Exmark Laser Z XS LXS25KD605, Laser Z XS LXS25KD665, Laser Z XS LXS25KD725 Operator's Manual

ForSerialNos.

720,000&Higher

LAZERZ®XS

DIESELMODELS

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

PartNo.4500-169Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.

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

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

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

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

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

©2004–2007—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

2

Contactusatwww.Exmark.com.

PrintedintheUSA.

AllRightsReserved

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 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.

2. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for
part and freight charges where applicable.

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus® order, he contacts Exmark by 3:00 p.m., central
time, with an Exmark Parts Plus® order of six (6) line items or less.

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor,
same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus® and if it arrives in accordance to the
program.

6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?

A. Under any circumstance the customer does not pay.

B. If the part does not arrive overnight due to:

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.

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus® order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

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

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

3

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

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

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

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

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

4

Contents

Introduction...........................................................4

Safety.....................................................................6

SafetyAlertSymbol.........................................6

SafeOperatingPractices..................................6

SafetyandInstructionalDecals.....................11

Specications.......................................................17

ModelNumbers............................................17

Systems.........................................................17

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

TorqueRequirements....................................19

ProductOverview................................................20

Operation.............................................................20

Controls........................................................20

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

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

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

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

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

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

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

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

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

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

CheckRolloverProtectionsSystems(Roll

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

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

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

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

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

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

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

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

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

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

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

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

LubricateMotionControlBronze

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

DrainFuelFilter............................................34

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

WheelHub-SlottedNutTorque

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

CheckEngineCoolantLevel..........................35

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

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

MobilHTSGrease(OrFood-Grade

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

Copper-BasedAnti-seize..............................37

DielectricGrease...........................................37

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

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

PumpDriveBeltTension...............................38

MuleDriveBeltTensionAdjustment.............38

DeckBeltTension........................................39

AlternatorBeltTension.................................39

BeltGuideAdjustment..................................39

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

BrakeAdjustment..........................................40

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

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

MotionControlLinkageAdjustment.............41

MotionControlDamperAdjustment.............42

CasterPivotBearingsPre-Load

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

Cleaning...........................................................43

CleanEngineCoolingSystem........................43

RemoveAccumulatedDebrisfromEngine

.................................................................43

CleanGrassBuild-UpUnderDeck................44

WasteDisposal..............................................44

Troubleshooting...................................................45

Schematics...........................................................48

5

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

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

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

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

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

6

Safety

DANGER

Incertainconditionsdieselfuelisextremely
ammableandvaporsareexplosive.

Areorexplosionfromdieselfuelcanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anydieselfuelthatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

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

•Neversmokewhenhandlingdieselfuel,
andstayawayfromanopenameor
wheredieselfuelfumesmaybeignited
byspark.

•Storedieselfuelinanapprovedcontainer
andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

WARNING

Dieselfuelisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleanddiesel
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Operation

WARNING

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

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

7

Safety

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts.

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

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

DANGER

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

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

8

Safety

Figure3

1.SafeZone-Usethe
mowerhereonslopes
lessthan15degrees

3.Water

2.DangerZone-Useawalk
behindmowerand/or
handtrimmernear
drop-offsandwater.

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

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

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatlossoftractionmayoccurgoing
downhill.Weighttransfertothefrontwheels
maycausedrivewheelstoslipandcauselossof
brakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’ srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem
(ROPS)

ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.

WARNING

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

•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely
necessary.

•DoNotwearseatbeltwhentherollbar
isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance
permits.

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

MaintenanceandStorage

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

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

•Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

9

Safety

•Carefullyreleasepressurefromcomponentswith
storedenergy.

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

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.

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

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

WARNING

Fuelsystemcomponentsareunderhigh
pressure.Theuseofimpropercomponents
canresultinsystemfailure,fuelleakageand
possibleexplosion.

Useonlyapprovedfuellinesandclampsfor
highpressuresystems.

10

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-303508

1-403005

1-513742

1-513746

1-513748

1-523552

1-633706

11

Safety

98-5954

103–0223

103–0261

103-1798

103-6936

103-7218

12

Safety

107-2102

107-2112

109-0872

109-1214

109-1215

13

Safety

109-1399

109-1921

109-2219

109-2263

109-2264

109-2478

14

Safety

109-2951

109-3148

109-6855

109–7949

19426-87881

19426-87903

15

Safety

107-9866

1.Fast

2.Slow

3.Neutral4.Reverse

16

Specications

Specications

ModelNumbers

SerialNos:720,000andHigher

LXS25KD605;LXS25KD665;LXS25KD725

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

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

FuelSystem

•Capacity:15.5gal.(58.6L)

•TypeofFuel:Dieselfuel,40cetaneorhigher.

•FuelFilter:In-line15Micron
ExmarkP/N98-7612.

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

•Fuelgaugeinlefthandfueltank.

ElectricalSystem

•ChargingSystem:ExternalAlternator

•ChargingCapacity:60amps

•BatteryType:BCIGroup26

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:One20ampbladetype;One30ampblade
type

SafetyInterlockSystem

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

•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,ormotioncontrolleversare
movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or
bothleversaremovedfromneutrallockposition
whilebrakeisengaged.

CoolingSystem

•Fan:Electricwithcontinuousoperationwith
enginerunning.

•CoolantLiquid:50/50mixofDexCool©
extendedlifeantifreezeandwater.

•CoolantCapacity:4quarts

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto
twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe
respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch
(todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting
heighttodesiredposition.

•DeckLiftAssistLever:Footpedalthatassists
inraisingthedeck.

Seat

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

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

17

Specications

•Armrests:Moldedadjustableip-uparmrests.

•SeatSafetySwitch:Incorporatedintothe
SafetyInterlockSystem.Timedelayseatswitch
eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearPW
variabledisplacementpistonpumps.

•WheelMotors:TwoParker/Rosswith11/4inch
taperedshafts.

•HydraulicOilType:UseMobil115W-50
Syntheticmotoroil.

•HydraulicOilCapacity:5.5qt.(5.2L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–0-12.0mph(19.3km/hr)forward.

–0-8.0mph(12.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

Pneumatic
(Air-Filled)

Semi-Pneumatic

DeckSize

60,66,&72

AllDecks

Quantity

22

TreadSize

“Multi-Trac
C/S”

Smooth

Size26x12.00-1213x6.50-6

PlyRating

4

Pressure

10psi(69kPa)

CuttingDeck

•CuttingWidth:

–60inch(152.4cm)

–66inch(167.6cm)

–72inch(182.9cm)

•Discharge:Side

•BladeSize:(3ea.)

–60inchDeck:20.75inches(52.7cm)

–66inchDeck:22.75inches(57.8cm)

–72inchDeck:24.75inches(62.9cm)

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

•DeckDrive:

–Electricclutchmountedonhorizontalengine

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

–Bladesaredrivenbyone“B”Sectionbelt

(w/self-tensioningidler)fromtransfershaft
ondecktobladespindles.

•Deck:

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

•DeckDepth:

–60inchDeck:6.0inches(15.2cm)

–66inchDeck:6.0inches(15.2cm)

–72inchDeck:6.0inches(15.2cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

Dimensions

OverallWidth:

60inch
Deck

66inch
Deck

72inch
Deck

Without
Deck

53.5inches
(135.9cm)

57.3inches
(145.5cm)

61.5inches
(156.2cm)

Deector
Up

61.4inches
(156.0cm)

68.0inches
(172.7cm)

74.3inches
(188.7cm)

Deector
Down

72.8inches
(184.9cm)

79.4inches
(201.7cm)

85.8inches
(217.9cm)

18

Specications

OverallLength:

60inch
Deck

66inch
Deck

72inch
Deck

RollBar­Up

81.9inches
(208.0cm)

83.4inches
(211.8cm)

85.8inches
(217.9cm)

RollBar­Down

92.5inches
(235.0cm)

94.0inches
(238.8cm)

96.4inches
(244.9cm)

OverallHeight:

RollBar-UpRollBar-Down

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

TreadWidth:(CentertoCenterof
Tires,Widthwise)

60inch
Deck

66inch
Deck

72inch
Deck

Drive
Wheels

41.9inches
(106.4cm)

45.9inches
(116.6cm)

45.9inches
(116.6cm)

Caster
Wheels

37.3inches
(94.7cm)

42.3inches
(107.4cm)

47.3inches
(120.1cm)

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

60inchDeck66inchDeck72inchDeck

56.0inches
(142.2cm)

57.6inches
(146.3cm)

60.2inches
(152.9cm)

CurbWeight:

60inchDeck66inchDeck72inchDeck

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

TorqueRequirements

BoltLocation

Torque

BladeDriveSheave
MountingNut

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

CutterHousingSpindle
Nut

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

BladeMountingBolt
(lubricatewithanti-seize)

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

EngineDeck/FrontFrame
MountBolts

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

BoltLocation

Torque

Anti-ScalpRollerNyloc
NutSeeFigure10

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

Anti-ScalpRollerHex
CapscrewSeeFigure10

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

EngineMountingBolts

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

WheelLugNuts

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

WheelMotorMounting
Bolts

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

WheelHubSlottedNutminimum125ft-lb

(169N-m)

RolloverProtectionSystem
(RollBar)MountingBolts

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

DeckDriveJackshaftNut

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

ClutchRetainingBolt
(securedwiththreadlocker)

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

19

Operation

ProductOverview

Figure4

1.MotionControlLever5.Controls

2.ParkingBrakeLever

6.SeatBelt

3.Height-of-CutLever

7.RollBar

4.FuelCap(BothSides)

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideofthe
consolecontroltheforwardandreversemotionof
themachine.Theleverscontroltheowofhydraulic
oilfromthehydrostaticpumptothedrivewheel
motorforeachside.

Movingtheleversforwardorbackwardturnsthe
wheelonthesamesideforwardorinreverse.Wheel
speedisproportionaltotheamounttheleveris
moved.

Movingtheleversoutwardfromthecenterposition
intotheT-slotlocksthemintheneutralposition
(Figure6).

ThrottleControl

Locatedonrightfueltank.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.

BrakeLever

Locatedonleftsideofunit,justtothefrontofthe
console.

Thebrakeleverengagesaparkingbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Theunitmustbetieddownandbrakeengagedwhen
transporting.

IgnitionSwitch

Locatedonrightfueltank.

Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”

20

Operation

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

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

HourMeter

Locatedontherightfueltank.

Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifthe
ignitionswitchisleftonwithoutenginerunning,
hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locateddirectlybelowtherightsideofconsole,next
tothecubby.

Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.

Thevalvehasthreepositions,eachpositionmade
in1/4turnincrements.

FuelFlowValveHandlePosition

“Off”Right

RightTank

Down

LeftTankLeft

FuelGauge

Locatedontheleftfueltank.

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

DriveWheelReleaseValves

Locatedonthetoprightfrontcornerofhydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
pushedwithouttheenginerunning.Unhookseat
latchandtiltseatuptogainaccesstopumps.

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

Nottowmachine.

TrackingAdjustmentKnob

LocatedundertheseatontheLHpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso
thatthemachinetracksstraightwiththedrivelevers
inthefullforwardposition.

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

Important:DoNotrotatetheknobtoofar,as
thismaycausethemachinetocreepinneutral.
RefertotheMotionControlLinkageAdjustment
sectioninMaintenance.

PTOEngagementSwitch

Locatedonrightfueltank.

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

CoolantTemperatureGauge

Locatedatthefrontoftheleftfueltank.

Thecoolanttemperaturegaugemonitorsthe
temperatureoftheenginecoolant.Anengine
overheatingconditionisindicatedbytheredarea
onthegaugeandanalarmwillsound.Refertothe
WarningBuzzerintheTroubleshootingsection.

Voltmeter

LocatednexttotheCoolantTemperatureGaugeat
thefrontoftheleftfueltank.

21

Operation

Thevoltmetermeasurethevoltageoutputofthe
alternator.Bothhighandlowvoltageswillpotentially
damagethebattery.

GlowPlugSwitchandLight

Locatedontherightfueltank.

Depressandholdtheswitchtoheattheglowplugs.
Theglowpluglightcomesonwhentheglowplug
switchisdepressed.Theglowpluglightindicatesthe
glowplugsarepreheatingthecombustionchamber.

LowOilPressureLight

Locatedontherightfueltank.

Lightwillcomeonwhenengineoilpressureislow
orlost.

WarningBuzzer

Locatedbehindtheseatundertheairdeectoron
theelectricalpanel.

Thebuzzerisawarningsignalthattheengine
isoverheatingortheoilpressureislow .Seethe
Troubleshootingsection.

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh
dieselfuelwithancetaneratingof40orhigher.

Note:DoNotusekeroseneorgasolineinsteadof
dieselfuel.Failuretoobservethiswilldamagethe
engine.

DoNotaddoiltofuel.

DoNotoverllfueltank.Neverllthefueltankso

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

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem
(ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe
tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand
installthetwopinsandsecurethemwiththe
hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe
rollbarintheraisedposition.Ensurethatthe
rearpartoftheseatissecuredwiththeseat
latch.

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

TurnthevalvetotheLHorRHtank.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral
lockposition.

22

Operation

2.Pullupandbackontheparkingbrakeleverto
engagetheparkingbrake.

3.PushinonthePTOswitchtothe“STOP”
position.

Note:Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.

4.Onawarmengine,placethethrottleinthe
“SLOW”position.

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

Note:DoNotusefuelleftoverfromsummer.

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

GlowPlugChart

AmbientTemperature

HoldGlowPlugsOn

Above50°F(10°C)

NONEED

50°F(10°C)to23°F(-5°C)

Approximately5seconds

Below23°F(-5°C)

Approximately10seconds

Limitofcontinuoususe

20seconds

Theglowpluglight,locatedneartheglow
plugswitch,willilluminatewhentheswitchis
depressed.Theglowpluglightindicatestheglow
plugsarepreheatingthecombustionchamber.

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

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades.
Besurethatallpersonsareclearofthemowerdeck
anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe
PTOcanbeengaged.

1.Setthethrottletothe“MIDW AY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”
position.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDW AY”position.

2.PushthePTOswitchintothe“STOP”position
todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral
lockposition.

4.Engagetheparkingbrake.

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

23

Operation

6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

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

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning
onelevertoomuchaheadoftheother.
Operatormaylosecontrolofthemachine,
whichmaycausedamagetothemachine
orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

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

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

Figure6

1.HandlesOut(Neutral
Lock)

5.Neutral

2.HandlesIn(Neutral)

6.Reverse

3.FrontofUnit

7.NeutralLock

4.Forward

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

3.Tomoveforwardinastraightlineapplyequal
forwardpressuretobothlevers.

Toturnleftorright,pullthemotioncontrollever
backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe
motioncontrolleversaremovedawayfrom
neutral.

4.Tostop,pullthemotioncontrolleversbackto
theneutralposition.

24

Operation

Figure7

1.HandlesOut(Neutral
Lock)

4.Forward

2.HandlesIn(Neutral)

5.Reverse

3.FrontofUnit

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

2.Tomoverearwardinastraightlineapplyingequal
pressurepullbothmotioncontrolleversrearward.

Toturnleftorright,releasepressureonthe
motioncontrollevertowardthedirectiondesired.

3.Tostop,pushthemotioncontrolleverstothe
neutralposition.

AdjustingtheCuttingHeight

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

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

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

Thedeckcanberaisedbypullingthedecklever
upand/orbypushingdownonthefootoperated

deckliftassistleverlocatedatthefrontright
corneroftheoorpan.

Note:Whenchangingthecuttingheight
positions,alwayscometoacompletestop
anddisengagethePTO.

Figure8

1.Leverintransportand5inch(12.7cm)cuttingheight
position

4.Inserttheheightadjustmentpinintothehole
correspondingtothedesiredcuttingheightand
installthehairpincotterpin.

Seethedecalonthesideofthedeckliftplatefor
cutheights.

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

Note:Thefootoperateddeckliftassistlever
canbeusedtomomentarilyliftthedecktoclear
objects.BesurethatPTOisdisengaged.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe
anti-scalprollersbyremovingthespringdisc
washerandbolt.

25

Operation

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

Figure9

Forcuttingheightsabove4.0inches(102mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller
mountingbracket

2.Cuttingheight

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

7.Besuretherollerboltsareinstalledwiththe
springdiscwasherbetweentheheadofthebolt
andthemountingbracket.

Note:Thefootoperateddeckliftassistlever
canbeusedtomomentarilyliftthedecktoclear
objects.BesurethatPTOisdisengaged.

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

Figure10

1.Springdiscwasher
(conetowardsbolthead)

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

2.Frontrightanti-scalp
bracketshown

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

Transporting

TransportingaUnit

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

CAUTION

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

DoNotdriveaunitonapublicstreetor
roadway.

26

Operation

WARNING

Loadingaunitonatrailerortruckincreases
thepossibilityofbackwardtip-over.
Backwardtip-overcouldcauseseriousinjury
ordeath.

•Useextremecautionwhenoperatinga
unitonaramp.

•Useonlyasingle,fullwidthramp;Do
Notuseindividualrampsforeachside
oftheunit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbroken
rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp
andgroundorbetweenrampandtrailer
ortruck.

•Avoidsuddenaccelerationwhiledriving
unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking
unitdownaramptoavoidtipping
backward.

LoadingaUnit

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

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

Important:DoNotattempttoturntheunit
whileontheramp,youmaylosecontroland
driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp
andsuddendecelerationwhenbackingdownaramp.
Bothmaneuverscancausetheunittotipbackward.

27

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitchand
engageparkingbrake,beforeyoudoany
maintenance.

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkenginecoolantlevel.

•Cleantheenginecoolingsystem.

•Removeaccumulateddebrisfromengine.

•Cleanthegrassbuild-upfromunderthedeck.

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheheightadjustmentshaftbearings.

•Greasethereardeckstruts.

Every50hours

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

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Drainfuellter.

Every160hours

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

Every200hours

•Greasethebrakebrackets.

Every500hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

28

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Every600hours

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

Every4,000hours

•

Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)

Monthly

•Checkthebatterycharge.

Yearly

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

•Greasethemuledrivebeltidlerarm.

•Greasethepumpdrivebeltidlerarm.

•Lubricatethecasterwheelhubs.

•Changethehydrauliclter.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Raiseradiatortogainaccesstodipstick.

CAUTION

Iftheradiatorproprodisnotsecurely
positionedinthenotchtheradiatormayfall.
Fallingradiatorcouldcauseseriousinjury.

Besuretheproprodisengagedsecurelyin
thenotchatthefarrightsideoftheslot.

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

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

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

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

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

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebattery
inthetablebelowandchargethebatteryforthe
recommendedtimeintervaltobringthechargeupto
afullchargeof12.6voltsorgreater.

Important:Makesurethenegativebattery
cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging

29

Maintenance

thebattery(seechartforrecommendedcharger
settings).

Voltage
Reading

Percent
Charge

Maximum
Charger
Settings

Charging
Interval

12.6or
greater

100%

16volts/7
amps

No
Charging
Required

12.4–12.675–100%

16volts/7
amps

30Minutes

12.2–12.450–75%

16volts/7
amps

1Hour

12.0–12.225–50%

14.4volts/4
amps

2Hours

11.7–12.00–25%

14.4volts/4
amps

3Hours

11.7orless

0%

14.4volts/2
amps

6Hoursor
More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure11

1.Installbushinginbladepriortoinstallingbushingin
spindle.

B.Installbushing/bladeassemblyintospindle.

Figure12

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

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

C.Applylubricanttothreadsofbladeboltas

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

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

Note:T opreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith,
parkingbrakeengaged,PTOdisengagedand

30

Maintenance

motioncontrolleversmovedoutintheneutral
lockposition.Theoperatordoesnotneedtobe

intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake
disengaged,PTOdisengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

Trytostartwithoperatorinseat,parkingbrake
engaged,PTOengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

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

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

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

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

Again,runengineatone-thirdthrottle,brake
engaged,andmoveleftmotioncontrolleverin

-enginemustinitiateshutdown.

Repeatagainmovingtherightleverin,then
movingbothleversin-enginemustinitiate
shutdownwhetheroperatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

CheckRolloverProtections
Systems(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

Makesurelatchpinandhairpinarefullyinstalled
andlanyardisingoodcondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper
operationofretractorandbuckle.Replacebefore
operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

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

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

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhooktwoairltercanisterlatchestogain
accesstotheaircleanerelement.

3.Removeaircleanercanistercoverandremove
outerelement.

4.Checktheconditionofthepaperelement.
Replaceifdirty,bentordamaged.

31

Maintenance

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

6.DoNotwashorusepressurizedairtoclean
paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe
rubberdustejectorispointingdownwardand
securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Fastendeckbeltspanstogetherwithmechanics
wireortiewraptopreventoilfromdrainingonto
belt.

4.Placepanundermachinetocatchoil.Remove
theoildrainplug.Allowoiltodrainandreplace
oildrainplug.

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

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

7.Removewireortiewrapfrombeltspans

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

9.Checkforleaks,includingaroundtheoillter.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand
removecap.Oillevelshouldbetothetopofthe
bafeinsidethetank.Ifnot,addoil.Useonly
Mobil115W-50syntheticmotoroil.Replace
hydraulicreservoircapandtightenuntilsnug.Do
Notovertighten.

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

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto10psi(69kPa).

4.Semi-pneumaticcastertiresdonotneedtobe
inated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.Removethe
airdetectorpanelonfrontsideoftheengine
compartmenttocheckpumpdrivebeltand
alternatorbelt.

32

Maintenance

3.Removeleftandrightbeltshieldsondeckandlift
upoorpantoinspectdeckdrivebelt.

4.Checkundermachinetoinspectthemule
drivebelt.RefertoMuleDriveBeltTension
AdjustmentsectioninAdjustments.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Front
Casterwheel
hubs

*0

2

*Yearly

2.Front
Caster
Pivots

*0

2

*Yearly

3.Height
Adjustment
Shaft
Bearings

1

540Hours

4.Deck
DriveBelt
IdlerArm

11

Yearly

5.Brake
Brackets

12

200Hours

6.Mule
DriveBelt
IdlerArm

11

Yearly

7.Pump
DriveBelt
IdlerArm

11

Yearly

8.Deck
RearStruts

12

40Hours

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.

Number6(MuleDriveBeltIdlerArm)Located

UnderEngineFrame

Number7(PumpDriveBeltIdlerArm)Located

UnderEngineFrame

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

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Figure13

1.Sealguard2.Spacernutwithwrench
ats

2.Removecasterwheelfromcasterforks.

33

Maintenance

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

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

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

9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

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

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

13.Torquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully.

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

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandlepivot
withaspraytypelubricantorlightoil.

LubricateBrakeRod
Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake
rodshaftwithaspraytypelubricantoralightoil
(bushingsarelocatedtotheinsideoftheange
bearings).

LubricateMotionControl
BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings
securingthemotioncontrolarmshaftswitha
lightoiloraspraytypelubricant.

DrainFuelFilter

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Placeadrainpanunderthefuellterandloosen
thedrainplugapproximately1turn.

3.Watershoulddrain.

4.Whenfuelbeginstoowfromthelter,tighten
thedrainplug.

Important:Waterorothercontaminantsinfuel
canseverelydamagefuelpumpand/ortheother
enginecomponents.

34

Maintenance

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe
fuelpump.Replacewhennecessary.

ReplacementFilters

Kubota

ExmarkP/N98-7612

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

Yearlythereafter

Note:UseonlyExmarkP/N103-2146.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raiseseat.

3.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

4.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

Important:Beforereinstallingnewlter,ll
itwithMobil115W-50andapplyathincoat
ofoilonthesurfaceoftherubberseal.

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

5.FillreservoirasstatedinCheckHydraulicOil

Level.

6.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

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

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

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

WheelHub-SlottedNut
TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor
taperedshaft:

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

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

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

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

5.Thentightennutuntilthenextsetofslotslineup
withthecrossholeinshaft.

6.Replacecotterpin.

Note:DoNotuseanti-seizeonwheelhub.

CheckEngineCoolantLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

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

35

Maintenance

WARNING

Enginecoolantishotandpressurizedand
radiatorandsurroundingpartsarehot.Spray
orsteamfromhot,pressurizedliquidinthe
enginecoolingsystemandtouchingahot
radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore
removingtheradiatorcaporservicingany
componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant
cancausepoisoning.

•DoNotswallow.

•Keepoutofreachofchildrenandpets.

ChangeEngineCoolant

ServiceInterval:Every4,000hours/Every4

years(whichevercomes
rst)Dex-Cool© ©

©

extended

lifecoolant(orangecolor)

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

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

WARNING

Enginecoolantishotandpressurizedand
radiatorandsurroundingpartsarehot.Spray
orsteamfromhot,pressurizedliquidinthe
enginecoolingsystemandtouchingahot
radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore
removingtheradiatorcaporservicingany
componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant
cancausepoisoning.

•DoNotswallow.

•Keepoutofreachofchildrenandpets.

3.Draincoolantwhenengineiscool.Coolantmay
bedrainedfromtheradiatorbyremovingthe
drainplugintherightrearcorner.Theengine
blockmaybedrainedbyremovingtherear
radiatorhoseand/orbyopeningthedraincock
ontheright-handsideoftheengineblock.

Figure14

1.Oildipstick

2.Draincock

4.Reinstallalldrainplugsandhosesandtighten
draincock.

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

36

Maintenance

WARNING

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

•DoNotoperatemachinewithoutthe
coversinplace.

•Keepngers,hands,andclothingclearof
rotatingcomponents.

•Shutoffengine,waitformovingpartsto
stop,engageparkingbrakeandremove
key,beforeperformingmaintenance.

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

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

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

FuelTank—Mounting
HardwareSpecications

ServiceInterval:Asrequired

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

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol
arms.

•Sheaveretainingboltintheendofengine
crankshaft.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

•Boltsretainingstubshafttoengineywheel.

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

Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or
Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

•Betweenthejackshaftandbearingsandthe
jackshaftandsheaves.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
locations:

OnthreadsofBladeBoltsSeeCheckMowerBlades
section.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

37

Maintenance

Adjustments

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

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

4.Setanti-scalprollerstotopholesorremovethem
completelyforthisadjustment.

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

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

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

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

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

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

frontswivelusinglockingnutinfrontofswivel.
Repeatforrightside.

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

Figure15

1.Applydownwardpressurehere

2.Placelockingpliersheretoholdspring

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

4.Removeforceondeckspringsbylooseningnutshere

5.Swivel

6.Frontofunit

7.Socketheadadjustingscrew

8.Jamnut

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

Note:Whenaboveadjustmentshavebeenmade,
thefrontofthedeckwillbeslightlylowerthanthe
rearofthedeck.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

MuleDriveBeltTension
Adjustment

Self-tensioningidler,adjustasfollows:

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktomakesurethecenterofthebolthead
inthecenterofthespringloadedpulley,onleft

38

Maintenance

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

3.Whenadjustmentisnecessary,loosentheidler
pulleyontheright-handsidesoitcanmoveup
anddownintheslot.

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

Repositiontheadjustingpulleytothebottomof
theslot.

Note:Wheninstallinganewbelt,itisnecessary
torepositiontherightadjustingpulleyupwardin
theslotinordertopositionthecenterofthespring
loadedpulleybetweenthealignmentholes.

Figure16

1.Frontofunit

2.Alignmentholes

Figure17

1.Springidlerpulley

3.Rightsideidlerpulley
(adjustable)

2.Frontofunit

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AlternatorBeltTension

Stopengine,waitforallmovingpartstostopand
removekey.Engageparkingbrake.

Tiltseatandremoveairdeectorpanel

Totightenalternatorbelt,loosenbothupperand
loweralternatormountingbolts.Rotatealternator
out,awayfromengineandretightenhardwareto
secureinplace.

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

BeltGuideAdjustment

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removethebeltshieldontherightsideofmower
deck.

3.Notebeltguideboltedtodeckneartheshield
supportstudandright-handpulley.Guideshould

39

Maintenance

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

4.Ifadjustmentisnecessary,loosentheboltsecuring
thebeltguideandmakeproperadjustment.
Tightenhardware.

Figure18

1.Endofslot

2.Beltguide

BrakeLinkAdjustment

Checktomakesurebrakeisadjustedproperly.

1.Disengagebrakelever(leverdown).

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

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

Figure19

1.Leverdown
(disengaged)

6.Removepintoadjust
rodlengthforadditional
brakeadjustment

2.Leverup(engaged)

7.Trunnionroller

3.Nylocnutbelowtrunnion
roller

8.Springretainerbracket

4.Nylocnutbelowspring

9.213/16inches(7.1cm)

5.1/8to3/16inch(3.2to

4.8mm)

10.Jamnutabovetrunnion
roller

BrakeAdjustment

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

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

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

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

40

Maintenance

ElectricClutchAdjustment

Noadjustmentnecessary.

ReverseIndicator
Adjustment

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatforward.

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

4.Checkwhereleverisrelativetonotchinconsole
(shouldbecenteredallowinglevertopivot
outwardtotheneutrallockposition).

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

6.Repeatonoppositesideofunit.

Figure20

1.Turnbolthere4.Yoke

2.Levercenteredinnotch5.Loosenhere

3.Endofslot

6.Reverseindicator

MotionControlLinkage
Adjustment

WARNING

Enginemustberunninganddrive
wheelsmustbeturningsomotioncontrol
adjustmentcanbeperformed.Contactwith
movingpartsorhotsurfacesmaycause
personalinjury.

Keepngers,hands,andclothingclearof
rotatingcomponentsandhotsurfaces.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

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

2.Unhookseatlatchandtiltseatforward.

3.Removetheelectricalconnectionfromtheseat
safetyswitch,locateddirectlytotheleftoftheseat
switchassemblybesidethehydraulicoilreservoir.

Temporarilyinstallajumperwireacrossthe
terminalsintheconnectorofthemainwiring
harness.

4.Runtheunitatleast5minuteswiththedrive
leversatfullforwardspeedtobringhydraulic
systemoiluptooperatingtemperature.

5.Loosenlocknutsfromtheballjointsateachend
ofthepumpcontrollinkage(Figure21).

41

Maintenance

Figure21

Right-HandSideofUnit

1.Turnheretoadjust

2.Loosenhere(right-hand
thread)

6.Startengine.Brakemustbeengagedand
motioncontrolleversouttostartengine.
Operatordoesnothavetobeintheseat
becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

7.Thereverseindicatorspringmustbecorrect
beforethefollowingadjustmentscanbemade.
SeetheReverseIndicatorAdjustmentsection.

Note:Themotioncontrolleverneedstobein
neutralwhilemakinganynecessaryadjustments.

Theleftrodassemblycontrolstheleftwheeland
therightrodassemblycontrolstherightwheel.

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

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

wheelmuststopturningorslightlycreepin
reverse(Figure22).

Figure22

Left-HandSideofUnit

1.TurnLHtrackingadjustmentknob.(DoNotloosenany
nutsonLHside)

10.Shutoffunit.Removejumperwirefromwire
harnessconnectorandplugconnectorintoseat
switch.

MotionControlDamper
Adjustment

Thetopdampermountingboltcanbeadjustedto
obtainamoredesiredmotioncontrolleverresistance.
SeeFigure23formountingoptions.

Figure23

1.Motioncontrolbracket

2.Leastresistance(softestfeel)

3.Mediumresistance(mediumfeel)

4.Mostresistance(rmestfeel)

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

6.Damper

7.Dampermustmovefreelyonbolt.

42

Maintenance

CasterPivotBearings
Pre-LoadAdjustment

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

Figure24

1.Springdiscwashers

Cleaning

CleanEngineCooling
System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore
oftenindryordirty
conditions.)

CAUTION

Excessivedebrisaroundtheenginecooling
airintakeandinsideofthepumpdrive
beltcompartmentanddamagedormissing
rubberbafescancausetheengineand
hydraulicsystemtooverheatwhichcan
createarehazard.

•Cleanalldebrisfrominsideofpumpdrive
beltcompartmentdaily.

•Cleandebrisfromradiatorscreenand
coredaily.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanalldebrisfrominsideofpumpdrivebelt
compartment.

3.Wipedebrisfromscreeninenginecover.

4.Rotateenginecoverforwardandwipedebris
fromradiatorcoreasrequired.

5.Inspectsealsinenginecoverandreplaceif
necessary.

RemoveAccumulatedDebris
fromEngine

ServiceInterval:Beforeeachuseordaily

Enginepartsshouldbekeptcleantoreducetherisk
ofoverheatingandignitionofaccumulateddebris.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removeairdeectorpanelfrombehindseat.

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

4.Reinstalltheairdeectorpanel.

43

Maintenance

Important:DoNotusewatertocleanengine.

Uselowpressurecompressedair.SeeEngine
Owner’sManual.

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.

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

44

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO .

2.Parkingbrakeisnotset.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock
position.

3.Ensurethedriveleversareintheneutral
lockposition.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty .

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

Starterdoesnotcrank.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow.

3.Addoiltothecrankcase.

4.Thethrottleisnotinthecorrectposition.

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

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

6.Dirt,water,orstalefuelisinthefuel
system.

6.ContactanAuthorizedServiceDealer.

7.Aircleanerisdirty.

7.Cleanorreplacetheaircleanerelement.

8.Electricalconnectionsarecorroded,loose
orfaulty .

8.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

Enginewillnotstart,startshard,orfailsto
keeprunning.

9.Relayorswitchisdefective.9.ContactanAuthorizedServiceDealer.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow.

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe
engineareplugged.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.V entholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

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

Enginelosespower.

7.Dirt,water,orstalefuelisinthefuel
system.

7.ContactanAuthorizedServiceDealer.

45

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

2.Addoiltothecrankcase.

3.Dirtyairlter.

3.Cleanorreplacetheaircleanerelement.

4.Coolantlevelislow.

4.Addcoolant.

5.Debrisonoraroundradiator.5.Removedebris.

Engineoverheats.

6.W aterpumporalternatorbeltisworn,
loose,orbroken.

6.ContactanAuthorizedServiceDealer.

1.Trackingneedsadjustment.1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

Mowerpullsleftorright(withleversfully
forward).

3.Reverseindicatorandmotioncontrol
linkageneedadjustment.

3.Adjustthereverseindicatorandthe
motioncontrollinkage.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

2.Changethebelt.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

4.Replacethespring.

Machinedoesnotdrive.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

cooldown.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

front-to-rear.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

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

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley ,orblade
pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

Abnormalvibration.

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley .2.Checkbeltfordamage;replaceif

necessary.Installdrivebeltandcheckbelt
guideforcorrectposition.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley .4.Installdeckpulleyandchecktheidler

pulley,idlerarmandspringforcorrect
positionandfunction.

Bladesdonotrotate.

5.Brokenormissingidlerspring.

5.Replacethespring.

1.Temperatureisincreasingoncoolant
temperaturegauge.

1.Turnunitoffandallowengineandengine
componentstocool.

2.Coolantlevelislow.

2.Addcoolant.

3.Debrisonoraroundradiator.3.Removedebris.

Warningbuzzeremitscontinuousbeep.(See
alsoEngineoverheats).

4.W aterpumporalternatorbeltisworn,
looseorbroken.

4.ContactAuthorizedServiceDealer.

46

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Oillevelislow .1.Checkoillevel.

Warningbuzzeremitsintermittentbeep.

2.Oilleakingfromengine.

2.ContactAuthorizedServiceDealer.

47

Schematics

Schematics

ElectricalDiagram

RED

BLACK

BLACK

YELLOW/BLACK

PINK

2

4

1

5

3

YELLOW/RED

ORANGE

BLACK

BLACK

YELLOW/BLACK

BLACK

PINK

5
43

2
1

RED

1

2

GROUND

ORANGE

BROWN/BLACK

PINK/BLACK

BLACK

RED

BROWN/BLACK

YELLOW/BLACK

YELLOW/BLACK

YELLOW

BLACK

BLACK

ORANGE/BLACK

ORANGE/BLACK

DK. GREEN
DK. GREEN

DK. GREEN
VIOLET

LT. BLUE
LT. BLUE

LT. GREEN

GRAY

TAN

TAN

LT. BLUE

BLACK

BROWN

BROWN

GRAY

ORANGE

GRAY

ORANGE

GRAY

BLACK

PINK/BLACK

WHITE

BLACK/GREEN

YELLOW/RED

BLACK/GREEN

BLACK/WHITE

BLACK/WHITE

DK. BLUE

BLACK

BLACK

YELLOW/BLACK

VIOLET

PINK

PINK

BLACK

PINK

YELLOW/BLACK

YELLOW/BLACK

YELLOW/BLACK

RED

ORANGE

ORANGE

RED

RED

RED

BLACK

GROUND

STARTER;

BATTERY (POS)

DIODE

GLOW SWITCH

S

P

+

ENGINE

3

4

A B

A

B

C

A

B

C

2

1

B A

SEAT DELAY

MODULE CONTROL

SEAT DELAY

MODULE INPUT

SEAT

SWITCH

PTO

CLUTCH

PTO

SWITCH

20 AMP FUSE

(IGN. SWITCH)

STARTER

SOLENOID

SIGNAL

GLOW

RELAY

START

RELAY

BRAKE

SWITCH

LH MOTION

CONTROL

RH MOTION

CONTROL

IGNITION

SWITCH

HOUR

METER

RED

RED

ORANGE

ORANGE

ORANGE

YELLOW

TAN

TAN

ORANGE/BLACK

LT. BLUE

LT.GREEN

DK. GREEN

DK. GREEN

DK. GREEN

LT. BLUE

LT. BLUE

VIOLET

BLACK

BLACK

BLACK

BLACK

RED
RED

ORANGE/BLACK

ORANGE

BROWN/BLACK

YELLOW/BLACK
YELLOW/BLACK

PINK/BLACK

SEAT DELAY

MODULE DIODE

GRAY

BLACK

OIL

SWITCH

OIL

PRESSURE

RELAY

ALTERNATOR

RELAY

FUEL

SOLENOID

ALTERNATOR

CONNECTOR

ALT "B"

TERMINAL

GLOW

PLUG

RAIL

TEMP.

SWITCH

DUAL

TONE

ALARM

TEMP AND

GLOW LED

30 AMP FUSE

(FAN)

40 AMP FUSE

(GL

OW)

BROWN/BLACK

YELLOW/BLACK

VIOLET

PINK

BLACK/WHITE

BLACK

DK. BLUE

RED

BLACK/WHITE

PINK

YELLOW/BLACK

PINK

BLACK

RED

YELLOW/BLACK

PINK/BLACK

YELLOW/BLACK

TEMP

SENDER

6 5 4 7

3 2 1 8

B A

2 1

54321

4 1 7 2 5 6 3 8 9

A B C

A B C

2

1

54321

3241

21

21

35412

21

12

321

543215432

1

1A 1B 2A 2B

BA

12345678

2

1

2 1

1

2

1

2

1

2

3

4

5

1

2

1

2

1

2

3

4

5

1

2

3

2 1

4

9

8

7

3

3

5

1

4

2

3

5

1

4

2

3

5

1

4

2

FUEL

PUMP

2B

2A

1A

1B

1

2

1

2

1

2

I

STARTER

MOTOR

BLACK

A

B

C

TEMP GAUGE

AND VOLTMETER

A

B

C

FAN

2

1

2

1

FAN

RELAY

OPEN WITH

BRAKE

ENGAGED

CLOSED WITH

BRAKE

ENG

AGED

BOTH MOTION CONTROL

SWITCHES ARE CLOSED WITH

CONTROL LEVERS IN NEUTRAL

LOCK POSITION

SWITCH IN: ORANGE TO PINK/BLACK

SWITCH OUT: ORANGE TO GRAY

SWITCH IS CLOSED

WITH OPER

ATOR

IN THE SEAT

NOTE:

CONNECTORS VIEWED FROM TERMINAL END

G006167

TERMINAL A

TERMINAL B

TERMINAL Y

TERMINAL X

TERMINAL S

TERMINAL I

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, AUX HYD, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, AUX HYD, PTO SWITCH

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

B + I + A

2. RUN

1. OFF

POSITION

3. START

48

Schematics

HydraulicDiagram

49

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 Warranty Period

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 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.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized 
 Exmark Service Dealer beyond first warrantable service.

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

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

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

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

There are no other express warranties except for engine and
special emission system coverage stated elsewhere herein or
included with the product.

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
of defective components 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.

Some states do not allow exclusions of incidental or
consequential damages, 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.

2-Year Limited Warranty

Exmark Turf Equipment

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

G006117

50

51

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

Standon

Check Us Out On The Web:

www.exmark.com

©2004–2007ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

PartNo.4500-169Rev.A
[phone]
Fax[phone]
PrintedintheUSA.