Exmark Lazer Z CT User Manual

For Serial Nos.

gher

370,000 & Hi

Part No. 103-4113

WARNING

POTENTIAL HAZARD
♦ This product is a piece of power equipment.

WHAT CAN HAPPEN
♦ Failure to follow safe operating practices can result in serious

operator injury or even death.

HOW TO AVOID THE HAZARD
♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condition.

♦ Stop engine and wait for all moving parts to stop. Remove spark

plug wire(s) or remove key before adjusting, servicing, or
performing maintenance.

♦ If mower deck becomes clogged, stop engine and wait for all

moving parts to stop. Remove spark plug wire(s) or remove key
before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts.

♦ Keep off mower unless seat platform is provided.

♦ Keep others off mower.

WARNING

POTENTIAL HAZARD
♦ Gasoline is harmful or fatal if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.

WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.

HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.

♦ Keep face away from nozzle and gas tank/container opening.

♦ Keep away from eyes and skin.

♦ Never siphon by mouth.

IMPORTANT

When the mower is used or operated on any California forest, brush or grass covered land, a working
spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 4442
Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.

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

i

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

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
central time, with an Exmark Parts Plus

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



shipment of six (6) line items or less.



order of six (6) line items or less.



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

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
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 5­speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.



order

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.

ii

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactured to give you a maximum amount of dependability and years
of trouble-free operation.

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety

instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS

ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong the life

of your mower, maintain its maximum efficiency, and promote safe operation.

If additional information is needed, or should you require trained mechanic service,

contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distributors are kept informed of the latest methods of
servicing and are equipped to provide prompt and efficient service in the field or at their service
stations. They carry ample stock of service parts or can secure them promptly for you from the
factory.

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

iii

TABLE OF CONTENTS

1. SAFETY PAGE

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

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

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

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

1.5 Maintenance & Storage....................................................................... 7

1.6 Safety Signs ..................................................................................... 8-9

2. SPECIFICATIONS

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

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

2.3 Fuel System ...................................................................................... 10

2.4 Electrical System............................................................................... 10

2.5 Operator Controls.............................................................................. 10

2.6 Seat .............................................................................................. 10-11

2.7 Hydrostatic Ground Drive System ..................................................... 11

2.8 Tires & Wheels .................................................................................. 11

2.9 Cutting Deck...................................................................................... 11

2.10 Dimensions........................................................................................ 12

2.11 Torque Requirements........................................................................ 12

3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate Mower .................................................................................. 12

3.2 Service Battery ............................................................................. 12-13

3.3 Install Drive Wheels........................................................................... 13

3.4 Check Tire Pressure.......................................................................... 13

3.5 Install Seat Retaining Rod................................................................. 14

3.6 Install Motion Control Levers............................................................. 14

3.7 Position Discharge Chute.................................................................. 14

3.8 Service Engine .................................................................................. 14

3.9 Service Hydraulic Oil ......................................................................... 15

4. OPERATION INSTRUCTIONS

4.1 Controls ........................................................................................ 15-17

4.2 Pre-Start ............................................................................................ 17

4.3 Mowing ......................................................................................... 17-18

4.4 Transporting ................................................................................. 18-20

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance................................................................... 20-28

5.2 Adjustments.................................................................................. 38-33

6. WASTE DISPOSAL

6.1 Motor Oil Disposal ............................................................................. 33

6.2 Mercury Switch Disposal ................................................................... 34

6.3 Battery Disposal ................................................................................ 34

7. TROUBLE SHOOTING.................................................................. 35-36

8. ELECTRICAL DIAGRAM.......................................................................... 37

9. HYDRAULIC DIAGRAM............................................................................ 38

10. WARRANTY......................................................................................... 39-40

iv

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to
identify important safety messages which must be followed to avoid accidents. This
symbol means:

The safety alert symbol appears above information which alerts you to unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous
situation which, if not avoided, COULD result in death or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous
situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

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

1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the
proper use of the equipment. If the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to explain this material to them.

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

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

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

1.3 PREPARATION

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

1.3.2 The use of personal protective equipment, such as (but not limited to) protection
for the eyes, ears, feet, and head is recommended.

CAUTION

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

dBA at the operator’s ear when in operation.

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

extended periods of time can cause hearing loss.

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

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

- 1 -

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

WARNING

POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.

WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.

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

where dangerous carbon monoxide fumes can collect.

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable

and highly explosive.

WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can burn you, others,

and cause property damage.

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

open flame or where gasoline fumes may be ignited by
spark.

♦ Refuel only outdoors.

♦ Store gasoline in an approved container and keep it

out of the reach of children.

♦ Add fuel before starting the engine. Never remove the

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

♦ Never fill the fuel tank so that the gasoline level rises

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

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

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

♦ Don not operate without entire exhaust system in place

and in proper working condition.

- 2 -

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable

and highly explosive.

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

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

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

container.

♦ Always place gasoline containers on the ground away

from your vehicle before filling.

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

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

♦ When practical, remove gas-powered equipment from

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

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

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

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

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

WARNING

POTENTIAL HAZARD
♦ Gasoline vapor can collect inside enclosed trailers and

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

WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in property

damage, personal injury, and/or death.

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

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

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

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

♦ Do not place any equipment that is leaking gasoline in

an enclosed trailer.

- 3 -

1.4 OPERATION

Although hazard control and accident prevention partially are dependent upon the
design and configuration of the equipment, these factors are also dependent upon
the awareness, concern, prudence, and proper training of the personnel involved in
the operation, transport, maintenance, and storage of the equipment. It is essential
that all Operator Safety Mechanisms be connected and in operating condition prior
to use for mowing.

WARNING

POTENTIAL HAZARD
♦ Operating engine parts, especially the muffler, become

extremely hot.

WHAT CAN HAPPEN

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

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

touching.

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

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

WARNING

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

entangled in rotating parts.

WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traumatic amputation

or severe lacerations.

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

safety devices in place and working properly.

♦ Keep hands, feet, hair, jewelry, or clothing away from

rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

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

DO NOT operate the mower when children or others are in the area!

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

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction

and/or tip-over could occur. The operator is responsible for safe operation on
slopes.

- 4 -

DANGER

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

loss of control.

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

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

HOW TO AVOID THE HAZARD

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

Note: A rollbar is available and its use is recommended for areas
where there are slopes, drop-offs or water. (See section 1.4.5.)

• See inside the back cover to determine the approximate slope angle of the
area to be mowed.

• Use a walk behind mower and\or a hand trimmer near drop-offs, ditches, steep
banks or water. This area can be dangerous, see Figure 1.

Figure 1

SAFE ZONE FOR MOWING

• Progressively greater care is needed as the slope increases.

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

disengage the blades and proceed slowly off the slope.

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

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

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

• Watch for ditches, holes, rocks, dips, and rises that change the operating
angle, as rough terrain could overturn the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing
area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachments. These can change the
stability of the machine and cause loss of control.

• Follow the manufacturer’s recommendations for wheel weights or
counterweights to improve stability.

1.4.5 A Rollover Protection System (ROPS) is available and its use is recommended for
areas where there are slopes, drop-offs or water.

- 5 -

IMPORTANT: When operating a machine with a ROPS always use the seatbelt.

• Be certain that the seat belt can be released quickly if the machine is driven or

rolls into ponds of water.

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

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

1.4.6 Use EXTREME caution when backing up. LOOK BEHIND YOU!!

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

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

1.4.9 DO NOT change the engine governor settings or overspeed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.

1.4.10 Disengage PTO before starting engine.

1.4.11 Start

the engine carefully with feet well away from the blades.

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

1.4.13 Stop engine, wait for all moving parts to stop, and remove key:

• Before checking, cleaning or working on the mower.

• After striking a foreign object (inspect the mower for damage and make

repairs before restarting and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

Stop the engine and wait for all moving parts to stop:

• Before refueling.

• Before dumping the grass catcher.

1.4.14 Before stopping the engine, place the throttle control midway between the “slow”
and “fast” positions. Allow the engine to run a minimum of 15 seconds; then stop
the engine.

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

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

• During transport to and from the job.

• When parked inside a building.

1.4.16 This mower was designed for one operator only. Keep all others away from
mower during operation.

1.4.17 Do Not mow with the discharge deflector raised, removed, or altered unless
there is a grass collection system or mulch kit in place and working properly.

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

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

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

1.4.21 If jump starting is required:

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

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

- 6 -

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

booster battery to any engine deck ground, preferably the engine block as
far away from the battery as possible.

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

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations
precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable from the negative battery post when the unit will be
allowed to sit for more than 30 days without use.

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

Note: To prevent damage due to freezing, battery should be fully charged before
putting away for winter storage.

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

1.5.5 Store fuel in a container specifically designed for this purpose in a cool, dry place.

1.5.6 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.

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

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

1.5.9 Check all bolts frequently to maintain proper tightness.

1.5.10 Keep all guards, shields and all safety devices in place and in safe working condition.

1.5.11 Frequently check for worn or deteriorating components that could create a hazard.

1.5.12 All replacement parts must be the same as or equivalent to the parts supplied as
original equipment.

WARNING

POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrate

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

surgically removed within a few hours by a doctor

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

good condition an all hydraulic connections and fittings

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

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

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

placing the motion control levers in neutral and

shutting off the engine before performing any work on

the hydraulic system.

- 7 -

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety
signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sure that current safety signs are affixed
to the replaced components.

1.6.4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or from Exmark Mfg. Co. Inc.

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

1.6.6 Familiarize yourself with the following safety signs and instruction labels. They
are critical to the safe operation of your Exmark commercial mower.

PART NO. 103-3995
LOCATION: Center of Console

PART NO. 106-6571
LOCATION: Top Center of Floorpan

PART NO. 1-513748
LOCATION: Bottom of

Floorpan

PART NO. 1-513746
LOCATION: On Engine

Blower Housing

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

Shields, Left and Right Sides

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

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

PART NO. 1-643401
LOCATION: On Tilt Switch

PART NO. 98-5954
LOCATION: Under Mower Deck

Belt Shield(s)

PART NO. 1-523552
LOCATION: Top of Hydraulic

Reservoir

- 8 -

PART NO. 103-0262
LOCATION: Below Center of

Console

PART NO. 1-633922
LOCATION: Front Left Corner

PART NO. 103-1997
LOCATION: Top of Console Under Seat

PART NO. 103-2644
LOCATION: Top of Hydraulic Reservoir

Top of Mower Deck

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

Deck, Under Floor Pan

PART NO. 103-4337
LOCATION: Bottom Side of Floor Pan

PART NO. 103-1077
LOCATION: On Top LH Side of Mower Deck

- 9 -

PART NO. 1-653147

4.5

6

5

3

1

4

0

LOCATION: Lefthand Side of

4.0

3.5

3.0

2.5

2.0

1.5

PART NO. 1-653140
LOCATION: RH Side of Cutting Height

Adjustment Plate

Cutting Height
Adjustment Plate

2. SPECIFICATIONS

2.1 MODEL NUMBER:

Serial Nos. 370,000 & Higher: LCT4418KC; LCT4818KC

2.2 ENGINE:

2.2.1 Engine Specifications: See Your Engine Owner’s Manual

2.2.2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity: 8 gal. (30 L.)

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

2.3.3 Fuel Filter: For Kohler: Replaceable in-line 15 Micron Kohler P/N 2405002

2.3.4 Fuel Shut-Off Valve: 1/4 turn increments (left tank, “OFF”, right tank)

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amps

2.4.3 Battery Type: BCI Group U1

2.4.4 Battery Voltage: 12 Volt

2.4.5 Polarity: Negative Ground

2.4.6 Fuses: Two 20 amp blade type

2.4.7 Safety Interlock System:

PTO must be disengaged, brake engaged, and motion control levers out
(neutral lock) to start engine. (It is not necessary for the operator to be in the
seat to start the engine.)

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

motion control levers are moved in or engine will stop.

Engine will stop if either the left, the right, or both levers are moved from neutral
lock position while brake is engaged.

2.4.8 Tilt Switch: Shuts off the engine when the unit is tilted more than 60° from
horizontal.

2.5 OPERATOR CONTROLS

2.5.1 Steering and Motion Control:

Separate levers, on each side of the console, control speed and direction of
travel of the respective drive wheels.

Steering is controlled by varying the position of the levers relative to each other.

Moving motion control levers outward

Motion control levers are adjustable to two heights.

2.5.2 PTO Switch: Engages electric clutch (to drive belt) which engages mower
blades.

2.5.3 Parking Brake Lever: Engages parking brake.

2.5.4 Deck Height Adjustment Lever: Sets cutting height to desired position.

(in slots) locks the drive system in neutral.

2.6 SEAT

2.6.1 Type: Standard seat: high back, foam padded (internal spring

suspension).

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

(dampened, adjustable spring suspension) with armrests.

- 10 -

2.6.2 Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other
components. Held in tilted position with prop rod. Adjustable fore and aft seat
track.

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

Optional suspension seat: molded adjustable flip-up armrests.

2.6.4 Seat Safety Switch: Incorporated into the Safety Interlock System.

Time delay seat switch eliminates rough ground cut-outs.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic Pumps: Two Hydro Gear BDP-10A variable displacement piston pumps.

2.7.2 Wheel Motors: Two Parker wheel drive motors with 1” tapered shafts.

2.7.3 Hydraulic Oil Type: Synthetic Mobil 1 15W-50.

2.7.4 Hydraulic Oil Capacity: 2.1 qt. (2.0 L.)

2.7.5 Hydraulic Filter: Replaceable cartridge type.

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

2.7.6 Speeds: 44” & 48” units: 0 – 7.2 mph (11.6 km/hr) forward.

0 – 4.0 mph (6.4 km/hr) reverse.

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

2.8 TIRES AND WHEELS

2.8.1 Tires:
Drive Tires

Front Caster Tires

Size Qty Tread Ply Inflation

20 x 10-10 2 “Multi Trac C/S” 4 13 psi (90 kPa)

11 x 4.00-5 2 Smooth 4 16 psi (110 kPa)

2.9 CUTTING DECK

2.9.1 Cutting Width: 44” deck 48” deck

44 in. (111.8 cm) 47.2 in. (120.0 cm)

2.9.2 Discharge: Side (Optional Mulch or Bag)

2.9.3 Blade Size: 44” deck 48” deck

(3 ea.) 15.25 in. (38.7 cm) 16.25 in. (41.3 cm)

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

2.9.5 Deck Drive: Electric clutch mounted on vertical engine shaft. Blades are driven
by one “B” Section belt (w/self-tensioning idler) direct from the engine.

2.9.6 Deck: Full floating deck is attached to out-front support frame.

Maximum turf protection is provided by three anti-scalp rollers.

Deck design allows for bagging, mulching or side discharge.

2.9.7 Cutting Height Adjustment: an extra-long cushioned lever is used to adjust the
cutting height from 1-1/2” (3.8 cm) to 4-1/2” (11.4 cm.) in 1/4” (.64 cm.)
increments.

The cutting height adjustment handle has a transport position and all
adjustments can be made while the operator remains seated.

2.9.8 Mulching Kit: Optional.

- 11 -

2.10 DIMENSIONS

p

2.10.1 Overall Width:

w/44” Deck 44 in. (111.7 cm) 47.4 in. (120.3 cm) 54.7 in. (138.9 cm)

w/48” Deck 44 in. (111.7 cm) 50.3 in. (122.4 cm) 58.1 in. (147.6 cm)

2.10.2 Overall Length: w/44” & 48” decks: 73.9 in. (187.7 cm)

2.10.3 Overall Height: w/44” & 48” decks: 40.0 in. (196.3 cm.)

2.10.4 Tread Width: (center to center of tires, widthwise)

Drive Wheels

Front Casters

2.10.5 Wheel Base: (center of caster tire to center of drive tire)

2.10.6 Curb Weight *: w/44” Deck: 810 lbs. (367.4 kg)

Without deck

w/44” Deck w/48” Deck

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

32.7 in. (83.1 cm) 32.7 in. (83.1 cm)

w/44” & 48” Deck: 46.2 in. (117.3 cm)

w/48” Deck: 830 lbs. (376.5 kg)

Discharge chute up Discharge chute down

2.11 TORQUE REQUIREMENTS

Bolt Location Torque

Cutter Housing Spindle Nut ......................................... 140-145 ft-lbs. (190-197 N-m)

Blade Mounting Bolt..................................................... 115-120 ft-lbs. (156-163 N-m)

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

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

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

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

Wheel Hub Slotted Nut ............................................... minimum 100 ft-lbs. (169 N-m)

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

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE MOWER

3.2 SERVICE BATTERY.

WARNING: Battery posts, terminals, and related accessories contain lead compounds,

chemicals known to the State of California to cause cancer and re

The machine is shipped with a filled lead acid battery.

3.2.1 Tilt seat up to gain access to the battery.

roductive harm. Wash

DANGER

POTENTIAL HAZARD
♦ Charging the battery may produce explosive gasses

WHAT CAN HAPPEN
♦ Battery gasses can explode causing serious injury.

HOW TO AVOID THE HAZARD

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

enclosed space.

♦ Make sure venting path of battery is always open once

battery is filled with acid.

- 12 -

3.2.2 Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of
the battery in the table below and charge the battery for the recommended time
interval to bring the charge up to a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected and the
battery charger used for charging the battery has an output of 16 volts and 7
amps or less to avoid damaging the battery (see chart below for recommended
charger settings).

Voltage

Reading

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

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

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

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

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

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

Percent

Charge

Charger Settings

CAUTION

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

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

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

charging the battery.

3.2.3 Connect the negative battery cables.

NOTE: If the positive cable is also disconnected, connect the positive (red)
cable to the positive battery terminal first, then the negative (black) cable and

green/white wire to the negative battery terminal. Slip insulator boot over the
positive terminal.

NOTE: If time does not permit charging the battery, or if charging equipment is
not available, connect the negative battery cables and run the vehicle
continuously for 20 to 30 minutes to sufficiently charge the battery.

Maximum

Charging Interval

3.3 INSTALL DRIVE WHEELS.

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

3.4 CHECK TIRE PRESSURE.

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

- 13 -

3.5 INSTALL SEAT RETAINING ROD.

A

3.5.1 Tilt seat up. Remove 5/16” nyloc nut from bolt attaching seat retaining rod to
seat frame. Remove ignition keys attached to bolt. Remove retaining rod from
seat and insert the “L” shaped end of the rod into the hole directly above the left­side hydraulic pump (the “L” must be positioned pointing up). Position the seat
retaining rod to the outside of the mounting tab on the seat frame and secure
with 5/16” x 1” bolt and nyloc nut. Tighten until snug, then loosen just enough so
the rod pivots freely.

3.6 INSTALL MOTION CONTROL LEVERS.

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

a) Install the left motion control lever onto the control arm shaft (See Figure 2)

on the left side of the console. Place the lever (with the mounting plate
towards the rear) on the outside of the control arm shaft and secure with the
bolts and washers. Position the lever so the bolts are in the center of the
slots on the lever mounting plate and tighten until snug. Repeat on opposite
side of unit.

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

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

If the levers do not align with each other, when in the neutral position, (See
Figure 3) loosen the hardware and make the appropriate adjustment by
sliding/tilting the lever(s) forward or backward until properly aligned and
tighten hardware.

MOTION

CONTROL

LEVER

MOUNT PLATE TO

THE REAR & OUTSIDE

OF ARM SHAFT

LEVERS IN

LIGNMENT

FIGURE 2 FIGURE 3

CONTROL ARM SHAFT LEVER ALIGNMENT

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

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

3.7 POSITION DISCHARGE CHUTE

3.7.1 Loosen two (2) 5/16” nyloc nuts attaching discharge chute. Lower the discharge
chute into position. Retighten nyloc nuts until chute is snug but can pivot freely.

3.8 SERVICE ENGINE

Refer to Engine Owner’s Manual.

- 14 -

3.9 SERVICE HYDRAULIC OIL

The machine is shipped with hydraulic oil in the reservoir. Run the machine for
approximately 15 minutes to allow any extra air to purge out of the hydraulic
system. Check hydraulic reservoir and if necessary fill the reservoir to the
appropriate level with Mobil 1 15W-50 synthetic motor oil. Replace hydraulic
reservoir cap and tighten until snug. Do not overtighten.

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

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4.1.1 Familiarize yourself with all controls before operating the mower.

4.1.2 Motion Control Levers: Located on each side of the console.

The left lever controls the flow of hydraulic oil from the left hydrostatic pump to
the left drive wheel motor. The right lever controls the flow of hydraulic oil from
the right hydrostatic pump to the right drive wheel motor.

IMPORTANT: To begin movement (forward or backward) the operator must
be in the seat, the brake lever must be disengaged (pushed down) before
the motion control levers can be moved in or the engine will kill.

When levers are centered in the T-slot the drive system is in the neutral position.
With levers moved out in the T-slot the drive system is in the neutral lock
position (See Figure 4).

FIGURE 4

MOTION CONTROL POSITIONS

By moving both levers an equal amount forward or back from the neutral position the
machine can be caused to move forward or backward in a straight line.

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

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

To make a zero turn to the left, pull the left lever back beyond neutral while
holding the right lever slightly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutral while
holding the left lever slightly ahead of neutral.

- 15 -

Pulling the levers back from the neutral position will cause the respective drive
wheels to rotate in a reverse direction (spring tension can be felt when moving
into reverse from neutral).

To turn to the left while backing, move the left lever forward toward neutral. To
turn to the right while backing, move the right lever forward toward neutral.

CAUTION

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

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

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

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

4.1.3 Tracking Adjustment Knob: Located under the seat on the LH pump control link.
Rotating this knob allows fine tuning adjustments so that the machine tracks straight
with the drive levers in the full forward position.

Stop machine and wait for all moving parts to stop. Engage park brake. Tilt seat
forward to gain access to the tracking knob. Rotate the knob counter-clockwise
(as viewed from the rear of the machine) to cause the machine to track more to
the right and clockwise to cause the machine to track more to the left. Adjust in
quarter-turn increments until the machine tracks straight. Check that the
machine does not creep when in neutral with the park brakes disengaged.

IMPORTANT: Do not rotate the knob too far, as this may cause the machine
to creep in neutral. Refer to section 5.2.11 for control linkage adjustment.

4.1.4 PTO Engagement Switch: Located just left of center on the console (left side of
ignition switch). Switch must be pulled out to the “ROTATE” position to engage
the blades. Switch is pushed in to the “STOP” position to stop the blades.

4.1.5 Choke Control: Located at center of console (right side of ignition switch).
Choke is used to aid in starting a cold engine. The choke control is pulled out to

be in the “ON” position and pushed in to be in the “OFF” position. DO NOT run
a warm engine with choke in the “ON” position.

4.1.6 Throttle Control: Located on console just right of center.
Throttle is used to control engine speed. Moving throttle lever forward will increase

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

4.1.7 Brake Lever: Located on left side of the console. The brake lever engages a
parking brake on the drive wheels.

Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.

The unit must be tied down and brake engaged when transporting.

4.1.8 Ignition Switch: Located on the lower center of console.
The ignition switch is used to start and stop the engine. The switch has three

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

Rotate clockwise to the next position to engage the starter (key must be held
against spring pressure in this position).

Brake must be engaged, motion control levers out (neutral lock position)
and PTO switch “OFF” to start engine. (It is not necessary for the operator to

be in the seat to start the engine.)

- 16 -

4.1.9 Hour Meter: Located left on center of console. The hour meter is connected to a
pressure switch installed in the engine block and it records the number of hours
that the engine has run. If ignition switch is left on without engine running, hour
meter will not run.

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

4.1.10 Fuel Shut-Off Valve: Located directly below center of console.

The fuel shut-off valve is used to shut off the fuel when the machine will not be
used for a few days, during transport to and from the jobsite, and when parked
inside a building. The valve has three positions, each position made in 1/4

turn increments.

Valve handle down is the “OFF” position. Rotate valve handle 1/4 turn right (from
“Off” position) for fuel flow from the right tank. Rotate valve handle 1/4 turn left
(from “Off” position) for fuel flow from the left tank.

4.1.11 Drive Wheel Release Valves: Located on the right front corner of the hydrostatic
pumps. Drive wheel release valves are used to release the hydrostatic drive
system to allow the machine to be pushed without the engine running. Tilt seat
up to gain access to pumps.

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

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

4.2 PRE-START

4.2.1 Fill fuel tanks. For best results use only clean, fresh regular grade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline may
also be used; however, combustion chamber and cylinder head will require more
frequent service. See Engine Owner's Manual. DO NOT add oil to gasoline.

Do Not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a
level that is 1/2” below the bottom of the filler neck to allow for fuel expansion and
prevent fuel spillage.

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

4.2.3 Refer to Maintenance, Section 5, and perform all the necessary inspection and
maintenance steps.

4.3 MOWING

4.3.1 Open fuel shut-off valve (left or right tank).

4.3.2 Starting Engine:

Brake must be engaged, the PTO switch disengaged, and the motion
control levers out (neutral lock position). (The operator does not need to be

in the seat to start the engine.)
On a cold engine, place the throttle midway between the “SLOW” and “FAST”

positions and pull choke to the “ON” position. Turn ignition switch to the “start”
position. Release the switch as soon as the engine starts.

IMPORTANT: DO NOT crank the engine continuously for more than ten (10)
seconds at a time. If the engine does not start, allow a 60 second cool­down period between starting attempts. Failure to follow these guidelines
can burn out the starter motor.

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

On a warm engine, place the throttle midway between the “SLOW” and “FAST”
positions and leave the choke in the “OFF” position.

- 17 -

4.3.3 Engaging PTO

POTENTIAL HAZARD
♦ The rotating blades under the mower deck are

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

deck when the blades are engaged.

POTENTIAL HAZARD
♦ An uncovered discharge opening will allow objects to

be thrown in an operator’s or bystander’s direction.

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

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

raised, removed, or altered unless there is a grass

collection system or mulch kit in place and working

properly.

DANGER

DANGER

The PTO clutch push-pull switch engages the cutting blades. Be sure that all
persons are clear of mower deck and discharge area before engaging PTO.

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

Set throttle to "midway" position. Pull outward on the switch to the “ROTATE”
position. Accelerate to full throttle to begin mowing.

4.3.4 Stopping PTO: Set the throttle to the “midway” position. Push in on the switch to
the “STOP” position stopping the PTO.

4.3.5 Stopping Engine: Bring unit to a full stop. Disengage the PTO, move motion
control levers out to the neutral lock position and engage parking brake.

Before stopping the engine, place the throttle control midway between the “slow”
and “fast” positions. Allow the engine to run a minimum of 15 seconds; then stop
the engine.

Rotate ignition switch to “OFF” position. Remove the key to prevent children or
other unauthorized persons from starting engine.

Close fuel shut-off valve when machine will not be used for a few days, when
transporting, and when the unit is parked inside a building.

4.4 TRANSPORTING

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

Secure a trailer with a safety chain.

- 18 -

CAUTION

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

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

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

is dangerous and can lead to accidents causing

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

may also be a violation of State laws and the operator

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

WARNING

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

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

injury or death.
HOW TO AVOID THE HAZARD

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

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

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

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

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

ramp to avoid tipping backward.

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

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

- 19 -

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

Avoid sudden acceleration when driving up a ramp and sudden deceleration when
backing down a ramp. Both maneuvers can cause the unit to tip backward.

5. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD
♦ While maintenance or adjustments are being made,

someone could start the engine.

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

you or other bystanders.

HOW TO AVOID THE HAZARD
♦ Remove the key from the ignition switch and pull the

wire(s) off the spark plug(s) before you do any
maintenance. Also push the wire(s) aside so it does
not accidentally contact the spark plug(s).

WARNING

POTENTIAL HAZARD
♦ The engine can become very hot.

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

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

making repairs around the engine area.

5.1 PERIODIC MAINTENANCE

5.1.1 Check engine oil level:

Service Interval: Daily

a) Stop engine, wait for all moving parts to stop and make sure unit is on a

level surface.
b) Check with engine cold.
c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the

dipstick. Do not screw into place. Remove the dipstick and read the oil level.
d) If the oil level is low, wipe off the area around the oil fill cap, remove cap,

and fill to the “FULL” mark on the dipstick. Use oil as specified in the

Engine Owner’s Manual.

DO NOT overfill.

IMPORTANT: DO NOT operate the engine with the oil level below the
“LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

- 20 -

5.1.2 Clean engine air cooling system:

Service Interval: Daily or more often in dry conditions

CAUTION

POTENTIAL HAZARD
♦ Excessive debris can cause the engine and hydraulic

system to overheat.

WHAT CAN HAPPEN
♦ Excessive debris around the engine cooling air intake

and inside of the pump compartment can create a fire
hazard.

HOW TO AVOID THE HAZARD
♦ Clean all debris from around the engine and hydraulic

pumps daily.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Clean all debris from rotating engine air intake screen and from around

engine shrouding.

5.1.3 Check battery charge:

Service Interval: Monthly

Allowing batteries to stand for an extended period without recharging them will
result in reduced performance and service life. To preserve optimum battery
performance and life, recharge batteries in storage when the open circuit voltage
drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before
putting away for winter storage.

a) Check the voltage of the battery with a digital voltmeter. Locate the voltage

reading of the battery in the table below and charge the battery for the

recommended time interval to bring the charge up to a full charge of 12.6

volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected

and the battery charger used for charging the battery has an output of 16

volts and 7 amps or less to avoid damaging the battery (see chart below for

recommended charger settings).

Voltage

Reading

Percent

Charge

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

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

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

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

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

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

5.1.4 Clean grass build-up under deck.

Service Interval: Daily

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

b) Raise deck to the transport (4.5” (11.4cm) cutting height) position. Lift the

front of unit and support unit using jack stands or equivalent support.

- 21 -

Maximum

Charger Settings

Charging Interval

POTENTIAL HAZARD
♦ Raising the mower deck for service or maintenance

relying solely on mechanical or hydraulic jacks could

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

support or may malfunction allowing the unit to fall,

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

for support. Use adequate jack stands or equivalent

support.

c) Clean out any grass build-up from underside of deck and in discharge chute.

5.1.5 Check mower blades.

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

b) Lift deck and secure in raised position as stated in Section 5.1.4.

c) Inspect blades and sharpen or replace as required.

d) Re-install the blades (if they were removed) by placing a block of wood

between the front or rear baffles and the blade then torque the blade bolts
to 115-120 ft. lbs (156-165 N-M). Be sure the spring disk washer cone is
installed toward the bolt head. (See Figure 5).

CAUTION

Service Interval: Daily

NOTE: Another option for blade replacement is to use a 1” wrench on the
flat areas at the base of the spindle to hold the spindle assembly in place
while applying torque to the blade bolt.

CAUTION

POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened

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

rotating at a high speed to come out from under the

deck, causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦ Replace the blade bolt after striking a foreign object.

Use only the following replacement parts:

Blade bolt – PN 103-1026

Spring disc washer – PN 1-513208
♦ DO NOT lubricate the threads of the bolt or spindle

before assembly.
♦ Torque the blade bolt to 115-120 ft. lbs (156-165 N-M).

- 22 -

FIGURE 5

BLADE BOLT INSTALLATION

5.1.6 Check safety interlock system.

Service Interval: Daily

a) Check starting circuit. Starter should crank with parking brake engaged,

PTO disengaged and motion control levers moved out in the neutral lock
position. The operator does not need to be in the seat to start the engine.

Try to start with operator in seat, parking brake disengaged, PTO

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

Try to start with operator in seat, parking brake engaged, PTO engaged
and motion control levers in the neutral lock position - starter must not
crank.

Try to start with operator in seat, parking brake engaged, PTO

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

starter must not crank.

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

brake and raise off of seat (but do not get off of machine) engine must
stop after approx. 1/2 second has elapsed (seat has time delay kill switch
to prevent cut-outs on rough terrain).

Run engine at one-third throttle, engage PTO and raise off of seat (but do
not get off of machine) engine must stop after 1/2 second has elapsed.

Run engine at one-third throttle, with brake disengaged, move levers in and
raise off seat (but do not get off of machine) engine must stop after 1/2
second has elapsed.

Again, run engine at one-third throttle, brake engaged, and move left
motion control lever in - engine must stop.

Repeat again moving the right lever in, then moving both levers in -
engine must stop whether operator is on seat or not.

NOTE: If machine does not pass any of these tests, do not operate.
Contact your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that operator safety mechanisms be connected
and in proper operating condition prior to use for mowing.

- 23 -

5.1.7 Check for loose hardware.

Service Interval: Daily

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating.

5.1.8 Service air cleaner.

Service Interval: See Engine Owner’s Manual

a) Stop engine, wait for all moving parts to stop, and remove key.
b) See Engine Owner’s Manual for cleaning instructions.

5.1.9 Change engine oil:

Service Interval: See Engine Owner’s Manual.

NOTE: Change oil and filter after first five (5) hrs. of operation. Follow
engine manufacturer’s recommendations for future oil changes.

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

b) Drain oil while engine is warm from operation.

c) Oil drain valve is located on right hand side of the engine. Place a pan

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

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

filter and unscrew filter to remove.

Before reinstalling new filter, apply a thin coating of oil on the surface of the
rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter
then tighten filter an additional 2/3 to 3/4 turn.

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

cap. Use oil recommended in engine owner’s manual. DO NOT overfill.

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

5.1.10 Check hydraulic oil level:

Service Interval: 40 hr.
a) Stop engine and wait for all moving parts to stop.
b) Clean area around hydraulic reservoir cap and remove cap.
c) Oil level should be to the top of the baffle inside the tank. If not add oil. Use

only Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap
and tighten until snug. Do not overtighten.

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

5.1.11 Check tire pressures:

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Check tire pressure in all four tires.
c) Inflate caster tires to 16 psi (1100 kPa).
d) Inflate drive tires to 13 psi (90 kPa).

- 24 -

NOTE: Do not add any type of tire liner or foam fill material to the tires.

Excessive loads created by foam filled tires may cause failures to the hydro drive
system, frame and other components. Foam filling tires will void the warranty.

5.1.12 Check condition of belts:

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Check under engine deck to check pump drive belt.
c) Remove left and right belt shields on deck and lift up floor pan to inspect

deck drive belt.

d) See Sections 5.2.3 and 5.2.4, for belt adjustment.

5.1.13 Lubricate grease fittings:

Service Interval: Refer to chart.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose

gun grease.

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

LUBRICATION CHART

FITTING

LOCATIONS

1. Front Caster wheel hubs w/o zerk

2. Front Caster Pivots 2 2 8 hours

3. Height Adjustment Shaft Bearings 1 5 40 hours

4. Deck Drive Belt Idler Arm 1 1 40 hours

5. Pump Drive Belt Idler Arm 1 1 40 hours

∗ See Section 5.1.14 for special lubrication instructions on the front caster wheel hubs.

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

No. 4 & 5 (Idler Arms)
Monthly disassemble belt and spring and
grease under a “NO LOAD” condition.

5.1.14 Lubricate caster wheel hubs:

Service Interval: Once Yearly

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Remove caster bolt and caster wheel from caster fork. Remove seal

guards from the wheel hub.

c) Remove one of the spacer nuts from the axle assembly in the caster wheel.

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

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

necessary.

e) Pack the bearings with a NGLI grade #1 multi-purpose grease.

INITIAL

PUMPS

∗0

NO. of

PLACES

2

SERVICE

INTERVAL

∗yearly

- 25 -

f) Insert (1) bearing, (1) new seal into the wheel.
g) If the axle assembly has had both spacer nuts removed (or broken loose), apply

a thread locking adhesive to (1) spacer nut and thread onto the axle with the
wrench flats facing outward. Do not thread spacer nut all of the way onto the end
of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the
spacer nut to the end of the axle inside the nut.

h) Insert the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing.

i) With the open end of the wheel facing up, fill the area inside the wheel

around the axle full of NGLI grade #1 multi-purpose grease.

j) Insert the second bearing and new seal into the wheel.

k) Apply a thread locking adhesive to the 2

with the wrench flats facing outward.

l) Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to 20-25

in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.

m) Re-install the seal guards over the wheel hub and insert wheel into caster

fork. Re-install caster bolt and tighten nut fully.

NOTE: Seals (Exmark PN 103-0063) must be replaced.
IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin the caster tire. The tire should not spin freely (more
than 1 or 2 revolutions) or have any side play. If the wheel spins freely
adjust torque on spacer nut until there is a slight amount of drag.

5.1.15 Lubricate seat switch actuator:

Service Interval: 160 hrs.

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

b) Tilt seat up.

c) Lubricate switch actuator rod with spray type lubricant or light oil.

5.1.16 Lubricate brake handle pivot:

Service Interval: 160 hrs.

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

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

or light oil.

5.1.17 Lubricate brake rod bushings:

Service Interval: 160 hrs.

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

b) Tilt seat up.

c) Lubricate bronze bushings on each end of brake rod shaft with a spray type

lubricant or a light oil. Shaft is located under the console.

5.1.18 Lubricate motion control bronze bushings:

Service Interval: 160 hrs.

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

b) Tilt seat up.

c) Lubricate bronze bushings on flange bearings securing the motion control

arm shafts with a light oil or a spray type lubricant.

nd

spacer nut and thread onto the axle

- 26 -

5.1.19 Remove engine shrouds and clean cooling fins:

Service Interval: 80 hrs.

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

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

dust, dirt and oil from external surfaces of engine, which can cause
improper cooling.

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

without cooling shrouds will cause engine damage due to overheating.

5.1.20 Check spark plug:

Service Interval: 160 hrs.

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

plug. See Engine Owners Manual.

5.1.21 Change fuel filter:

Service Interval: As Required

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

when necessary.

For Kohler engines use Kohler P/N 2405002.

5.1.22 Change hydraulic system filter:

Service Interval: After First 250 hrs.

Then yearly thereafter

NOTE: Use only Exmark Part No. 1-513211 for Summer use above
or Part No. 1-523541 for Winter use below 32°

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

b) Locate filter under right rear corner of engine deck.

c) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system.

d) Unscrew filter to remove and allow oil to drain from reservoir.

IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and
apply a thin coat of oil on the surface of the rubber seal.

Turn the filter clockwise until rubber seal contacts the filter adapter then
tighten the filter an additional 2/3 to 3/4 turn.

e) Fill reservoir as stated in Section 5.1.10.

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

support) just high enough to allow drive wheels to turn freely.

g) Start engine and move throttle control ahead to full throttle position. Move

the speed control levers to the full speed and run for several minutes. Shut
down machine and recheck oil level.

Do not change hydraulic system oil (except for what can be drained when
changing filter), unless it is felt the oil has been contaminated or been
extremely hot.

Changing oil unnecessarily could damage hydraulic system by
introducing contaminates into the system.

5.1.23 Wheel hub - slotted nut torque specification.

When tightening the slotted nut on the wheel motor tapered shaft:

a) Torque the slotted nut to 100 ft. lbs (136 N-M).

b) Further tighten the nut until the next set of slots line up with the cross hole

in the shaft.

32° F (0°C)

F (0°C).

- 27 -

c) Replace cotter pin.

Note: Do not use antiseize on the wheel hub.

5.1.24 Fuel Tank – mounting hardware specification.

When installing the nuts onto the fuel tank studs, fully tighten the nyloc nut and
back off 1/2 turn. This allows for normal fuel tank expansion and contraction with
changes in temperature and fuel levels.

5.1.25 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type”
are used on the following fasteners:

a) Pump drive sheave setscrews.

b) Square head setscrews on Hydro pump control arms.

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

d) Caster wheel spacer nuts.

e) Fuel tank bulk head fitting nuts.

Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock Retaining I
or Retaining II” are used on the following:

a) Fuel tank studs where studs are inserted into tank.

5.1.26 Mobil HTS grease (or food-grade antisieze) is used in the following locations:

a) Between the cutter housing spindle and bearings.

b) Between the cutter housing spindle and sheave.

c) Under top cutter housing bearing guard.

5.1.27 Dielectric grease is used on all blade type electrical connections to prevent
corrosion and loss of contact.

5.2 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,
and remove key before servicing, cleaning or making adjustments to the unit.

5.2.1 Cutting Height Adjustment.

a) Stop machine and move drive levers out to neutral lock position.

b) Disengage PTO.

c) Raise the deck lever to the transport position (also the 4.5” (11.4 cm)

cutting height position). See Figure 6.

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

complete stop and disengage the PTO.

LEVER IN 1.5” (3.8 cm)

LEVER IN TRANSPORT
AND 4.5” (11.4 cm)
CUTTING HEIGHT
POSITION

FIGURE 6

CUTTING HEIGHT POSITION

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

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

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

down onto height

adjustment pin to mow at selected height.

CUTTING HEIGHT POSITION

- 28 -

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

position.

g) Adjust anti-scalp rollers for Normal Operating Conditions. Stop engine, wait

for all moving parts to stop, and remove key. Place rollers in one of the
positions shown in Figure 7. Rollers will maintain 3/4 in. (19 mm) clearance
to the ground to minimize gouging and roller wear or damage.

For Maximum Deck Flotation, place rollers one hole position lower. Rollers
should maintain 1/4 in. (6.4 mm) minimum clearance to ground. Do Not
adjust rollers to support the deck. Be sure bolt is tightened properly or loss of
anti-scalp roller may result.

ANTI-SCALP ROLLER ADJUSTMENT

5.2.2 Deck Leveling:

a) Position mower on a flat surface.

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

c) Check tire pressure of all four (4) tires. If needed, adjust to 13 psi (90 kPa).

d) Set anti-scalp rollers to top holes or remove completely for this adjustment.

e) Raise the deck to the 4.5” (11.4 cm) height position and take as much force

as possible off of the two large deck lift springs by loosening the nuts at the
front of each spring. See Figure 8.

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

(3.3 cm) thick blocks under the rear edge of the cutting deck skirt; one on
each side of the cutting deck. Place a 1-1/8” (2.9 cm) block under the
center front edge, but not under the anti-scalp roller brackets.

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

deck. Loosen four (4) nuts which secure front swivels (two per side), until
front chains are loose and front of deck is supported by the 1-1/8” (2.9 cm)
block. Do not loosen front chain hardware.

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

will tend to rotate the deck lift handle up, out of the 1 1/2” (3.8 cm) position.
Press down on the rear deck support arm (as shown in Figure 7) to firmly
return the deck lift handle to the 1 1/2” (3.8 cm)
deck lift handle. While continuing to press down,
rear chains and tighten hardware at the bottom of
Downward pressure may now be released.

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

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

FIGURE 7

position. DO NOT push on

take the slack out of the

the rear chains.

- 29 -

10 1/2” (26.7 cm) For 44” Deck

10” (25.4 cm) For 48” Deck

FIGURE 8

SWIVEL ADJUSTMENT

SPRING COMPRESSION ADJUSTMENT

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

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

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

transport position, See Figure 6. Adjust spring compression until proper
distance is obtained between the two washers (See Figure 8) by turning the
nut at the front of each spring. Lock nuts in position with jam nuts.

l) Reposition anti-scalp rollers and tighten securely.

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

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

5.2.3 Pump Drive Belt Tension.

Self-tensioning - No adjustment necessary.

5.2.4 Deck Belt Tension.

Self-tensioning - No adjustment necessary.

5.2.5 Adjust Seat Switch.

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

shut off when the operator raises off the seat (with brake disengaged or
PTO engaged) but will continue to run with operator in seat (a slight shift in
weight should not shut machine off). Normal adjustment is when length of
spring is 2.09” (5.3 cm ) (with seat up).

NOTE: To prevent rough ground cut-outs the unit is equipped with a
time delayed seat switch. When the operator raises off the seat with
either the brake disengaged or the PTO engaged, the engine should
stop after 1/2 second has elapsed.

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

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

5.2.6 Park Brake Adjustment.

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

b) Disengage the park brake.

c) Remove the hairpin in park brake linkage at the rear of the unit. Turn the

linkage in the yoke until the distance from the lower front corner of the brake
bar measured vertically to the crown of the tire is 1”(2.5 cm) to 1 5/16”(3.3 cm)
with the park brake disengaged. Re-install the hairpin. See Figure 9.

- 30 -

FIGURE 9

PARK BRAKE ADJUSTMENT

5.2.7 Adjust Throttle Lever Tension.

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

b) Tension in throttle lever can be adjusted by adjusting the tightness of the

lever pivot bolt, which is located under the console. See Figure 10.

FIGURE 10

THROTTLE TENSION

5.2.8 Electric Clutch Adjustment:

No adjustment necessary.

5.2.9 Reverse Indicator Adjustment:

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

b) Tilt seat forward.

c) Begin with either the left or right motion control lever. Move lever to the

neutral position and pull lever back until the clevis pin (on arm below pivot
shaft) contacts the end of the slot (just beginning to put pressure on spring),
See Figure 11.

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

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

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

slight rearward pressure on the motion control lever, turn the head of the
adjustment bolt in the appropriate direction until lever is centered (keeping
rearward pressure on the lever will keep the pin at the end of the slot and
allow the adjustment bolt to move the lever to the appropriate position).
Tighten lock nut.

f) Repeat on opposite side of unit.

- 31 -

5.2.10 Motion control linkage adjustment.

(

)

WARNING

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

turning so motion control adjustment can be performed.
WHAT CAN HAPPEN
♦ Contact with moving parts or hot surfaces may cause

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

components and hot surfaces.

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or maintenance

relying solely on mechanical or hydraulic jacks could be

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

support or may malfunction allowing the unit to fall,

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

support. Use adequate jack stands or equivalent

support.

a) This adjustment must be made with the drive wheels turning. First raise the

frame and block up so that drive wheels can rotate freely.

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

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

Temporarily install a jumper wire across the terminals in the connector of
the wiring harness.

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

bring hydraulic system oil up to operating temperature.

d) Tilt seat forward.

e) Loosen lock nuts from the ball joints at each end of the RH pump control

linkage (See Figure 11).

NOTE: The nuts to the rear of the unit on each rod have left-hand threads.

LOOSEN

HERE

REVERSE

INDICATOR

YOKE

END OF

SLOT

TURN BOLT

HERE

LOOSEN HERE

LEFTHAND THREAD

TURN HERE

TO ADJUST

FIGURE 11

LOOSEN HERE

(RIGHTHAND THREAD)

RH MOTION CONTROL ADJUSTMENT

- 32 -

f) Start engine. Brake must be engaged and motion control levers out to

start engine. Operator does not have to be in the seat because of the
jumper wire being used. Run engine at full throttle and release brake.

g) The reverse indicator spring must be correct before the following

adjustments can be made. See Section 5.2.10.

h) Bring the RH motion control lever into the neutral position. Adjust RH pump

control rod length by rotating the double nuts on the rod in the appropriate
direction until the wheels slightly creep in reverse. (See Figure 11). Move
the motion control lever to the reverse position and while applying slight
pressure to the lever, allow the reverse indicator spring to bring the levers
back to neutral. The wheel must stop turning or slightly creep in reverse.

NOTE: The motion control lever needs to be in neutral while making
any necessary adjustments.

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

i) Bring the LH motion control lever into the neutral position. Adjust the LH

pump control rod length by rotating the tracking adjustment knob in the
appropriate direction until the wheels slightly creep in reverse. Move the
motion control lever to the reverse position and while applying slight
pressure to the lever allow the reverse indicator spring to bring the levers
back to neutral. The wheel must stop turning or slightly creep in reverse.
See Figure 12.

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

connector into seat switch.

6. WASTE DISPOSAL

6.1 MOTOR OIL DISPOSAL

Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at
a certified recycling center or according to your state and local regulations.

FIGURE 12

LH MOTION CONTROL ADJUSTMENT

- 33 -

6.2 MERCURY SWITCH DISPOSAL

CAUTION

POTENTIAL HAZARD
♦ The mercury contained in the tilt switch is poisonous.
WHAT CAN HAPPEN
♦ Exposure to mercury can cause severe illness.
HOW TO AVOID THE HAZARD

♦ Never attempt to open or repair the tilt switch
♦ Avoid contact with the mercury.

The tilt switch (PN 1-633782) on this unit contains mercury, a hazardous material. Mercury
that is outside a sealed container vaporizes at room temperature. The vapors are harmful.
Mercury can be absorbed through the skin. Do not attempt to open or repair this switch.

A very small amount of mercury is contained in a hermetically sealed body. The steel
switch is then potted in a hard epoxy in a plastic case. It is unlikely that the mercury will
ever escape from the enclosure. These high performance and reliable inexpensive
switches are recyclable. Mercury is an important and beneficial compound but requires
special care in handling and disposal. When used and managed properly, mercury is not
a threat to people or the environment. This information is presented to users so that they
are aware that these switches contain mercury and will apply sound disposal practices
when these devices reach their normal end of life or are damaged.

Several states have passed laws concerning the disposal of devices containing mercury.
In all the remaining states it is advisable to follow similar procedures. The laws state that
these sealed devices contain mercury and should not be placed in the garbage until the
mercury is removed and reused, recycled or otherwise managed to insure that it does not
become part of solid waste or waters. Management and disposal practices must be within
relevant federal, state or local laws.

Return the switch to your Exmark dealer if it is faulty and is being replaced or if the unit
containing the switch is no longer operating and is being scrapped. If the switch is
damaged or broken open use extreme caution in handling. Call you local waste
management authority or Exmark Customer Service for instructions.

6.3 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric acid, which is

poisonous and can cause severe burns

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

can cause severe burns.

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

to protect skin and clothing when handling electrolyte.

♦ Do not swallow electrolyte.

Federal law states that batteries should not be placed in the garbage. Management and
disposal practices must be within relevant federal, state or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating and
is being scrapped, take the battery to a local certified recycling center. If no local recycling
is available, return the battery to any certified battery reseller.

- 34 -

7. TROUBLE SHOOTING

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

a) Refer to Tracking Adjustment Section 4.1.3.

b) Check air pressure in tires; 13 psi/drive, 16 psi/pneumatic castors.

c) Check reverse indicator and motion control linkage adjustment. See

Section 5.2.10 and 5.2.11.

7.2 MOWER CUTS UNEVENLY.

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

uniform cutting height may be obtained with higher tire pressure on rough
terrain. A lower tire pressure provides more flotation. Higher pressures in
front casters may cause them to shimmy on hard surfaces.

b) Check deck support chains.

c) Check deck leveling

Note: The front of the mower deck will be approximately 1/4” (6.4 mm)
lower than the back of the mower deck. This is the “rake” of the deck.

d) Check blades tip to tip for straightness (they should be within 3/16" (4.8

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

7.3 ENGINE WILL NOT START.

a) Make sure battery is at a full charge.

b) Be sure the throttle control is midway between the “SLOW” and “FAST”

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

c) Make sure there is fuel in the fuel tank and that the fuel valve is open.

d) Be sure the seat switch is properly adjusted. See Section 5.2.5.

e) Make sure the parking brake is set and motion control levers are moved out

(neutral lock position).

f) Check that the PTO is disengaged.

h) Check that the spark plug wires are properly connected.

i) Check for loose or faulty wiring connections.

j) Check for corrosion at all wiring connections. Even minor corrosion may

cause a faulty connection. Clean connector terminals thoroughly with
electrical contact cleaner, apply dielectric grease and reconnect.

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

NOTE: After carefully checking the above steps, attempt to start the engine. If
it does not start, contact your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be
connected and in proper operating condition prior to mower use.

When a problem occurs, do not overlook the simple causes. For example,
starting problems could be caused by an empty fuel tank.

The following table lists some of the common causes of trouble. Do not attempt
to service or replace major items or any items that call for special timing of
adjustments procedures (such as valves, governor, etc.). Have this work done
by your Engine Service Dealer.

(See Adjustments Section 5.2.2.)

- 35 -

PROBLEM

Will not start

Hard starting

Stops suddenly

Lacks power

Operates

erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel

consumption

ENGINE TROUBLESHOOTING TABLE

NO

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X XXXX

XXX XXXX

XXX XXXX

XX XXXXXX

XX XXXX X

XXX

XX XX X

XXXX X

XXXXX

XX X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

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8. ELECTRICAL DIAGRAM

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9. HYDRAULIC DIAGRAM

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10. WARRANTY

Limited Warranty

Exmark Commercial Turf Equipment

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 material or workmanship.

This warranty is limited to one year from the date of original retail purchase (90 days for rental use)
for any Exmark mower that is used for commercial or any other income producing purpose. The
blade spindle assemblies will be warranted for three years, one year parts and labor with an
additional two years parts only, from date of original retail purchase against defects in materials or
workmanship. The frame and hydrostatic traction drive system, excluding hoses, will be warranted
for two full years from date of original retail purchase against defects in materials or workmanship.
We will extend the Peerless 5-speed transmission manufacturer's warranty from 90 days to one
year. Belts and tires are warranted for 90 days against defects in materials or workmanship.

The engine warranty is covered by its respective engine manufacturer. Please refer to the engine
manufacturers warranty statement that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines. Engine warranties should be referred to the nearest
authorized service outlet of the engine manufacturer.

This warranty extends only to the original retail purchaser of the equipment. This warranty may
not be assigned or transferred without the prior express written consent of Exmark and Exmark
Warranty Company. The warranty period commences upon the date of the original retail purchase.

The Exmark turf equipment, including any defective part, must be returned to an authorized
Exmark service dealer within the warranty period. The warranty shall extend to the expense of
repair or replacement (as determined by us) of the defective part, including labor. The warranty
shall not extend to the expense of delivering the mower to the dealer for warranty work nor the
expense of returning it back to the owner after repair or replacement. Our responsibility in respect
to claims is limited to making the required repairs or replacements, and no claim of breach of
warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark
mower. Proof of purchase may be required by the dealer to substantiate any warranty claim. All
warranty work must be performed by an authorized Exmark service dealer.

This warranty extends only to turf equipment operated under normal conditions and properly
serviced and maintained. The warranty expressly does not cover: (i) any damage or deterioration
due to normal use, wear and tear, or exposure; (ii) normal maintenance services, such as oil
change, cleaning, lubrication; adjustment; (iii) replacement of service items, such as oil, lubricants,
spark plugs, or other items subject to normal service replacement; (iv) damage or defects arising
out of or relating to misuse, neglect, alteration, negligence or accident; (v) repair or replacement
arising from operation of or use of the turf equipment which is not in accordance with operating
instructions as specified in the operator's manual or other operational instructions provided by
Exmark; (vi) repair or replacement arising as a result of any operation from turf equipment that has
been altered or modified so as to, in the determination of Exmark or Exmark Warranty Company,
adversely affect the operation, performance or durability of the equipment or that has altered,
modified or affected the turf equipment so as to change the intended use of the product; (vii) repair
or replacement necessitated by 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; (viii) repairs or replacements resulting
from parts or accessories which have adversely affected the operation, performance or durability of
the turf equipment; or (ix) damage or defects due to or arising out of repair of turf equipment by
person or persons other than an authorized Exmark service dealer or the installation of parts other
than genuine Exmark or Exmark recommended parts.

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

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be
repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty Company shall
have any liability for any other cost, loss or damage, including but not limited to, any incidental or
consequential loss or damage. In particular, we shall have no liability or responsibility for: (i)
expenses relating to gasoline, oil or lubricants; (ii) loss, cost or expense relating to transportation
or delivery of turf equipment from the location of owner or location where used by owner to or
from any authorized Exmark service dealer; (iii) 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; (iv) rental of like
or similar replacement equipment during the period of any warranty, repair or replacement work;
(v) any telephone or telegram charges or travel charges; (vi) loss or damage to person or
property other than that covered by the terms of this warranty; (vii) any claims for lost revenue,
lost profit or additional cost as a result of a claim of breach of warranty; or (viii) attorney's fees.

There are no representations or warranties which have been authorized and provided to the buyer
of the turf equipment, other than as set forth in this warranty. Any and all statements or
representations made by any seller of this equipment, including those set forth in any sales
literature or made orally by any sales representative, are superseded by the terms of this
warranty. Any affirmation of fact or promise made by Exmark , Exmark Warranty Company or any
of their representatives to the buyer which relates to the goods that are the subject of this
warranty shall not be regarded as part of the basis of the bargain and shall not be deemed to
create any express warranty that such goods shall conform to the affirmation or promise.

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR
WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING
THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED
HEREIN, RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.

This warranty applies to all Exmark turf equipment sold in the United States and Canada and
intended to be used for commercial purposes.

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SERVICE RECORD

Date Description of Work Done Service Done By

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SEE EXMARK’S COMPLETE

M

LINE OF PRODUCTS FOR TURF CARE

LAZER Z

LAZER Z

TURF RANGER

TURF TRACER

METRO

ULTRA VAC

®

®

XP LAZER Z® CT

®

®

®

™

LAZER Z® HP

VIKING HYDRO

TURF TRACER® HP

METRO® HP

ULTRA VAC™ QDS

GRASS CATCHER MICRO-MULCH

™

ACCESSORY

SELF STEERING SULKY

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

©1997-2002 PART NO. 103-4113
EXMARK MFG. CO. INC. [phone]
INDUSTRIAL PARK BOX 808 FAX [phone]
BEATRICE, NE 68310
ALL RIGHTS RESERVED PRINTED IN U.S.A.

FG. CO.

®