustrod lengthforadditional brakeadjustment

7.Trunnionroller

8.Springretainerbracket

9.2.81inches(7.1cm)

10.Jamnutabovetrunnion roller

BrakeAdjustment

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

1.Endofslot

Figure17

2.Beltguide

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

3.Ifadjustmentisnecessary,loosenjamnutabove thetrunnionroller.Adjustthenylocnutunder thetrunnionrolleruntildistancelistedabove

Page 37

existsbetweenthespringretainerbracketandthe adjacentnylocnut.Tightenthejamnutabove thetrunnionroller.

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

Maintenance

ElectricClutchAdjustment

Noadjustmentnecessary.

ReverseIndicator Adjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatforward.

3.Beginwitheithertheleftorrightmotioncontrol lever.Movelevertotheneutralpositionandpull leverbackuntiltheclevispin(onarmbelowpivot shaft)contactstheendoftheslot(justbeginning toputpressureonspring).(Figure19).

4.Checkwhereleverisrelativetonotchinconsole (shouldbecenteredallowinglevertopivot outwardtotheneutrallockposition).

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

6.Repeatonoppositesideofunit.

Figure19

1.Turnbolthere4.Yoke

2.Levercenteredinnotch5.Loosenhere

3.Endofslot

6.Reverseindicator

MotionControlLinkage Adjustment

WARNING

Enginemustberunninganddrive wheelsmustbeturningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

1.Thisadjustmentmustbemadewiththedrive wheelsturning.Firstraisetherearofmachine

Page 38

Maintenance

upandsupportwithjackstands(orequivalent support)justhighenoughtoallowthedrive wheelscanrotatefreely.

2.Unhookseatlatchandtiltseatforward.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locateddirectlytotheleftoftheseat switchassemblybesidethehydraulicoilreservoir.

Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

4.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulic systemoiluptooperatingtemperature.

5.Loosenlocknutsfromtheballjointsateachend ofthepumpcontrollinkage(Figure20).

byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(Figure20).Movethemotion controllevertothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringtobringtheleversbackto neutral.Thewheelmuststopturningorslightly creepinreverse.Whenadjustmentiscomplete, tightenlocknutsontoballjoints.

9.BringtheLHmotioncontrolleverintothe neutralposition.AdjusttheLHpumpcontrolrod lengthbyrotatingthetrackingadjustmentknobin theappropriatedirectionuntilthewheelsslightly creepinreverse.Movethemotioncontrollever tothereversepositionandwhileapplyingslight pressuretotheleverallowthereverseindicator springtobringtheleversbacktoneutral.The wheelmuststopturningorslightlycreepin reverse(Figure21).

Figure20

Right-HandSideofUnit

1.Turnheretoadjust

2.Loosenhere(right-hand thread)

6.Startengine.Brakemustbeengagedand motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

7.Thereverseindicatorspringmustbecorrect beforethefollowingadjustmentscanbemade. SeetheReverseIndicatorAdjustmentsection.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

Theleftrodassemblycontrolstheleftwheeland therightrodassemblycontrolstherightwheel.

8.Bringthemotioncontrolleverintotheneutral position.AdjustRHpumpcontrolrodlength

Figure21

Left-HandSideofUnit

1.TurnLHtrackingadjustmentknob.(DoNotloosenany nutsonLHside)

10.Shutoffunit.Removejumperwirefromwire harnessconnectorandplugconnectorintoseat switch.

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure22formountingoptions.

Page 39

Maintenance

Cleaning

CleanEngineCooling System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

Figure22

1.Motioncontrolbracket

2.Leastresistance(softestfeel)

3.Mediumresistance(mediumfeel)

4.Mostresistance(rmestfeel)

5.Torquenylocnutto200in-lb(16.7ft-lb).Boltmust protrudepastendofnylocnutaftertorque.

6.Damper

7.Dampermustmovefreelyonbolt.

CasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut untilwashersareatandbackoff1/4ofaturn toproperlysetthepre-loadonthebearings.If disassembled,makesurethespringdiscwashersare reinstalledasshowninFigure23.

CAUTION

Excessivedebrisaroundtheenginecooling airintakeandinsideofthepumpdrive beltcompartmentanddamagedormissing rubberbafescancausetheengineand hydraulicsystemtooverheatwhichcan createarehazard.

Cleanalldebrisfrominsideofpumpdrive beltcompartmentdaily.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screenandfromaroundengineshrouding.

3.Cleanalldebrisfrominsideofpumpdrivebelt compartment.

4.Inspectrubberenginebafesforpropert. Replaceifnecessary.

1.Springdiscwashers

Figure23

RemoveAccumulatedDebris fromEngine

ServiceInterval:Beforeeachuseordaily

Enginepartsshouldbekeptcleantoreducetherisk ofoverheatingandignitionofaccumulateddebris.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removefrontpanelfromengineandcleanaround theintakemanifold,fuelpump,andcarburetor.

3.Reinstallthefrontpanel.

Important:DoNotusewatertocleanengine. Uselowpressurecompressedair.SeeEngine Owner’sManual.

Page 40

Maintenance

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Page 41

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank.

Enginewillnotstart,startshard,orfailsto keeprunning.

1.PTOisengaged.

2.Parkingbrakeisnotset.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow .

4.Thethrottleandchokearenotinthe correctposition.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotproperlyadjusted.8.Adjusttheseatswitch.

9.Electricalconnectionsarecorroded,loose orfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral lockposition.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

11.Clean,adjustorreplacesparkplug.

12.Checkthesparkplugwireconnection.

Enginelosespower.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.Ventholeinthefuelcapisplugged.

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

7.Dirt,water,orstalefuelisinthefuel system.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

Page 42

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Engineoverheats.

Mowerpullsleftorright(withleversfully forward).

Machinedoesnotdrive.

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesforthe engineareplugged.

1.Trackingneedsadjustment.1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

3.Reverseindicatorandmotioncontrol linkageneedadjustment.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

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

2.Addoiltothecrankcase.

3.Removetheobstructionsfromthecooling nsandairpassages.

3.Adjustthereverseindicatorandthe motioncontrollinkage.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration.

Bladesdonotrotate.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley.2.Checkbeltfordamage;replaceif

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

5.Brokenormissingidlerspring.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

necessary.Installdrivebeltandcheck adjustingshaftsandbeltguidesforcorrect position.

pulley,idlerarmandspringforcorrect positionandfunction.

5.Replacethespring.

Page 43

Schematics

ORANGE/BLACK STRIPE

DK BLUE

WHITE

TAN

DK GREEN

GREY

SEAT DELAY

MODULE DIODE

STARTER

SOLENOID

DK. GREEN

TAN

BLACK

WHITE

DK. GREEN/WHITE STRIPE

ORANGE/BLACK STRIPE

DK. GREEN/WHITE STRIPE

YELLOW

PINK/BLACK STRIPE

DK. GREEN

LT. GREEN

LT. BLUE

BLACK

GREY

TAN

BROWN

LT. BLUE

BLACK

TAN

SEAT DELAY

MODULE CONTROL

SEAT

SWITCH

ELECTRIC

CLUTCH

(PTO)

GROUND

FUSE

20 AMP

FUSE

20 AMP

ENGINE

CONNECTOR

RH MOTION

CONTROL

LH MOTION

CONTROL

BRAKE

START

RELAY

IGNITION

SWITCH

HOUR

METER

PTO

SWITCH

SEAT DELAY

MODULE INPUT

KILL

RELAY

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM WIRE END

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, ENGINE, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, ENGINE, PTO SWITCH

DK. GREEN

VIOLET

RED

TAN

BLACK

VIOLET

PINK

VIOLET

RED

PINK

RED

YELLOW

TAN

ORANGE

DK BLUE

ORANGE

GREY

PINK/BL

ACK STRIPE

BOTH MOTION CONTROL SWITCHES

ARE CLOSED WITH CONTROL LEVERS

IN NEUTRAL LOCK POSITION

CHARGE

RELAY

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

B + I + A

2. RUN

1. OFF

POSITION

3. START

TERMINAL A

TERMINAL B

TERMINAL Y

TERMINAL X

TERMINAL S

TERMINAL I

SWITCH IS CLOSED WITH

OPERATOR IN SEAT

SWITCH IN - ORANGE TO PINK/BLACK

SWITCH OUT - ORANGE TO GREY

G006157

Schematics

ElectricalDiagram

Page 44

Schematics

Page 45

Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part on these products and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.

This warranty applies to Exmark commercial turf equipment sold in the U.S. or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*

* The Engine warranty is covered by the engine manufacturer. Please refer to the engine manufacturer’s warranty statement that is included in the literature packet.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

454647

Page 46

Page 47

Page 48

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-376Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark FrontRunner Air-Cooled User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual