Exmark Laser Z CT Operator's Manual

For Serial Nos.

540,000 & Highe

Part No. 103-9180

WARNING

POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating pr actices can result in serious

operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condit ion. ♦ Stop engine and wait for all moving parts to stop. Remove spark

plug wire(s) or remove key before adjust ing, servicing, or

performing maint enance. ♦ If mower deck becomes clogged, stop engine and wait for all

moving parts to stop. Remove spark plug wire(s) or r em ove k ey

before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts . ♦ Keep off mower unless seat platf o r m is pr ovided. ♦ Keep others off mower.

WARNING

POTENTIAL HAZARD ♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals. WHAT CAN HAPPEN ♦ Failure to use caution may cause serious injury or illness. HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors. ♦ Keep face away from nozzle and gas tank/container opening. ♦ Keep away from eyes and skin. ♦ Never siphon by mouth.

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442 Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.

This spark ignition system complies with Canadian ICES-002 Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s M anual with your unit. Should this engine O wner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. Exmark, or its distributors and dealers, accept no responsibility f or variat ions which may be evident in the actual specifications of its product s and t he statements and descriptions contained in this publication.

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995 Program

If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part

6. Who pays for the part A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

order of six (6) line items or less.

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

and freight if it fails to arrive overnight in accordance to the program?

1. The dealer not submitting the Exmark Parts Plus

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactur ed to give you a maximum amount of dependability and years of trouble-free oper at ion.

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong the life of your mower, maintain its maximum ef ficiency, and promote safe operation.

If additional information is needed, or should you require trained mechanic ser vice, contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and dist r ibut or s ar e kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the f ield or at their service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you from the factor y.

All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol............................................................................1

1.2 Training..............................................................................................1

1.3 Preparation......................................................................................1-3

1.4 Operation ........................................................................................4-7

1.5 Maintenance & Storage...................................................................7-8

1.6 Safety Signs..................................................................................8-10

2. SPECIFICATIONS

2.1 Model Numbers................................................................................10

2.2 Engine..............................................................................................10

2.3 Fuel System ................................................................................ 10-11

2.4 Electrical System..............................................................................11

2.5 Operator Controls.............................................................................11

2.6 Seat..................................................................................................11

2.7 Hydrostatic Ground Drive System..................................................... 12

2.8 Tires & Wheels.................................................................................12

2.9 Cutting Deck.....................................................................................12

2.10 Dimensions..................................................................................12-13

2.11 Torque Requirements.......................................................................13

3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate Mower.................................................................................13

3.2 Install Rollover Protection System (Roll Bar)...............................13-15

3.3 Service Battery............................................................................15-16

3.4 Install Drive Wheels..........................................................................16

3.5 Check Tire Pressure.........................................................................16

3.6 Check Park Brake.......................................................................16-17

3.7 Install Seat .......................................................................................17

3.8 Install Motion Control Levers.......................................................17-18

3.9 Position Discharge Chute.................................................................18

3.10 Service Engine.................................................................................18

3.11 Service Hydraulic Oil........................................................................18

4. OPERATION INSTRUCTIONS

4.1 Controls.......................................................................................18-20

4.2 Pre-Start...........................................................................................20

4.3 Mowing........................................................................................20-22

4.4 Transporting................................................................................22-23

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance..................................................................23-31

5.2 Adjustments ................................................................................31-37

6. WASTE DISPOSAL

6.1 Motor Oil Disposal............................................................................37

6.2 Battery Disposal...............................................................................37

7. TROUBLE SHOOTING ..................................................................38-39

8. ELECTRICAL DIAGRAM .........................................................................40

9. HYDRAULIC DIAGRAM...........................................................................41

10. WARRANTY.............................................................................................42

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / O r ange background. Indicates a pot ent ially hazardous

situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous

situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit.

1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and t he proper use of the equipment. If the operator(s) or m echanic(s) can not read English it is the owner’s responsibility to explain this material t o them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children, teenagers, or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark.

1.3.2 The use of per sonal pr ot ective equipment, such as (but not limited to) pr otection for the eyes, ears, feet , and head is r ecom m ended.

CAUTION

POTENTIAL HAZARD ♦ This machine produces sound levels in excess of 85

dBA at the operator’s ear when in operation.

WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for

extended periods of time can cause hearing loss.

HOW TO AVOID THE HAZARD ♦ Wear hearing protection when operating this machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect t he area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operat or or bystander s.

WARNING

POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.

WHAT CAN HAPPEN ♦ Carbon monoxide can kill you.

HOW TO AVOID THE HAZARD ♦ Do not run engine indoors or in a small confined area

where dangerous carbon monoxide fumes can collect.

DANGER

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flamm able

and highly explosive.

WHAT CAN HAPPEN ♦ A fire or explosion from gasoline can bur n you, ot hers,

and cause property damage.

HOW TO AVOID THE HAZARD ♦ DO NOT smoke while refueling , and stay away from

an open flame or where gasoline fumes m ay be ignited by spark.

♦ Refuel only outdoors. ♦ Store gasoline in an approved container and keep it

out of the reach of children.

♦ Add fuel before start ing the engine. Never remove the

cap of the fuel tank or add fuel when engine is running or when the engine is hot.

♦ Never fill the fuel tank so t hat the gasoline level rises

above a level that is 1/2” below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage.

♦ If fuel is spilled, DO NOT attempt to start the engine.

Move away from the area of the spill and avoid creating any source of ignition unt il fuel vapors have dissipated.

♦ Don not operate without entire exhaust system in place

and in proper working condition.

DANGER

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flamm able

and highly explosive.

WHAT CAN HAPPEN ♦ A static charge can ignite g asoline vapors. A fire or

explosion from gasoline can burn you, others, and cause property damage.

HOW TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved

container.

♦ Always place gasoline containers on the ground away

from your vehicle before f illing.

♦ Do not fill gasoline containers inside a vehicle or on a

truck or trailer bed because interior car pet s or plastic truck bed liners may insulate the container and slow the loss of any static charge.

♦ When practical, r emove gas-powered equipment from

the truck or trailer and r efuel the equipment with its wheels on the ground.

♦ If this is not possible, then refuel such equipment on a

truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

♦ If a gasoline dispenser nozzle must be used, keep the

nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

WARNING

POTENTIAL HAZARD ♦ Gasoline vapor can collect inside enclosed trailers and

may be ignited by electrical sparks or hot engine/exhaust components.

WHAT CAN HAPPEN ♦ Explosion and fire may occur, resulting in proper t y

damage, personal injury, and/or death.

HOW TO AVOID THE HAZARD ♦ Provide adequate ventilation of any enclosed trailer to

prevent build up of gasoline vapors, especially at floor level.

♦ Refuel only outdoors, never inside an enclosed trailer. ♦ Be sure all fuel tanks and gasoline st or age containers

have proper caps installed to prevent spillage and minimize vapor escaping into the trailer.

♦ Do not place any equipment that is leaking gasoline in

an enclosed trailer.

1.4 OPERATION

Although hazard control and accident prevention parti al l y are dependent upon the

design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of t he personnel i nvolved in the operation, transport, maintenance, and storage of the equipment. It is essential that all Operator Safet y M echanisms be connected and in operating condition prior to use for mowing.

WARNING

POTENTIAL HAZARD ♦ Operating engine parts, especially the m uffler, become

extremely hot.

WHAT CAN HAPPEN

♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc. can cat ch fire.

HOW TO AVOID THE HAZARD ♦ Allow engine parts, especially the muff ler , to cool before

touching.

♦ Remove accumulated debris from muffler and engine area. ♦ Install and maintain in working order a spar k arrester before

using equipment on forest - covered, grass-covered, or brush-covered unimproved land.

WARNING

POTENTIAL HAZARD ♦ Hands, feet, hair, clothing, or accessories can become

entangled in rotating part s.

WHAT CAN HAPPEN ♦ Contact with rotating parts can cause traum at ic am putation

or severe lacerations.

HOW TO AVOID THE HAZARD ♦ Do not operate the machine without guards, shields, and

safety devices in place and working properly.

♦ Keep hands, feet, hair, je welry, or clot hing away from

rotating parts.

1.4.1 Give complete, undivided attention t o the job at hand.

1.4.2 Mow only in daylight or good artificial lig ht, keeping away from holes and hidden hazards. NEVER carry passengers.

DO NOT operate the mower when children or others are in t he ar ea!

1.4.3 When feasible, avoid operating the equipment in wet grass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action and/or tip-over could occur. The operator is r esponsible for safe operation on slopes.

DANGER

POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and

loss of control.

WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches, steep banks, or

water can cause rollovers, which may result in serious injury, death or drowning.

HOW TO AVOID THE HAZARD

♦ Do not mow slopes when grass is wet. ♦ Do not mow near drop-offs or near water. ♦ Do not mow slopes greater than 15 degrees. ♦ Reduce speed and use extreme caution on slopes. ♦ Avoid sudden turns or rapid speed changes.

• See inside the back cover to determine the approximate slope angle of t he

area to be mowed.

• Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep

banks or water. This area can be dangerous, see Figure 1.

Figure 1

SAFE ZONE FOR MOWING

• Progr essively great er care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. I f tires lose traction,

disengage the blades and proceed slowly off the slope.

• Avoid sudden starts when mowing uphill. Mower may tip backwards.

• Be aware that loss of traction may occur going downhill. Weight transf er to

the front wheels may cause drive wheels to slip and cause loss of braking and steering.

• Watch for ditches, holes, rocks, dips, and rises that chang e t he oper ating

angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing

area. Tall grass can hide obstacles.

• Use extreme care with grass cat chers or attachments. These can change t he

stability of the machine and cause loss of control.

• Follow the manufact urer’s recommendations for wheel weights or

counterweights to improve stability.

1.4.5 A Rollover Protection System (roll bar) is installed on the unit.

WARNING

POTENTIAL HAZARD ♦ There is no rollover protection when the roll bar is down.

WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches, steep banks, or

water can cause rollovers, which may result in serious injury, death or drowning.

HOW TO AVOID THE HAZARD ♦ Keep the roll bar in the raised and locked position and use

seat belt.

♦ Lower the roll bar only when absolutely necessary. ♦ Do not wear seat belt when the roll bar is down. ♦ Drive slowly and carefully. ♦ Raise the roll bar as soon as clearance permits.

• Be certain t hat the seat belt can be released quickly if the m achine is dr iven or

rolls into ponds of water.

• Check carefully for overhead clearances (i.e. branches, door ways, and

electrical wires) before driving under any objects and do not contact them.

1.4.6 Use EXTREME caut ion when backing up. LOOK BEHIND YOU!!

1.4.7 Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be m owed.

1.4.8 Never operate the mower with defect ive guar ds, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper working condition.

1.4.9 DO NOT change the engine g overnor set tings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury.

1.4.10 Disengage PTO before starting engine.

1.4.11 Start

1.4.12 Keep hands, feet, and clothing away from rotating parts while the mower is being

1.4.13 Stop engine, wait for all m o ving par t s t o stop, and remove key:

• Before checking, cleaning or working on the m ower.

• After str iking a foreign object ( inspect t he m ower for damage and make

• Before clearing blockages.

• Whenever you leave the mower.

Stop the engine and wait for all moving part s t o stop:

• Before refueling.

• Before dumping the grass catcher.

the engine carefully with feet well away from the blades.

operated.

repairs before restart ing and operating the mower).

1.4.14 Before stopping the engine, place the throt t le cont r ol midway between the “slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.

1.4.15 The fuel system is provided with a shut-of f valve. The fuel shut-off valve is used to shut off the fuel:

• When the machine will not be used for a few days.

• During transport to and from the job.

• When parked inside a building.

1.4.16 This mower was designed for one operator only. Keep all ot her s away fr om mower during operation.

1.4.17 Do Not mow with the discharge deflector raised, rem oved, or altered unless there is a grass collection system or mulch k it in place and work ing properly.

1.4.18 Be aware of the mower discharge and direct discharge away from others.

1.4.19 Do Not operate the mower under the influence of alcohol or drugs.

1.4.20 Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

1.4.21 If jump star ting is required:

a) connect the positive (+) power cable from the positive post on the booster

battery to the positive terminal post on the star ter solenoid switch (this post has the positive battery cable attached to it).

b) connect the negative or ground cable (-) from the negative post on the

booster battery to any engine deck gr ound, pr eferably the engine block as far away from the battery as possible.

c) disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

1. 5. 1 For engine maintenance, follow the engine m anufacturer’s recommendations precisely as stated in the engine manual.

1. 5. 2 Disconnect the battery cable from t he negative battery post when the unit will be allowed to sit for more than 30 days without use.

1. 5. 3 Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and ser vice life. To preserve optimum battery performance and lif e, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, bat t er y should be fully charged before

putting away for winter storage.

1. 5. 4 Keep engine, engine area, and hydraulic pump area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. These materials can become combust ible and may result in a fire.

1. 5. 5 Store fuel in a container specif ically desig ned for this purpose in a cool, dry place.

1. 5. 6 Keep the mower and fuel container in locked stor age to prevent children from playing or tampering with them.

1. 5. 7 Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present.

1. 5. 8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly.

1. 5. 9 Check all bolts frequently to maintain proper tightness.

1. 5. 10 Keep all guards, shields and all safety devices in place and in safe working condition.

1. 5. 11 Frequently check for worn or deterior ating components that could create a hazard.

1. 5. 12 All replacement parts must be the same as or equivalent to the parts supplied as original equipment.

WARNING

POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrat e

skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin must be

surgically removed within a few hours by a doctor

familiar with this form of injury or gangrene ma y result . HOW TO AVOID THE HAZARD ♦ Make sure all hydraulic fluid hoses and lines are in

good condition an all hydraulic connections and fittings

are tight before applying pressure to hydraulic system. ♦ Keep body and hands away from pinhole leaks or

nozzles that eject high pressure hydraulic fluid. ♦ Use cardboard or paper, not your hands, to f ind

hydraulic leaks. ♦ Safely relieve all pressure in the hydraulic system by

placing the motion control levers in neutral and

shutting off t he engine before perform ing any work on

the hydraulic system.

1.6 SAFETY SIGNS

1. 6. 1 Keep all safety signs legible. Remove all grease, dirt, and debr is from safety signs and instructional labels.

1. 6. 2 Safety signs must be replaced if they are missing or illegible.

1. 6. 3 When new components are installed, be sure that curr ent safety signs are affixed to the replaced components.

1. 6. 4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or fr om Exmar k Mfg. Co. Inc.

1. 6. 5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1. 6. 6 Familiarize yourself with the following safety signs and inst r uction labels. They are critical to the safe operation of your Exmark commercial mower.

PART NO. 108-5995 LOCATION: Top of Console Under Seat

PART NO. 103-4891 LOCATION: Center of Console

PART NO. 103-4892 LOCATION: Right of Throttle

Control on RH Tank

PART NO. 103-4930 LOCATION: Right of Choke

PART NO. 1-303508 LOCATION: Front Right Corner Top of Mower Deck

PART NO. 1-403005 LOCATION: Left and Right Corners

of Mower Deck

PART NO. 1-513742 LOCATION: On Top of Mower

Deck Belt Shields, Left and Right Sides

PART NO. 103-4903 LOCATION: Top Front of RH Tank

Control on RH Tank

PART NO. 98-5954 LOCATION: Under Mower Deck

Belt Shield(s)

PART NO. 1-523552 LOCATION: Top of Hydraulic

Reservoir

PART NO. 103-2644 LOCATION: Top of Hydraulic

Reservoir

PART NO. 107-2102 LOCATION: RH Inside Surface

of Upper Roll bar

PART NO. 1-633922 LOCATION: Front Left Corner Top

of Mower Deck

PART NO. 1-513746 LOCATION: On Engine

Blower Housing

PART NO. 103-9116 LOCATION: Bottom Side of Floor Pan

PART NO. 107-2112 LOCATION: Top Center of Floorpan

2. SPECIFICATIONS

PART NO. 1-653477 LOCATION: Left of Center on Mower

Deck, Under Floor Pan

PART NO. 103-7491 LOCATION: On Top LH Side of Mower Deck

PART NO. 1-513748 LOCATION: Bottom of

Floorpan

PART NO. 1-653147 LOCATION: Lefthand Side of Cutting

Height Adjustment Plate

2.1 MODEL NUMBER:

Serial Nos. 510, 000 & Hi gher : LCT4418BV; LCT4818BV; LCT5218BV

2.2 ENGINE:

2. 2. 1 Engine Specifications: See Your Engine Owner’s Manual

2. 2. 2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM

2.3 FUEL SYSTEM

2. 3. 1 Capacity: 5.8 gal. (21.9 L.)

2. 3. 2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher.

2. 3. 3 Fuel Filter: Replaceable in-line Briggs and Stratton P/ N 493629

2. 3. 4 Fuel Shut-Off Valve: in-line, 1/4 tur n

2.4 ELECTRICAL SYSTEM

2. 4. 1 Charging System: Flywheel Alternator

2. 4. 2 Charging Capacity: 15 amps

2. 4. 3 Battery Type: BCI Group U1

2. 4. 4 Battery Voltage: 12 Volt

2. 4. 5 Polarity: Negative Ground

2. 4. 6 Fuses: Two 20 amp blade type

2. 4. 7 Safety Interlock System:

PTO must be disengaged, brake engaged, and motion control levers out

(neutral lock) to start engi ne. (It is not necessary for the operator t o be in the seat to start the engine.)

Operator must be in seat when PTO is engaged, brake is disengaged, or

motion control levers are moved in or engine will stop.

Engine will stop if either the left, the right, or both levers are moved from

neutral lock position while brake is engaged.

2.5 OPERATOR CONTROLS

2. 5. 1 Steering and Motion Control:

Separate levers, on each side of the console, control speed and direction of

travel of the respective drive wheels.

Steering is controlled by varying the position of the levers relative to each other . Moving motion control levers outward Motion control levers are adjustable to two heights.

2.5.2 PTO Switch

: Engages electric clutch (t o dr ive belt) which engages mower

blades.

2. 5. 3 Parking Brake Lever

2. 5. 4 Deck Height Adjustment Lever

: Engages parking brake.

: Sets cutting height to desired position.

(in slots) locks the drive system in neutral.

2.6 SEAT

2. 6. 1 Type: Standard seat: high back, foam padded (internal spring suspension).

Optional Seat accessory: custom ride suspension system can be added to the

standard set to increase comfort .

Optional suspension seat: high back, low profile foam- in- place cushion

(dampened, adjustable spring suspension) with armrests.

2. 6. 2 Mounting: Hinged to tilt up for access to hydraulic pumps, batt er y and other components. Held in tilted position with prop rod. Adjustable fore and aft seat t r ack.

2.6.3 Armrests: Optional: foam padded flip-up armrests with height adjustment.

Optional suspension seat: molded adjustable flip-up armrests.

2. 6. 4 Seat Safety Switch: Incorporated into t he Safety Interlock System.

Time delay seat switch eliminates rough ground cut- outs.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2. 7. 1 Hydrostatic Pumps: Two Hydro Gear BDP-10A variable displacement piston pumps.

2. 7. 2 Wheel Motors: Two Hydro Gear wheel drive motors with 1 1/4” tapered shafts.

2. 7. 3 Hydraulic Oil: Use Mobil 1 15W-50 Synthetic Motor Oil.

2. 7. 4 Hydraulic Oil Capacity: 2.1 qt. (2.0 L.)

2. 7. 5 Hydraulic Filter: Replaceable cartridge type.

P/N 1-513211: 10 microns, 18 psi bypass (Summer use above 32° F (0°C)) P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F(0°C))

2. 7. 6 Speeds: All units: 0 – 7.2 mph ( 11.6 km/hr) for ward.

0 – 4.0 mph (6.4 km/hr) r everse.

2. 7. 7 Drive wheel release valves allow machine to be moved when the engine is not running.

2.8 TIRES AND WHEELS

2.8.1 Tires:

Drive Tires 20 x 10-10 2 “Turf Mate” 4 13 psi (90 kPa) Front Caster Tires 11 x 4.00-5 2 Smooth 4 16 psi (110 kPa)

Size Qty Tread Ply Inflation

2.9 CUTTING DECK

2.9.1 Cutting W idt h: 44 in. (111.8 cm) 47.2 in. (120.0 cm) 52 in. (132.1 cm)

2. 9. 2 Discharge: Side (Optional Mulch or Bag)

2.9.3 Blade Size:

(3 ea.)

2.9.4 Blade Spindles: solid steel spindles with 1” (2.54 cm) I.D. bearings.

2. 9. 5 Deck Drive: Elect r ic clutch mounted on vertical engine shaft. Blades ar e dr iven by one “B” Section belt (w/self-tensioning idler) direct from the engine.

2. 9. 6 Deck: Full floating deck is attached to out-front suppor t frame.

Maximum turf protection is provided anti-scalp rollers:

44” and 48” Decks: Qty 3

52” Decks: Qty 5.

Deck design allows for bagging, mulching or side discharge.

2. 9. 7 Cutting Height Adjustm ent : an extr a- long cushioned lever is used to adjust the cutting height fr om 1- 1/ 2” (3.8 cm) to 4-1/2” (11.4 cm. ) in 1/4” (.64 cm.) increments.

The cutting height adjustment handle has a transport position and all

adjustments can be made while the operator remains seated.

2. 9. 8 Mulching Kit: Optional.

44” deck 48” deck 52” deck

15.25 in. (38.7 cm) 16.25 in. (41.3 cm) 18.00 in. (45.7 cm)

2.10 DIMENSIONS

2.10.1 Overall Width:

Without deck 44 in. (111.7 cm) 44 in. (111.7 cm) 44 in. (111.7 cm) Discharge chute up 47.4 in. (120.3 cm) 50.3 in. (122.4 cm) 54.3 in. (137.9 cm) Discharge chute down 54.7 in. (138.9 cm) 58.1 in. (147.6 cm) 63.8 in. (162.1 cm)

2.10.2 Overall Length:

Roll Bar - Up 73.9 in. (187.7 cm) 73.9 in. (187.7 cm) 75.5 in. (191.8 cm)

Roll Bar - Down 79.6 in. (202.2 cm) 79.6 in. (202.2 cm) 81.2 in. (206.2 cm)

2.10.3 Overall Height:

w/44” Deck w/48” Deck w/52” Deck

44” Deck 48” Deck 52” Deck

Roll Bar - Up Roll Bar - Down

69.4in. (176.3 cm) 51.3 in. (130.3 cm)

2. 10. 4 Tread W idt h: ( c ent er to center of tires, widthwise)

44” Deck 48” Deck 52” Deck

Drive Wheels

Front Casters

34.9 in. (88.6 cm) 34.9 in. (88.6 cm) 34.9 in. (88.6 cm)

32.7 in. (83.1 cm) 32.7 in. (83.1 cm) 34.1 in. (86.6 cm)

2. 10. 5 Wheel Base: (c ent er of caster tire to center of drive tire)

44” Deck 48” Deck 52” Deck

46.2 in. (117.3 cm) 46.2 in. (117.3 cm) 46.2 in. (117.3 cm)

2.10.6 Curb Weight: 44” Deck 48” Deck 52” Deck

880 lbs. (399 kg) 910 lbs. (413 kg) 970 lbs. (440 kg)

2.11 TORQUE REQUIREMENTS

Bolt Location Torque Cutter Housing Spindle Nut (secured with threadlocker) 140-145 ft-lbs. (190-197 N-m)

Blade Mounting Bolt................................................................55-60 ft-lbs. (75-81 N-m)

Engine Deck/Front Frame Mount Bolts...................................30-35 ft-lbs. (41-47 N-m)

Anti-Scalp Roller Nuts.............................................................40-45 ft-lbs. (54-61 N-m)

Engine Mounting Bolts ...........................................................25-30 ft-lbs. (34-41 N-m)

Wheel Motor Mounting Bolts.................................................72-77 ft-lbs. (98-104 N-m)

Wheel Hub Slotted Nut ..................................................minimum 125 ft-lbs. (169 N-m)

Wheel Lug Nuts ..................................................................90-95 ft-lbs. (122-129 N-m)

Rollover Protection System (roll bar) Mounting Bolts ..............30-35 ft-lbs. (41-47 N-m)

Clutch Retaining Bolt (secured with threadlocker)...................55-60 ft-lbs. (75-81 N-m)

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE MOWER

3.2 INSTALL ROLLOVER PROTECTION SYSTEM (ROLL BAR)

3. 2. 1 Disassemble roll bar from the cr at e.

a) Remove roll bar tubes from sides of crat e and remove screws that attach the

wheel hub retaining plate to the bottom of the crate.

b) Remove the two brackets used to mount the bott om of the upper roll bar tube

to the crate. Remove the 1/2-13 x 3 1/4 capscrews and 1/2-13 hex flang e lock nuts from the t wo brack et s at each end of the upper roll bar tube and retain for later use.

3. 2. 2 Raise the rear of the unit and support it with jack stands or equivalent support.

CAUTION

POTENTIAL HAZARD ♦ Raising the rear of the unit for assembly relying solely

on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough

support or may malfunction allowing the unit to fall,

which could cause injury. HOW TO AVOID THE HAZARD ♦ DO NOT rely solely on mechanical or hydraulic jacks

for support. Use adequate jack stands or equivalent

support.

3. 2. 3 Remove the wheel nuts from both sides of the unit and retain for later use.

3. 2. 4 Install the two lower roll bar tubes. a) Locate the left and right lower roll bar tubes.

b) Align lower roll bar tubes along wheel moto r channels as shown in Figur e 2. c) LOOSELY install lower roll bar hardware (four 3/8-16 x 1 capscrews, four

spring disk washers and four 3/8-16 whizlock nuts) from the bolt bag to the tubes on each side as shown in Figure 2:

NOTE: Be sure the spring disk washer cone is installed t owards the head of

the capscrew.

FIGURE 2

LOWER ROLL BAR INSTALLATION

3.2.5 Install the upper u-shaped section of the roll bar. (Ref er ence Figure 3 for

alignment and installation instructions below): a) Locate the latch pin assemblies (pin and hairpin connected with a lanyard). b) Install a 1/2-13 x 3 1/4 capscrew in the washer on the lanyard of each pin

assembly.

Note: Make sure the bent tab in the washer is towards the head of the bolt.

b) Lightly oil the inside surfaces of the ear-shaped plates at the upper end of

the lower roll bar tubes.

c) Locat e t he upper u-shaped section of the roll bar. Inst all t he upper roll bar

section using the two 1/2-13 x 3 1/4 capscrews from step b and two 1/2-13 hex flange lock nuts. Do not over tig ht en. Make sur e upper roll bar can pivot freely.

Notes:

• Make sure the capscrew and nuts are installed with the nut to the inside of the roll bar.

• Make sure the tab on the lanyard washer is installed as shown and points toward the front of t he unit .

d) Torque all lower roll bar hardware attached to t he m achine frame to 30 ft- lbs.

(41-47 N-m).

e) Tighten the front knobs against the upper roll bar ends.

FIGURE 3

UPPER ROLL BAR INSTALLATION

3.3 SERVICE BATTERY

WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash

hands after handling.

The machine is shipped with a filled lead acid battery.

3. 3. 1 Unhook seat latch and tilt seat up to gain access to the battery.

DANGER

POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses

WHAT CAN HAPPEN ♦ Battery gasses can explode causing serious injury. HOW TO AVOID THE HAZARD

♦ Keep sparks, flames, or cigarettes away from battery. ♦ Ventilate when charging or using batter y in an

enclosed space.

♦ Make sure venting path of battery is always open once

battery is filled with acid.

3. 3. 2 Check the voltage of the bat tery with a digital voltmeter. Locate the voltage r eading of the battery in the table below and charge the bat tery for the recommended time interval to bring the charge up t o a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected and the

battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the batter y (see char t below f or r ecom mended charger settings).

Voltage

Reading

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours

11.7 – 12.0 0 – 25% 14. 4 volts/ 4 am ps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

Percent

Charge

Maximum

Charger Settings

Charging Interval

CAUTION

POTENTIAL HAZARD ♦ If the ignition is in the “ ON” position there is potential

for sparks and engag em ent of components. WHAT CAN HAPPEN ♦ Sparks could cause an explosion or moving parts

could accidentally engage causing personal injury. HOW TO AVOID THE HAZARD ♦ Be sure ignition switch is in the “OFF” position before

charging the battery.

3. 3. 3 Connect the negative battery cables. NOTE: I f the positive cable is also disconnected, connect the positive (red)

cable to the positive battery terminal first, then the negative (black) cable and green/white wire to the negative battery ter m inal. Slip insulator boot over the positive terminal.

NOTE: If time does not perm it char ging the battery, or if char ging equipment is

not available, connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to suf ficiently charge the battery.

3.4 INSTALL DRIVE WHEELS

3.4.1 Mount drive wheels with the valve stem to the outside of the unit. Secure using four (4) 1/2-20 wheel nuts (installed on studs in hubs) for each wheel. Torque to 95 ft-lbs (128 NxM).

3.5 CHECK TIRE PRESSURE

3.5.1 Check tire pressure in caster and drive tires. Proper inflation pressure for caster tires is 16 psi (110 kPa). Proper inflation for drive tires is 13 psi (90 kPa) . Adjust if necessary.

3.6 CHECK PARK BRAKE

3.6.1 Disengage the park brake. Measure the distance vert ically from the lower front corner of the brake bar to the crown of the tire. The distance should measur e 1” (2.5 cm) to 1 5/16”(3.3 cm) . To adjust the brake, loosen the j am nut s next t o t he yoke at each end of the park brake linkage. Place a wrench on one of the two nuts near the front of the park brake linkage. Turn the linkage until the distance from the lower front cor ner of the brake bar measured vertically to t he cr own of the tire is 1” (2.5 cm) to 1 5/16” ( 3.3 cm) with the park brake disengaged. Retighten the jam nuts. See Figure 4.

3.7 INSTALL SEAT

3.7.1 a) Remove seat assembly from the crate.

b) Remove the four 5/16-18 whizlock nuts from t he seat track studs at the

c) Align the seat track studs on the bott om of the seat with the holes in the

FIGURE 4

PARK BRAKE ADJUSTMENT

bottom of the seat. Retain for use later.

seat frame. Place seat on top of the frame and secure with the four 5/16-18 whizlock nuts remove in step b).

3.8 INSTALL MOTION CONTROL LEVERS.

3.8.1 Loosen and remove the two (2) 3/8” x 1” bolts and spring disc washers which attach the motion control levers to the control arm shafts f or shipping and the two (2) 3/8” x 1” bolts and spring disc washers which are screwed into the control arm shafts.

a) Install the left motion control lever onto the contr ol ar m shaft (See Figure 5)

on the left side of the console. Place the lever (with the mounting plate towards the rear) on the outside of t he cont r ol ar m shaft and secure with the bolts and washers. Position the lever so the bolts are in the center of the slots on the lever mounting plate and tig hten until snug. Repeat on opposite side of unit.

NOTE: There are two lever height options available. Place the levers in the

top two holes to increase height of the levers, or in t he bottom two holes to decrease the height of the levers.

If the levers do not align with each other, when in the neutral position, (See

Figure 6) loosen the hardware and make the appropr iate adjustment by sliding/tilting the lever(s) forward or backward until properly aligned and tig hten hardware.

MOTION

CONTROL

LEVER

MOUNT PLATE TO

THE REAR & OUTSIDE

OF ARM SHAFT

FIGURE 5 FIGURE 6

CONTROL ARM SHAFT LEVER ALIGNMENT

LEVERS IN

ALIGNMENT

b) If the ends of the levers hit against each other, while in the drive position (levers

rotated in as far as possible), make adjustments by moving the levers outwards to the neutral lock position and carefully bending them outward. Move them back to the drive position and check for clearance, repeat if necessary.

3.9 POSITION DISCHARGE CHUTE

3.9.1 Loosen two (2) 5/16” nyloc nuts at t aching discharge chute. Lower the discharge chute into position. Retighten nyloc nuts until chut e is snug but can pivot freely.

3.10 SERVICE ENGINE

Refer to Engine Owner’s Manual.

3.11 SERVICE HYDRAULIC OIL

The machine is shipped with hydraulic oil in the reservoir. Run the machine f or

approximately 15 minutes to allow any extra air to purge out of t he hydraulic system. Check hydraulic reservoir and if necessary f ill the reservoir to the appropriate level with Mobil 1 15W-50 synthetic mot or oil. Replace hydraulic reservoir cap and tighten until snug. Do not overt i ghten.

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the temperature of the oil. The “HOT” level shows the level of oil when it is at 225°F (107°C). The “COLD” level shows the level of the oil when it is at 75°F ( 24°C) . Fill to the appropriate level depending upon the tem per at ure of the oil. For example: If the oil is about 150° F (65°C). Fill to halfway between the “HOT” and “COLD” levels. If the oil is at room temperature (about 75° F (24°C)), fill only to the “COLD” level.

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4.1.1 Familiarize yourself with all controls before operating t he mower.

4. 1. 2 Motion Control Levers

The left lever controls the flow of hydraulic oil from the left hydrost atic pump to

the left drive wheel motor. The r ight lever controls the flow of hydraulic oil f rom the right hydrostatic pump to the right drive wheel motor.

IMPORTANT: To begin movement (forward or backward) the operator must

be in the seat, the brake lever must be disengaged (pushed down) before the motion control levers can be moved in or the engine will kill.

When levers are centered in the T-slot the drive system is in the neutral position.

With levers moved out in t he T-slot the drive system is in the neutral lock position (See Figure 7).

: Located on each side of the console.

FIGURE 7

MOTION CONTROL POSITIONS

By moving both levers an equal amount forward or back from the neutral position

the machine can be caused to move forward or backward in a straight line.

Movement of the left lever forward will cause the left drive wheel to rotate in a

forward direction. Movement of the right lever f orw ard will cause the right drive wheel to rotate in a forward direction. To stop forward travel, pull the levers back to the neutral position.

To turn left while moving forward, move the left l ever back toward neutral to

slow the left drive wheel. To turn right while moving forward, move the right lever back toward neutral to slow the right drive wheel.

To make a zero turn to the left, pull the left lever back beyond neutral while

holding the right lever slight ly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutr al while

holding the left lever slight ly ahead of neutral.

Pulling the levers back from the neutral position will cause the respective drive

wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutr al) .

To turn to the left while backing, move the left lever f orward toward neutral. To

turn to the right while backing , m ove the right lever forward toward neutral.

CAUTION

POTENTIAL HAZARD ♦ Machine can spin very rapidly by positioning one lever

too much ahead of the other. WHAT CAN HAPPEN ♦ Operator may lose control of the machine, which may

cause damage to the machine or injury. HOW TO AVOID THE HAZARD

♦ Use caution when making turns. ♦ Slow the machine down before making sharp turns.

4. 1. 3 Tracking Adjustment Knob: Located under the seat on the LH pump control link. Rotating this knob allows fine tuning adj ustments so that the machine track s st r aight with the drive levers in the full forward position.

Stop machine and wait for all moving parts t o stop. Engage park brake. Unhook

seat latch and tilt seat forward to gain access to the tracking k nob. Rotate the knob counter-clockwise (as viewed from the rear of t he m achine) to cause the machine to track more to the r ig ht and clockwise to cause the machine to track more to the left. Adjust in quar ter-turn increments until the m achine t racks straight. Check that the machine does not creep when in neutral with the park brakes disengaged.

IMPORTANT: Do not rotate the knob too far, as this may cause the machine

to creep in neutral. Refer to section 5.2. 10 f or cont rol l inkage adjustment.

4. 1. 4 PTO Engagement Switch

: Located on the right tank.

Switch must be pulled out to the “ROTATE” position to engage the blades.

Switch is pushed in to the “STOP” position to stop the blades.

4.1.5 Choke Control

: Located on the right fuel t ank.

Choke is used to aid in starting a cold engine. DO NOT run a warm engine with

choke in the “ON” position.

Moving the choke lever forward will put the choke in the “ON” position and

moving the choke lever to the rear will put the choke in the “OFF” position.

4.1.6 Throttle Control

: Located on the right tank.

Throttle is used to control engine speed. Moving throttle lever forward will increase

engine speed and moving throttle lever to the rear will decrease engine speed.

4.1.7 Brake Lever

: Located on left side of t he console. The brake lever engages a

parking brake on the drive wheels.

Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage the brake. The unit must be tied down and brake engaged when transpor ting.

4.1.8 Ignition Switch

: Located on the right tank.

The ignition switch is used to start and stop the engine. The switch has three

positions “OFF”, “ON” and “START”. Insert the key into switch and rotate clockwise to the “ON” position.

Rotate clockwise to the next position to engage the starter (key must be held

against spring pressure in this position) .

Brake must be engaged, motion control levers out (neutr al lock position)

and PTO switch “OFF” to start engine. (It is not necessary for the operator t o be in the seat to start the engine. )

4.1.9 Hour Meter

: Located on the right tank.

The hour meter is connected to a pressur e switch installed in t he engine block

and it records the number of hour s t hat the engine has run. If ignit ion switch is left on without engine running, hour m eter will not run.

NOTE: This switch is not a low oil sensor and will not alert the operator if the

engine oil is low.

4. 1. 10 Fuel Shut-Off Valve

: Located In the fuel line midway between the fuel tank and

the engine behind seat.

The fuel shut-off valve is used to shut off the fuel when the machine will not be

used for a few days, during transport to and from the jobsite, and when park ed inside a building.

Rotate the valve 1/4 turn clockwise to shut of f fuel. Rotate the valve 1/4 tur n

counter-clockwise to turn on fuel.

4.1.11 Fuel Gauge

: Located on the left f uel t ank. The fuel gaug e m onitors the amount

of fuel in the tank .

4. 1. 12 Drive Wheel Release Valves

: Located on the right front corner of the hydrostatic pumps. Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running. Unhook seat latch and tilt seat up to gain access to pum ps.

With a 5/8 wrench, turn both valves one turn counter-clockwise to release drive

system.

Turn clockwise to reset system. DO NOT overtighten. DO NOT tow machine.

4.2 PRE-START

4. 2. 1 Fill fuel tank. For best r esults use only clean, fresh regular gr ade unleaded gasoline with an octane rating of 87 or higher . Regular grade leaded gasoline may also be used; however, combustion chamber and cylinder head will require more fr equent service. See Engine Owner's Manual. DO NOT add oil to gasoline.

Do Not overfill fuel tank . Never fill the fuel tank so t hat the fuel level rises above a

level that is 1/2” below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage.

4. 2. 2 Make sure you understand the controls, their locations, their functions, and their safety requirements.

4. 2. 3 Refer to Maintenance, Section 5, and perf orm all the necessary inspection and maintenance steps.

4.3 MOWING

4. 3. 1 Operate units with the roll bar in the raised and locked position and use seat belt. There is no rollover protection when the roll bar is down. If it is necessary to lower roll bar do not wear the seat belt. Raise the roll bar as soon as clear ance permits.

4. 3. 2 Open fuel shut-off valve.

4.3.3 Starting Engine

Brake must be engaged, the PTO switch disengaged, and the motion

control levers out (neutral lock posit ion). (The operator does not need to be in the seat to start the engine. )

On a cold engine, place the throttle midway between the “SLOW” and “FAST ”

positions and place the choke to the “ON” posit ion. Turn ignition switch to the “start” position. Release the switch as soon as the eng ine starts.

IMPORTANT: DO NOT crank the engine continuously for more than ten (10)

seconds at a time. If the engine does not start, allow a 60 second cooldown period between starting attempts. Failure to f ol l ow these guidelines can burn out the starter motor.

After starting a cold engine, gradually return choke to the “OFF” position as the

engine warms up.

On a warm engine, place the throttle midway between the “SLOW” and “FAST”

positions and leave the choke in the “OFF” position.

4.3.4 Engaging PTO

DANGER

POTENTIAL HAZARD ♦ The rotating blades under the mower deck are

dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or kill you. HOW TO AVOID THE HAZARD ♦ DO NOT put hands or feet under t he mower or mower

deck when the blades are engaged.

DANGER

POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be

thrown in an operator’s or bystander’s direction. Also,

contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can cause serious injury

or death. HOW TO AVOID THE HAZARD ♦ Never operate the mower with the discharge deflector

raised, removed, or altered unless there is a grass

collection system or mulch kit in place and working

properly.

The PTO clutch push-pull switch engages t he cutting blades. Be sure that all

persons are clear of mower deck and discharge area before engaging PTO.

IMPORTANT: Operator must be in seat before the PTO can be engaged.

Set throttle to "midway" position. Pull outward on the switch to the “ROTATE”

position. Accelerate to full throttle to begin mowing.

4.3.5 Stopping PTO

: Set the throttle to the “midway” position. Push in on the switch to

the “STOP” position stopping t he PTO.

4.3.6 Stopping Engine

: Bring unit to a full stop. Disengage the PTO, move motion

control levers out to the neutral lock position and engage parking brake.

Before stopping the eng ine, place t he throttle control midway between the “slow”

and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.

Rotate ignition switch to “OFF” posit ion. Rem o ve the key to prevent children or

other unauthorized persons from star t ing engine.

Close fuel shut-off valve when machine will not be used for a few days, when

transporting, and when the unit is park ed inside a building.

4.4 TRANSPORTING

4. 4. 1 Transporting a Unit: Use a heavy-duty trailer or truck to transport the m achine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Be sure that t he t railer or truck has all necessary lighting and marking as required by law.

Secure a trailer with a safety chain.

CAUTION

POTENTIAL HAZARD ♦ This unit does not have proper turn signals, lights,

reflective markings, or a slow moving vehicle emblem. These items are required to drive on a public street or

roadway. WHAT CAN HAPPEN ♦ Driving on a street or roadway without such equipment is

dangerous and can lead to accidents causing personal

injury. ♦ Driving on a street or roadway without such equipment

may also be a violation of State laws and the operator

may be subject to traffic tickets and/or fines. HOW TO AVOID THE HAZARD ♦ Do not drive a unit on a public street or roadway.

WARNING

POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck increases the

possibility of backward tip-over. WHAT CAN HAPPEN ♦ Backward tip-over of the unit could cause serious injury

or death. HOW TO AVOID THE HAZARD

♦ Use extreme caution when operating a unit on a ramp. ♦ Use only a single, full width ramp; DO NOT use individual

ramps for each side of the unit. ♦ If individual ramps must be used, use enough ramps to

create an unbroken ramp surface wider than the unit. ♦ DO NOT exceed a 15° angle between ramp and ground

or between ramp and trailer or truck. ♦ Avoid sudden acceleration while driving unit up a ramp to

avoid tipping backward. ♦ Avoid sudden deceleration while backing unit down a

ramp to avoid tipping backward.

4.4.2 Loading a Unit

: Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tire s is recommended instead of individual ramps f or each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. I f it is not possible to use one full width ramp, use enough individual ramps t o sim ulate a full width continuous ramp.

Ramp should be long enough so that the angles between the ramp and t he

ground and the ramp and the trailer or truck do not exceed 15°. A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck. St eeper angles may also cause the unit to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible.

DO NOT attempt to turn the unit while on the ramp, you may lose control and

drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration when

backing down a ramp. Both maneuvers can cause the unit to tip backward.

5. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD ♦ While maintenance or adjustments are being made,

someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure

you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ignition switch and pull the

wire(s) off the spark plug(s) before you do any

maintenance. Also push the wire(s) aside so it does not

accidentally contact the spark plug(s).

WARNING

POTENTIAL HAZARD ♦ The engine can become very hot.

WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns.

HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before service or

making repairs around the engine area.

5.1 PERIODIC MAINTENANCE

5. 1. 1 Check engine oil level: Service Interval: Daily

a) Stop engine, wait for all moving parts to st op and m a ke sure unit is on a

level surface.

b) Check with engine cold.

c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the

dipstick. Screw dipstick into place. Remove the dipst ick and read the oil level.

d) If the oil level is low, wipe off the area around the oil fill cap, remove cap,

and fill to the “FULL” mark on the dipstick. Use oil as specified in t he Engine Owner’s Manual.

DO NOT overfill.

IMPORTANT: DO NOT operate the engine with the oil level below the

“LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

5. 1. 2 Clean engine air cooling system

Service Interval: Daily or more often in dry condi t i ons

CAUTION

POTENTIAL HAZARD ♦ Excessive debris can cause the engine and hydraulic

system to overheat. WHAT CAN HAPPEN

♦ Excessive debris around the engine cooling air intake

and inside of the pump compartment can create a fire

hazard. HOW TO AVOID THE HAZARD

♦ Clean all debris from around the engine and hydraulic

pumps daily.

a) Stop engine, wait for all moving parts to stop, and remove key.

b) Clean all debris from rotating eng ine air intake screen and from around

engine shrouding.

5. 1. 3 Check battery charge

: Service Interval: Monthly Allowing batteries t o stand for an extended period without recharging t hem will

result in reduced performance and ser vice life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, bat t er y should be fully charged before

putting away for winter storage.

a) Check the voltage of the bat tery with a digital voltmeter. Locate the voltage

reading of the batter y in the t able below and charge the battery for the recommended time interval to bring t he charge up to a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected

and the battery charger used for char ging the battery has an output of 16 volts and 7 amps or less to avoid damaging the batter y (see char t below f or recommended charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours

11.7 – 12.0 0 – 25% 14. 4 volts/ 4 am ps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

5. 1. 4 Clean grass build-up under deck. Service Interval: Daily

a) Stop engine, wait for all moving parts to st op, and remove key. b) Raise deck t o t he transport (4.5” (11.4cm) cut ting height) position. Lif t the

front of unit and support unit using jack stands or eq uivalent support.

CAUTION

POTENTIAL HAZARD ♦ Raising the mower deck for service or m aint enance

relying solely on mechanical or hydraulic jacks could

be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough

support or may malfunction allowing the unit to fall,

which could cause injury. HOW TO AVOID THE HAZARD ♦ DO NOT rely solely on mechanical or hydraulic jacks

for support. Use adequate jack stands or equivalent

support.

c) Clean out any grass build-up f r om under side of deck and in discharge chute.

5. 1. 5 Check mower blades

. Service Interval: Daily a) Stop engine, wait for all m oving parts to stop, and remove key. b) Lift deck and secure in r aised posit ion as st ated in Section 5.1.4. c) Inspect blades and sharpen or replace as required.

d) Re-install the blades (if they were removed) in the following order (See

Figure 8):

1) Install bushing thr ough blade with bushing flange on bottom (grass) side of blade.

2) Install bushing/ blade com bo int o spindle.

3) Install blade bolt and spring disc washer. Be sure the spring disc washer cone is installed towards the bolt head. Place a block of wood between front or rear baffles and the blade then torque the blade bolts to 55-60 ft-lbs. (75-81 N- m).

FIGURE 8

BLADE BOLT INSTALLATION

IMPORTANT: DO NOT use components other than the original blade, blade bushing, spring disc washer, and blade bolt supplied with the unit. Failure t o use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or weak after striking a foreign object.

CAUTION

POTENTIAL HAZARD ♦ Operating a mower deck with loose or weakened blade

bolts can be dangerous. WHAT CAN HAPPEN ♦ A loose or weakened blade bolt could allow a blade

rotating at a high speed to come out from under the deck,

causing serious injury or property damage. HOW TO AVOID THE HAZARD ♦ Always re-install original Exmark blades, blade bushings,

spring disc washers, and blade bolts in the correct

positions as shown.

5.1.6 Check safet y interlock system. Service Interval: Daily a) Check starting circuit. Start er should crank with parking brake engaged,

PTO disengaged and motion contro l levers m oved out in t he neut ral lock position. The operator does not need to be in t he seat to start the engine.

Try to start with operator in seat, parking brak e disengaged, PTO

disengaged and motion control levers in the neutral lock posit ion - starter must not crank.

Try to start with operator in seat, parking brak e engaged, PTO engaged

and motion control levers in the neutral lock position - starter must not crank.

Try to start with operator in seat, parking brak e engaged, PTO

disengaged, and the left motion control lever in, starter must not crank, repeat again with the right lever in, then with both l evers i n -

starter must not crank.

b) Check kill circuits. Run engine at one-third thrott le, disengage parking

brake and raise off of seat ( but do not get off of machine) engine must stop after approx. 1/2 second has elapsed (seat has t im e delay k ill switch to prevent cut-outs on rough terr ain) .

Run engine at one-third throt tle, engage PTO and raise off of seat ( but do

not get off of machine) engine must stop af t er 1/2 second has elapsed.

Run engine at one-third throt tle, with brake disengaged, move levers in and

raise off seat (but do not get off of machine) engine must stop aft er 1/ 2 second has elapsed.

Again, run engine at one-t hir d t h r ot tle, brake engaged, and move left

motion control lever in - engine must st op.

Repeat again moving the right lever in, then moving both levers in -

engine must stop whether operator is on seat or not.

NOTE: If machine does not pass any of these tests, do not operate.

Contact your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that operator safety mechanisms be connected

and in proper operating condition prior to use for mowing.

5. 1. 7 Check rollover protections systems (roll bar) pins Service Interval: Daily a) Make sure latch pin and hair pin ar e fully installed and lanyard is in good

condition.

5. 1. 8 Check for loose hardware

. Service Interval: Daily a) Stop engine, wait for all moving part s t o stop, and remove key. b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

5. 1. 9 Service air cleaner

. Service Interval: See Engine Owner’s Manual a) Stop engine, wait for all moving parts t o stop, and remove key. b) See Engine Owner’s Manual for cleaning instructions.

5. 1. 10 Change engine oil

: Service Interval: See Engine Owner’s Manual. NOTE: Change oil and filter after first five (5) hrs. of operation. Follow

engine manufacturer’s recommendations for future oil changes. a) Stop eng ine, wait for all moving parts to stop, and r em ove k ey. b) Drain oil while engine is warm from operation. c) Oil drain valve is located on right hand side of the engine. Place a pan

under the machine to catch oil and open valve with 10 mm wrench. Allow oil to drain then close valve.

d) Replace the oil filter as per the Engine Owner’s Manual. Clean around oil

filter and unscrew filter t o remove.

Before reinstalling new filter, apply a thin coat ing of oil on the surface of the

rubber seal. Turn filt er clockwise until rubber seal contacts the filt er adapt er then tighten filter an addit ional 2/ 3 to 3/4 turn.

e) Clean around oil fill cap and remove cap. Fill to specif ied capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NO T overfill.

f) Start the engine and check for leaks. St op engine and recheck oil level.

5.1.11 Check hydraulic oil level: Service Interval: 40 hr. a) Stop engine and wait for all moving parts to stop. b) Clean area around hydraulic r eser voir cap and r em ove cap.

c) Oil level should be to the top of the baffle inside the tank. If not add oil. Use

only Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap

and tighten until snug. Do not overt i ght en.

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the

temperature of the oil. The “HOT” level shows the level of oil when it is at 225°F (107°C). The “COLD” level shows the level of the oil when it is at 75°F (24°C). Fill to the appropriate level depending upon the temperature of t he oil. For example: If the oil is about 150° F ( 65° C) , fill to halfway between the “HOT” and “COLD” levels. If the oil is at room temperature (about 75° F (24°C)), fill only to the “COLD” level.

5. 1. 12 Check tire pressures Service Interval: 40 hrs. a) Stop engine, wait for all moving parts to st op, and remove key. b) Check tire pressure in all four tires. c) Inflate caster tires to 16 psi (1100 kPa). d) Inflate drive tires to 13 psi (90 kPa). NOTE: Do not add any type of tire liner or foam fill material to the tires.

Excessive loads created by foam filled tires may cause failures to the hydro drive

system, frame and other components. Foam filling tires will void the warranty.

5. 1. 13 Check condition of belts

a) Stop eng ine, wait for all moving parts to stop, and r em ove k ey. b) Check under engine deck to check pump drive belt. c) Remove left and right belt shields on deck and lift up f loor pan to inspect

deck drive belt.

d) See Sections 5.2. 3 and 5. 2.4, for belt adjustment .

5. 1. 14 Lubricate grease fitting s

a) Stop eng ine, wait for all moving parts to stop, and r em ove k ey. b) Lubricat e fittings with one to two pumps of NGLI grade #2 multi-purpose

gun grease.

Refer to the following chart for fitting locations and lubrication schedule.

Service Interval: 40 hrs.

Service Interval: Refer to chart.

LUBRICATION CHART

FITTING

LOCATIONS

1. Front Caster wheel hubs w/o Zerk

2. Front Caster Pivots

3. Height Adjustment Shaft Bearings 1 5 40 hours

4. Deck Drive Belt Idler Arm 1 1 yearly

5. Pump Drive Belt Idler Arm 1 1 yearly ∗ See 5.1.14 Section c) for special lubrication instructions on t he front caster pivots and

Section 5.1.15 for special lubrication inst r uctions on the front caster wheel hubs.

No. 5 (Pump Dri ve Bel t Idler Arm) Located Under Engine Frame - Grease through hole in top of engine frame, between pumps.

INITIAL

PUMPS

∗0 ∗0

NO. of

PLACES

2 2

SERVICE

INTERVAL

∗yearly

c) Lubricate front caster pivots once a year. Remove hex plug and cap. Thr ead

grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thr ead plug back in. Place cap back on.

5.1.15 Lubricate caster wheel hubs:

Service Interval: Once Yearly

a) Stop engine, wait for all moving parts to

stop, and remove key.

b) Remove caster bolt and caster wheel from

caster fork. Remove seal g uar ds from the wheel hub.

c) Remove one of the spacer nuts from the

axle assembly in the caster wheel. Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) f r om the wheel assembly.

CASTER WHEEL ASSEMBLY

FIGURE 9

d) Pry out seals, and inspect bearings for wear or dam age and replace if

necessary. e) Pack the bearings with a NGLI grade #1 multi-purpose grease. f) Insert (1) bearing, ( 1) new seal into the wheel. NOTE: Seals (Exmark PN 103-0063) must be replaced. g) If the axle assembly has had both spacer nuts removed (or broken loose),

apply a thread locking adhesive to (1) spacer nut and thr ead onto the axle

with the wrench flats facing outward. Do not thr ead spacer nut all of the

way onto the end of the axle. Leave approximately 1/8” (3 mm) f r om the

outer surface of the spacer nut to the end of the axle inside the nut. h) Insert the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing. i) With the open end of the wheel facing up, fill the ar ea inside t he wheel

around the axle full of NGLI grade #1 multi-purpose grease. j) Inser t the second bearing and new seal into the wheel.

k) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

with the wrench flats facing outward. l) Torque the nut to 75-80 in-lbs. (8 - 9 N- m ), loosen, then re-torque t o 20- 25

in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut. m) Re-install the seal guards over the wheel hub and insert wheel into caster

fork. Re-install cast er bolt and tighten nut fully. IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin t he caster tire. The tire should not spin freely

(more than 1 or 2 revolutions) or have any side play. If the wheel spins

freely adjust torque on spacer nut unt il there is a slight amount of dr ag.

5. 1. 16 Lubricate seat switch actuator

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s t o stop, and remove key. b) Unhook seat lat c h and t ilt seat up. c) Lubricate switch actuator rod with spray type lubricant or light oil.

5. 1. 17 Lubricate brake handle pivot

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s t o stop, and remove key.

b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant

or light oil.

5. 1. 18 Lubricate brake rod bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s t o stop, and remove key. b) Unhook seat lat c h and t ilt seat up. c) Lubricate bronze bushings on each end of brake rod shaf t with a spray type

lubricant or a light oil. Shaf t is located under the console.

5. 1. 19 Lubricate motion control bronze bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s t o stop, and remove key. b) Unhook seat lat c h and t ilt seat up. c) Lubricate bronze bushings on flange bearings securing the motion control

arm shafts with a light oil or a spr ay type lubricant .

5. 1. 20 Remove engine shrouds and clean cooling fins

Service Interval: 80 hrs. a) Stop engine, wait for all moving part s t o stop, and remove key.

b) Remove cooling shrouds from engine and clean cooling fins. Also clean

dust, dirt and oil from external sur faces of engine, which can cause

improper cooling. c) Make sure cooling shrouds are properly reinstalled. Operating the engine

without cooling shrouds will cause engine damage due to overheating.

5. 1. 21 Check spark plug

Service Int erval : 160 hrs.

a) Remove spark plug, check condition and reset gap, or replace with new

plug. See Engine Owners Manual.

5. 1. 22 Change fuel filter

Service Interval: As Required

a) A fuel filter is installed bet ween the fuel tanks and the engine. Replace

when necessary. For Kohler eng ines use Kohler P/N 2405002. For Kawasaki engines use Kawasaki P/N 49019-7001

5. 1. 23 Change hydraulic system filter

Service Interval: After First 250 hrs. Then yearly thereafter

NOTE: Use only Exmark Part No. 1-513211 for Summer use above 32° F

(0°C) or Part No. 1-523541 f or Winter use below 32° F (0°C). a) Stop engine, wait for all moving part s t o stop, and remove key. b) Locate filter under right r ear corner of engine deck. c) Car efully clean area around filter. It is important that no dirt or

contamination enter hydraulic system. d) Unscrew filter to remove and allow oil to drain from reservoir. IMPORTANT: Before reinstalling new filter, f ill it with Mobil 1 15W-50 and

apply a thin coat of oil on the surface of the rubber seal. Turn the filter clockwise until rubber seal cont acts the filter adapter t hen

tighten the filter an addit ional 2/ 3 to 3/4 turn. e) Fill reservoir as stated in Section 5.1.10.

f) Raise the rear of machine up and support with jack st ands (or equivalent

support) just high enough t o allow drive wheels to turn freely. g) Start engine and move thrott le cont r ol ahead to full throttle position. Move

the speed control levers to the full speed and run for several minutes. Shut

down machine and recheck oil level. Do not change hydraulic system oil (except for what can be drained when

changing filter), unless it is felt the oil has been contaminat ed or been

extremely hot. Changing oil unnecessarily could damage hydraulic system by

introducing contaminates into the system.

5.1.24 Wheel hub

- slotted nut torque specification. When tightening the slot t ed nut on the wheel motor tapered shaft: a) Torque the slotted nut t o 125 ft. lbs (169 N-M). b) Check distance from bott om of slot in nut to inside edge of hole. Two

threads (0.1”) or less should be showing.

c) I f more than two threads (0.1”) ar e showing rem o ve nut and install washer

(PN 1-523157) between hub and nut. d) Torque the slotted nut t o 125 ft. lbs (169 N-M) e) Then tighten the nut until the next set of slots line up with the cross hole in

the shaft. f) Replace cotter pin. Note: Do not use antiseize on the wheel hub.

5.1.25 Fuel Tank

– mounting hardware specification.

When installing the nuts onto the fuel tank st uds, fully tighten the nyloc nut and

back off 1/2 t ur n. This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels.

5. 1. 26 Thread locking adhesives such as “Loctit e 242” or “Fel-Pro, Pro-Lock Nut T ype”

are used on the following fasteners: a) Pump drive sheave setscrews. b) Square head setscrews on Hydro pump control arms.

c) Clutch retaining bolt in the end of engine crankshaft.

d) Caster wheel spacer nuts.

e) Fuel tank bulk head fitting nuts.

f) Cutter housing spindle nut Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock Ret aining I

or Retaining II” are used on the following: a) Fuel tank st uds where studs ar e inser t ed int o tank.

5. 1. 27 Mobil HTS grease (or food-grade antisieze) is used in the following locations: a) Between the cutter housing spindle and bearings. b) Between the cutter housing spindle and sheave. c) Under top cutter housing bearing guar d.

5.1.28 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

5.2 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait for al l moving parts to stop,

and remove key before servicing, cleaning or making adjustments to the unit.

5. 2. 1 Cutting Height Adjustment. a) Stop machine and move drive levers out to neutr al lock position. b) Disengage PTO. c) Raise t he deck lever to the transport position (also the 4. 5” (11.4 cm)

cutting height position). See Figure 10.

NOTE: When changing cutting height positions, always come to a

complete stop and disengage the PTO.

FIGURE 10

CUTTING HEIGHT POSITION

d) Insert height adjustment pin into hole corresponding to desired cutting

height and install hairpin cotter. See decal on deck lift plate.

e) Move lever out of transport (or 4.5” (11.4 cm ) cutting height) position and

down onto height

adjustment pin to mow at selected height.

f) To transport, move lever back up to tr anspor t (or 4.5” (11.4 cm) cutting height)

position.

g) Adjust anti-scalp rollers for Normal Operating Condit ions. St op engine, wait

for all moving parts to st op, and remove key. Place rollers in one of the positions shown in Figure 10. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize goug ing and roller wear or damage.

For Maximum Deck Flotation, place rollers one hole position lower. Roller s

should maintain 1/4 in. (6.4 mm) m inim um clear ance to ground. Do Not adjust rollers to support the deck. Be sure bolt is tightened properly or loss of anti-scalp roller may result. Torque the whizlock nuts on each end to 40-45 ft-lbs (54-61 N-m).

FIGURE 11

ANTI-SCALP ROLLER ADJUSTMENT

5. 2. 2 Deck Leveling: a) Position mower on a flat surface. b) Stop engine, wait for all moving part s t o stop, and remove key. c) Check tire pressure in drive tires. Proper inflation pressure for drive tires is

13 psi (90 kPa). Proper inflat ion for caster tires is 16 psi (110 kPa) . Adjust if necessary.

d) Set anti-scalp rollers to top holes or r em ove completely for this adjustment. e) Raise the deck to the 4.5” (11.4 cm ) height position and take as much f or ce

as possible off of the two large deck lift springs by loosening t he nut s at the front of each spring . See Figure 12.

f) Lower the deck to the 1-1/2” (3.8 cm ) height position. Place two 1-5/16”

(3.3 cm) thick blocks under t he r ear edge of the cutting deck skirt; one on each side of the cutting deck. Place a 1-1/8” (2.9 cm) block under the center front edge, but not

under the anti-scalp roller brackets.

g) Loosen the two (2) bottom chain bolts in slots at the r ear of the cutting

deck. Loosen four (4) nut s which secure f ront swivels (two per side), until front chains are loose and front of deck is supported by the 1-1/8” (2. 9 cm ) block. Do not loosen front chain har dware.

h) When hardware is loosened, rem aining tension in the large support springs

will tend to rotate the deck lif t handle up, out of the 1 1/2” (3.8 cm) position. Press down on the rear deck support arm (as shown in Figure 7) t o firmly return the deck lift handle to the 1 1/2” (3.8 cm) position. DO NOT push on deck lift handle. While continuing to press down, rear chains and tighten hardware at the bottom of

take the slack out of the

the rear chains.

Downward pressure may now be released.

i) On left side, adjust f ront swivel using the locking nut behind the swivel until

the front chain is tight and all slack is removed from linkage. Do not lift front of deck off 1-1/8” (2.9 cm ) block. Secure front swivel using locking nut in front of swivel. Repeat for right side.

ADJUST FRONT DECK

HEIGHT HERE

10 1/2" (26.7 cm) For 44” Deck

10” (25.4 cm) For 48” Deck

9 1/2" (24.1 cm) For 52” Deck

FIGURE 12

SWIVEL ADJUSTMENT

SPRING COMPRESSION ADJUSTMENT

j) Recheck that blocks fit just snugly under the deck skirt and that the tension

on all the chains are approximately equal. Make sure all chain attachm ent bolts are tight.

k) Raise deck lift lever to the 4.5” (11.4 cm) cutting height position (also

transport position, See Figure 6. Adjust spring compression until proper distance is obtained between the two washers (See Figure 12) by turning the nut at the front of each spring. Lock nuts in position with jam nut s.

l) Reposition anti-scalp rollers and t ighten securely.

NOTE: When above adjustments have been made, the front of

the deck will be slightly lower than the rear of the deck.

5. 2. 3 Pump Drive Belt Tension Self -tensioning - No adjustment necessary.

5. 2. 4 Deck Belt Tension. Self -tensioning - No adjustment necessary.

5. 2. 5 Adjust Seat Switch

a) If necessary, adjust the seat actuator rod length to where the machine will

shut off when the operator raises off the seat (with brake disengaged or PTO engaged) but will continue to run with operator in seat (a slight shift in weight should not shut machine off ) . Nor mal adjustment is when length of spring is 2.09” (5.3 cm ) (with seat up) .

NOTE: To prevent rough ground cut-outs the unit is equipped w ith a

time delayed seat switch. When the operator raises of f the seat with either the brake disengaged or the PTO engaged, the engine should stop after 1/2 second has elapsed.

b) To adjust seat switch, loosen lock nut on bottom of the actuator rod (5/16 x 7”

bolt) and adjust the nuts to move the actuat or plate up or down on the rod.

5.2.6 Park Brake Adjustm ent

. a) Stop engine, wait for all m oving parts to stop, and remove key. b) Disengage the park brake. c) Loosen the jam nuts next to the yoke at each end of t he par k brake linkage.

See Figure 13.

d) Place a wrench on one of the two nuts near the front of the park brake

linkage.

e) Turn the linkage unt il t he distance from the lower front corner of the brake bar

measured vertically to the crown of the tire is 1” (2. 5 cm ) to 1 5/16”(3.3 cm) with the park brake disengaged See Figure 13.

f) Tighten the jam nuts loosened in step c).

FIGURE 13

PARK BRAKE ADJUSTMENT

5.2.7 Adjust Throttle Lever Tension

. a) Stop engine, wait for all m oving par ts to stop, and remove key. b) Tension in throttle lever can be adjusted by adjust ing the tightness of the

lever pivot bolt, which is located under the console. See Figure 14.

FIGURE 14

THROTTLE TE NSION

5. 2. 8 Electric Clutch Adjustm ent

No adj ust ment necessary.

5. 2. 9 Reverse Indicator Adjustment

: a) Stop engine, wait for all moving parts t o stop, and remove key. b) Unhook seat latch and tilt seat for ward. c) Begin with either t he left or right motion cont r ol lever. Move lever to the

neutral position and pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning t o put pr essure on spring), See Figure 15.

d) Check where lever is relative to notch in console (should be centered

allowing lever to pivot outward to the neutral lock position) .

e) If adjustment is needed, loosen the nut against the yoke and while applying

slight rearward pressure on the motion contr ol lever, turn the head of the adjustment bolt in the appropriat e dir ection until lever is centered (keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appr opr iate position). Tighten lock nut.

f) Repeat on opposite side of unit .

5. 2. 10 Motion control linkage adjustment

WARNING

POTENTIAL HAZARD ♦ Engine must be running and drive wheels must be

turning so motion control adjust m ent can be per formed. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces may cause

personal injury. HOW TO AVOID THE HAZARD ♦ Keep fingers, hands, and clothing clear of rotating

components and hot surfaces.

CAUTION

POTENTIAL HAZARD ♦ Raising the mower deck for service or m aint enance

relying solely on mechanical or hydraulic jacks could be

dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough

support or may malfunction allowing the unit to fall,

which could cause injury. HOW TO AVOID THE HAZARD ♦ DO NOT rely solely on mechanical or hydraulic jacks for

support. Use adequate jack st ands or equivalent

support.

a) This adjustment must be made with the drive wheels turning. Fir s t r aise the

frame and block up so that dr ive wheels can rotate freely.

b) Remove the electrical connection from the seat safety switch, located directly

to the left of t he seat switch assembly beside the hydraulic oil reservoir.

Temporarily install a jumper wire across the terminals in the connector of

the wiring harness.

c) Run the unit at least 5 minutes with the drive levers at full forward speed to

bring hydraulic system oil up to operating tem per ature. d) Unhook seat latch and tilt seat for ward. e) Loosen lock nuts from the ball joint s at each end of the RH pump control

linkage (See Figure 15). NOTE: The nuts to the rear of the unit on each rod have left-hand threads.

TURN BOLT

HERE

REVERSE

INDICATOR

LOOSEN

HERE

YOKE

END OF

SLOT

LOOSEN HERE

(LEFTHAND THREAD)

TURN HERE

TO ADJUST

LOOSEN HERE

(RIGHTHAND THREAD)

FIGURE 15

RH MOTION CONTROL ADJUSTMENT

f) Start eng ine. Brake must be engaged and mot ion control levers out to

start engine. Operator does not have to be in the seat because of the

jumper wire being used. Run engine at full throttle and release br ake.

g) The reverse indicator spring must be cor r ect before the following

adjustments can be made. See Section 5.2.9. h) Bring the RH motion control lever into the neutral position. Adjust RH pump

control rod length by rotating t he double nut s on the rod in the appropriate

direction until the wheels slightly creep in reverse (See Figur e 15) . Move the

motion control lever to the reverse position and while applying slight pr essure

to the lever, allow the reverse indicator spring to br ing the levers back to

neutral. The wheel must stop turning or slightly creep in reverse.

NOTE: The motion control lever needs to be in neutral while making

any necessary adjustments.

The left rod assembly controls the left wheel and the right rod assembly

controls the right wheel. i) Br ing the LH motion control lever into the neut r al position. Adjust the LH

pump control rod length by rotating t he t racking adjustment knob in the

appropriate direction until the wheels slightly creep in reverse. Move the

motion control lever to the reverse position and while applying slight

pressure to the lever allow the reverse indicator spring to br ing the levers

back to neutral. The wheel must stop t urning or slightly creep in reverse.

See Figure 16.

FIGURE 16

LH MOTION CONTROL ADJUSTMENT

j) Shut off unit. Remove jumper wire from wire harness connector and plug

connector into seat switch.

6. WASTE DISPOSAL

6.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at

a certified recycling center or accor ding to your state and local regulations.

6.2 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is

poisonous and can cause severe burns

WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it touches skin

can cause severe burns.

HOW TO AVOID THE HAZARD ♦ Wear safety glasses to shield eyes, and rubber gloves to

protect skin and clothing when handling electrolyte.

♦ Do not swallow electrolyte.

Federal law states that bat teries should not be placed in the garbage. Management and

disposal practices must be within relevant federal, state or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating and

is being scrapped, take the battery to a local certified recycling center. I f no local recycling is available, return the battery to any cert ified battery reseller.

7. TROUBLE SHOOTING

7.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).

a) Refer to Tracking Adjustment Sect ion 4. 1. 3. b) Check air pr essure in tires; 13 psi/drive, 16 psi/pneumatic castors. c) Check reverse indicator and m ot ion cont rol linkage adjustment. See

Section 5.2.9 and 5.2.10.

7.2 MOWER CUTS UNEVENLY.

a) Check air pressure in tires; 13 psi/drive, 16 psi/pneum atic casters. A more

uniform cutting heig ht may be obtained with higher tire pressure on rough

terrain. A lower tire pressure provides more flotation. Higher pressures in

front casters may cause them to shimm y on hard surfaces. b) Check deck support chains.

c) Check deck leveling

Note: The front of the mower deck will be approximately 1/4” (6.4 mm)

lower than the back of the mower deck. This is the “rake” of t he deck. d) Check blades tip to tip for straightness (they should be within 3/16" (4.8

mm) or one blade width from being in line.)

7.3 ENGINE WILL NOT START.

a) Make sure batter y is at a full charge. b) Be sure the thr ottle control is midway between the “SLOW” and “ FAST”

positions, and the choke is in the “ON” position for a cold engine or the

“OFF” position for a warm eng ine. c) Make sure there is fuel in the fuel tank and that the f uel valve is open. d) Be sure the seat switch is properly adjusted. See Section 5.2.5. e) Make sure the parking brake is set and m ot ion cont r ol levers ar e m oved

out (neutral lock position). f) Check that t he PTO is disengaged. h) Check that the spark plug wires are proper ly connected. i) Check for loose or faulty wiring connections. j ) Check for corrosion at all wiring connections. Even minor cor r osion may

cause a faulty connection. Clean connector terminals thor oughly with

electrical contact cleaner, apply dielectric grease and r econnect.

(See Adjustments Section 5.2.2.)

NOTE: When disconnecting electrical connectors DO NOT pull on the wires

to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start t he engine. If

it does not start, contact your authorized Exmark service dealer.

IMPO RTANT: It is essential that all operat or saf et y mechanisms be

connected and in proper operating condition prior to mower use.

When a problem occurs, do not overlook t he sim ple causes. For example,

starting problems could be caused by an empty fuel tank.

The following table lists some of t he common causes of trouble. Do not att em pt

to service or replace major items or any item s t hat call for special timing of adjustments procedures (such as valves, governor, etc. ) . Have this work done by your Engine Service Dealer.

PROBLEM

Will not start Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel

consumption

ENGINE TROUBLESHOOTING TABLE

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X XXXX X X X X X X X

X X X X X X X

X X X X X X X X X X X X X X X X X X

X X X X X X X X X X

XX X X X X X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

8. BRIGGS & STRATTON ELECTRICAL DIAGRAM

9. HYDRAULIC DIAGRAM

10. 2-Year Limited Warranty

Exmark Turf Equipment

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 manufactured by Exmark 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 turf equipment purchased on or after October 1, 2004 sold in the US 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.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement that is included in the literature packet. We are not authorized to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

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

1. 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. Customers may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales receipt) to the Exmark Service Dealer.

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

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer. and tear, or exposure. filters, fuel, lubricants, tune-up parts, and adjustments. or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance. 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.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

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 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.

As a condition to this warranty, customer shall have read the operator's manual and shall have completed and submitted to Exmark Warranty Company, within the prescribed time, the Exmark warranty registration.

General Conditions

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

nor Exmark Warranty Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge 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.

There are no understandings, agreements, representations, or warranties, express or implied, including but not limited to any regarding the merchantability (that product is fit for ordinary use) or fitness for use (that product is fit for a particular purpose), not specified herein, respecting the equipment which is the subject of this 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.

NOTES

- 43 -

NOTES

- 44 -

SERVICE RECORD

Date Description of Work Done Service

Done By

- 45 -

- 46 -

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

FG. CO. INC.

Exmark Laser Z CT Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual