Exmark LAZER Z HP 523 Operator's Manual

LAZERZ®HP523

ForSerialNos.720,000&Higher

PartNo.4500-257Rev .A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.

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

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

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

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

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

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

2

Contactusatwww.Exmark.com.

PrintedintheUSA.

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

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

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

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

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready .

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

3

Contents

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

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

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

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

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

Specications.......................................................14

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

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

Dimensions...................................................15

TorqueRequirements....................................16

ProductOverview................................................17

Operation.............................................................17

Controls........................................................17

Pre-Start........................................................18

OperatingInstructions..................................19

Transporting.................................................22

Maintenance.........................................................24

RecommendedMaintenanceSchedule(s)...........24

PeriodicMaintenance.......................................25

CheckEngineOilLevel.................................25

CheckBatteryCharge....................................25

CheckMowerBlades.....................................26

CheckSafetyInterlockSystem.......................26

CheckRolloverProtectionSystem(Roll

Bar)Pins...................................................27

CheckSeatBelt..............................................27

CheckforLooseHardware............................27

ServiceAirCleaner........................................27

ChangeEngineOil........................................27

CheckHydraulicOilLevel.............................28

CheckTirePressures.....................................28

CheckConditionOfBelts..............................28

LubricateGreaseFittings...............................28

LubricateCasterWheelHubs........................29

LubricateBrakeHandlePivot........................30

LubricateBrakeRodBushings.......................30

LubricateMotionControlBronze

Bushings...................................................30

LubricateSeatSwitchActuator......................30

CheckSparkPlugs.........................................30

ChangeHydraulicSystemFilter.....................30

WheelHub-SlottedNutTorque

Specication..............................................31

ThreadLockingAdhesives.............................31

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................31

Copper-BasedAnti-seize..............................31

DielectricGrease...........................................31

Adjustments.....................................................32

DeckLeveling...............................................32

PumpDriveBeltTension...............................32

DeckBeltTension........................................32

BrakeLinkAdjustment..................................32

BrakeAdjustment..........................................33

ElectricClutchAdjustment............................33

ReverseIndicatorAdjustment........................33

MotionControlLinkageAdjustment.............34

AdjustSeatSwitch........................................35

CasterPivotBearingsPre-Load

Adjustment...............................................35

Cleaning...........................................................36

CleanEngineCoolingSystem........................36

RemoveEngineShroudsandCleanCooling

Fins...........................................................36

CleanGrassBuild-UpUnderDeck................36

WasteDisposal..............................................36

Troubleshooting...................................................37

Schematics...........................................................39

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

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

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

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

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

5

Safety

DANGER

Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

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

•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

DANGER

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

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

6

Safety

Operation

WARNING

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

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts.

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

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

7

Safety

DANGER

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

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

Figure3

1.SafeZone-Usethe
mowerhereonslopes
lessthan15degrees

3.Water

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

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

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

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatlossoftractionmayoccurgoing
downhill.W eighttransfertothefrontwheels
maycausedrivewheelstoslipandcauselossof
brakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem
(ROPS)

ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.

WARNING

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

•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely
necessary.

•DoNotwearseatbeltwhentherollbar
isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance
permits.

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

8

Safety

MaintenanceandStorage

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

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

•Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.

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

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

9

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-303508

1-403005

1-513742

1–513746

1-513748

1-523552

10

Safety

1–633922

1–653147

98-5954

103–2644

103–4892

103–4930

11

Safety

103–6340

103–9287

107-2102

107-2112

12

Safety

109–1196

109-3148

109–7949

103–4891

108–5995

1.Fast

2.Slow

3.Neutral4.Reverse

13

Specications

Specications

ModelNumbers

SerialNos:720,000andHigher

LHP23KC523;LHP27KC523

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’ s
Manual

•RPM:FullSpeed:3600±50RPM(NoLoad)
Idle:1500RPM

FuelSystem

•Capacity:11.2gal.(42.0L)

•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.

•FuelFilter:In-line15Micron
KohlerP/N2405010.

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

•Fuelgaugeinlefthandfueltank.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12V olt

•Polarity:NegativeGround

•Fuses:Two20ampbladetype

SafetyInterlockSystem

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

•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,ormotioncontrolleversare
movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or
bothleversaremovedfromneutrallockposition
whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto
twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe
respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch
(todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting
heighttodesiredposition.

•DeckLiftAssistLever:Footpedalthatassists
inraisingthedeck.

Seat

•Type:Standardseatwithhighback,foampadded
(internalsuspension)andarmrests.

Optionalseataccessories:

–Customridesuspensionsystemtoenhance

StandardSeat.

–Deluxesuspensionseatwithhighback,low

prolefoam-in-placecushion(dampened,
adjustablespringsuspension)andarmrests.

•Mounting:Hingedtotiltupforaccessto
hydraulicpumps,batteryandothercomponents.
Heldintiltedpositionwithproprod.Adjustable
foreandaftseattrack.

•Armrests:

–Standardseat:foampaddedip-uparmrests.

14

Specications

–Optionalsuspensionseat:moldedadjustable

ip-uparmrests.

•SeatSafetySwitch:Incorporatedintothe
SafetyInterlockSystem.Timedelayseatswitch
eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearvariable
displacementpistonpumps.

•WheelMotors:TwoParkerwith11/4inch
taperedshafts.

•HydraulicOilType:UseMobil115W-50
Syntheticmotoroil.

•HydraulicOilCapacity:2.1qt.(2.0L)

•HydraulicFilter:Replaceablecartridgetype.

–Summeruseabove32°F(0°C)

P/N109-4180:25microns,10psibypass

–Winterusebelow32°F(0°C)

P/N1-523541:40microns,18psibypass

•Speeds:

–0-9.5mph(15.3km/hr)forward.

–0-5.5mph(8.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

Pneumatic
(Air-Filled)

Pneumatic
(Air-Filled)

Quantity

22

Tread

TurfMasterSmooth

Size23x9.50-1213x5.00-6

PlyRating

44

Pressure

13psi(90kPa)13psi(90kPa)

CuttingDeck

•CuttingWidth52inchDeck:52inches(132.1cm)

•Discharge:Side

•BladeSize:(3ea.)18.00inches(45.7cm)

•BladeSpindles:Solidsteelspindleswith1inch
(25.4mm)I.D.bearings.

•DeckDrive:

–Electricclutchmountedonverticalengine

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

–Bladesaredrivenbyone“B”Sectionbelt

(w/self-tensioningidler)directfromthe
engine.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport
frame.Maximumturfprotectionisprovidedwith
anti-scalprollers:

52inchDecks:Quantity5

Deckdesignallowsforbagging,mulchingorside
discharge.

•DeckDepth:

52inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:

Anextra-longcushionedleverisusedtoadjust
thecuttingheightfrom11/2inch(3.8cm)to
41/2inches(11.4cm)in1/4inch(6.4mm)
increments.Thecuttingheightadjustmenthandle
hasatransportpositionandalladjustmentscan
bemadewhiletheoperatorremainsseated.Units
alsohaveafootoperateddeckliftassistleverto
aidinraisingthedeck.

•MulchingKit:Optional.

Dimensions

OverallWidth:

52inchDeck

WithoutDeck47.9inches(121.7cm)

DeectorUp54.7inches(138.9cm)

DeectorDown63.2inches(160.5cm)

OverallLength:

52inchDeck

RollBar-Up77.3inches(196.3cm)

RollBar-Down83.4inches(211.8cm)

15

Specications

OverallHeight:

RollBar-UpRollBar-Down

69.4inches(176.3cm)51.3inches(130.3cm)

TreadWidth:(CentertoCenterof
Tires,Widthwise)

52inchDeck

DriveWheels38.4inches(97.5cm)

CasterWheels34.6inches(87.9cm)

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

47.2inches(119.9cm)

CurbWeight:

1103lb(500kg)

TorqueRequirements

BoltLocation

Torque

CutterHousingSpindle
Nut

140-145ft-lb
(190–197N-m)

BladeMountingBolt
(lubricatewithanti-seize)

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

EngineDeck/FrontFrame
MountBolts

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

Anti-ScalpRollerNyloc
NutSeeFigure10

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

Anti-ScalpRollerHex
CapscrewSeeFigure10

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

EngineMountingBolts

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

WheelLugNuts

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

WheelMotorMounting
Bolts

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

WheelHubSlottedNutminimum125ft-lb

(169N-m)

RolloverProtectionSystem
(RollBar)MountingBolts

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

ClutchRetainingBolt
(securedwiththreadlocker)

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

16

Operation

ProductOverview

Figure4

1.MotionControlLever5.Controls

2.ParkingBrakeLever

6.SeatBelt

3.Height-of-CutLever

7.RollBar

4.FuelCap(BothSides)

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideofthe
consolecontroltheforwardandreversemotionof
themachine.Theleverscontroltheowofhydraulic
oilfromthehydrostaticpumptothedrivewheel
motorforeachside.

Movingtheleversforwardorbackwardturnsthe
wheelonthesamesideforwardorinreverse.Wheel
speedisproportionaltotheamounttheleveris
moved.

Movingtheleversoutwardfromthecenterposition
intotheT-slotlocksthemintheneutralposition
(Figure6).

ChokeControl

Locatedonrightfueltank.

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

ThrottleControl

Locatedonrightfueltank.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.

BrakeLever

Locatedonleftsideoftheconsole.

Thebrakeleverengagesaparkingbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

17

Operation

Theunitmustbetieddownandbrakeengagedwhen
transporting.

IgnitionSwitch

Locatedonrightfueltank.

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

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

HourMeter

Locatedontherightfueltank.

Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifthe
ignitionswitchisleftonwithoutenginerunning,
hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow.

FuelShut-OffValve

Thevalveislocatedinthefuellinebesidetheengine,
nearthefuellter.

Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.

Rotatethevalve1/4turnclockwisetoshutofffuel.
Rotatethevalve1/4turncounterclockwisetoturn
onfuel.

FuelGauge

Locatedontheleftfueltank.

Thefuelgaugemonitorstheamountoffuelinboth
tanks.Fuelisusedevenlyfrombothtanks.

DriveWheelReleaseValves

Locatedontherightfrontcornerofhydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
pushedwithouttheenginerunning.Unhookseat
latchandtiltseatuptogainaccesstopumps.

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

Nottowmachine.

TrackingAdjustmentKnob

LocatedundertheseatontheLHpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso
thatthemachinetracksstraightwiththedrivelevers
inthefullforwardposition.

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

Important:DoNotrotatetheknobtoofar,as
thismaycausethemachinetocreepinneutral.
RefertotheMotionControlLinkageAdjustment
sectioninMaintenance.

PTOEngagementSwitch

Locatedontherightfueltank.

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

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch

18

Operation

(13mm)belowthebottomofthellernecktoallow
forfuelexpansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem
(ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe
tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand
installthetwopinsandsecurethemwiththe
hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe
rollbarintheraisedposition.Ensurethatthe
rearpartoftheseatissecuredwiththeseat
latch.

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

Thefuelshutoffvalveislocatedinthefuelline
besidetheengine,nearthefuellter.Rotatethevalve
1/4turncounterclockwisetoturnonfuel.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral
lockposition.

2.Pullupandbackontheparkingbrakeleverto
engagetheparkingbrake.

3.PushinonthePTOswitchtothe“STOP”
position.

Note:Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.

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

5.Onacoldengine,pushthechokeleverforward
intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF”
position.

6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.

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

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

19

Operation

DANGER

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

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades.
Besurethatallpersonsareclearofthemowerdeck
anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe
PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”
position.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position
todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral
lockposition.

4.Engagetheparkingbrake.

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

6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

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

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning
onelevertoomuchaheadoftheother.
Operatormaylosecontrolofthemachine,
whichmaycausedamagetothemachine
orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

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

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

Figure6

1.HandlesOut(Neutral
Lock)

5.Neutral

2.HandlesIn(Neutral)

6.Reverse

3.FrontofUnit

7.NeutralLock

4.Forward

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

20

Operation

3.Tomoveforwardinastraightlineapplyequal
forwardpressuretobothlevers.

Toturnleftorright,pullthemotioncontrollever
backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe
motioncontrolleversaremovedawayfrom
neutral.

4.Tostop,pullthemotioncontrolleversbackto
theneutralposition.

Figure7

1.HandlesOut(Neutral
Lock)

4.Forward

2.HandlesIn(Neutral)

5.Reverse

3.FrontofUnit

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

2.Tomoverearwardinastraightlineapplyingequal
pressurepullbothmotioncontrolleversrearward.

Toturnleftorright,releasepressureonthe
motioncontrollevertowardthedirectiondesired.

3.Tostop,pushthemotioncontrolleverstothe
neutralposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted
from11/2inchto41/2inches(3.8cmto11.4cm)
in1/4inch(6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Raisethedeckheightlevertothetransport
position(alsothe41/2inch(11.4cm)cutting
heightposition)(Figure8).

Thedeckcanberaisedbypullingthedecklever
upand/orbypushingdownonthefootoperated
deckliftassistleverlocatedatthefrontright
corneroftheoorpan.

Note:Whenchangingthecuttingheight
positions,alwayscometoacompletestop
anddisengagethePTO.

Figure8

1.Leverintransportand41/2inch(11.4cm)cutting
heightposition

4.Inserttheheightadjustmentpinintothehole
correspondingtothedesiredcuttingheightand
installthehairpincotterpin.

Seethedecalonthesideofthedeckliftplatefor
cutheights.

5.Movethedeckheightleveroutofthetransport
position(or41/2inch(11.4cm)cuttingheight)
anddownontotheheightadjustmentpintomow
atselectedheight.

Note:Thefootoperateddeckliftassistlever
canbeusedtomomentarilyliftthedecktoclear
objects.BesurethatPTOisdisengaged.

21

Operation

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe
anti-scalprollersbyremovingtheboltandspring
discwasher.

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

Figure9

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller
mountingbracket

2.Cuttingheight

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

7.Besuretherollerboltsareinstalledwiththe
springdiscwasherbetweentheheadofthebolt
andthemountingbracket.

Note:Thefootoperateddeckliftassistlever
canbeusedtomomentarilyliftthedecktoclear
objects.BesurethatPTOisdisengaged.

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

9.Ifthe3/8nylocnuthasbeenremoved,
reinstallandtorqueto30–35ft-lb(41–47
N-m).(Figure10).

Figure10

1.Springdiscwasher
(conetowardsbolthead)

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

2.Frontrightanti-scalp
bracketshown

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

Transporting

TransportingaUnit

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

CAUTION

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

DoNotdriveaunitonapublicstreetor
roadway.

22

Operation

WARNING

Loadingaunitonatrailerortruckincreases
thepossibilityofbackwardtip-over.
Backwardtip-overcouldcauseseriousinjury
ordeath.

•Useextremecautionwhenoperatinga
unitonaramp.

•Useonlyasingle,fullwidthramp;Do
Notuseindividualrampsforeachside
oftheunit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbroken
rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp
andgroundorbetweenrampandtrailer
ortruck.

•Avoidsuddenaccelerationwhiledriving
unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking
unitdownaramptoavoidtipping
backward.

LoadingaUnit

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

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

Important:DoNotattempttoturntheunit
whileontheramp,youmaylosecontroland
driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp
andsuddendecelerationwhenbackingdownaramp.
Bothmaneuverscancausetheunittotipbackward.

23

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

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

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionsystem(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheenginecoolingsystem.

•Cleanthegrassbuild-upfromunderthedeck.

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheheightadjustmentshaftbearings.

•Greasedeckrearstruts.

Every50hours

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

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Removetheengineshroudsandcleanthecoolingns.

Every160hours

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

•Lubricatetheseatswitchactuator.

•Checkthesparkplugs.

Every200hours

•Greasebrakebrackets.

24

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Every500hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

Monthly

•Checkthebatterycharge.

Yearly

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

•Greasethepumpdrivebeltidlerarm.

•Lubricatethecasterwheelhubs.

•Changethehydrauliclter.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstickand
wipeoiloff.Reinsertthedipstick.Donotscrew
intoplace.Removethedipstickandreadtheoil
level.

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

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

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

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

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended
timeintervaltobringthechargeuptoafullcharge
of12.6voltsorgreater.

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

Voltage
Reading

Percent
Charge

Maximum
Charger
Settings

Charging
Interval

12.6or
greater

100%

16volts/7
amps

No
Charging
Required

12.4–12.675–100%

16volts/7
amps

30Minutes

12.2–12.450–75%

16volts/7
amps

1Hour

12.0–12.225–50%

14.4volts/4
amps

2Hours

25

Maintenance

Voltage
Reading

Percent
Charge

Maximum
Charger
Settings

Charging
Interval

11.7–12.00–25%

14.4volts/4
amps

3Hours

11.7orless

0%

14.4volts/2
amps

6Hoursor
More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin
theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure11

1.Installbushinginbladepriortoinstallingbushingin
spindle.

B.Installbushing/bladeassemblyintospindle.

Figure12

1.Usewrenchherefor
bladeinstallation.This
nuthasbeentorquedto
140–145ft-lb(190–197
N-m)

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

C.Applylubricanttothreadsofbladeboltas

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

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

26

Maintenance

1.Checkstartingcircuit.Startershouldcrankwith,
parkingbrakeengaged,PTOdisengagedand
motioncontrolleversmovedoutintheneutral
lockposition.Theoperatordoesnotneedtobe
intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake
disengaged,PTOdisengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

Trytostartwithoperatorinseat,parkingbrake
engaged,PTOengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

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

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

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

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

Again,runengineatone-thirdthrottle,brake
engaged,andmoveleftmotioncontrolleverin

-enginemustinitiateshutdown.

Repeatagainmovingtherightleverin,then
movingbothleversin-enginemustinitiate
shutdownwhetheroperatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

CheckRolloverProtection
System(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

Makesurelatchpinandhairpinarefullyinstalled
andlanyardisingoodcondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper
operationofretractorandbuckle.Replacebefore
operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

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

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.SeeEngineOwner’sManualforcleaning
instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseislocatedonlefthandsideof
engine.Placepanundermachinetocatchoil.

27

Maintenance

Removeplugfromendofdrainhose.Allowoil
todrainandreplaceoildrainplug.Torqueplug
to20-24ft-lb.

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

5.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.

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

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

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

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

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Checktirepressureincastertires.

5.Inatedrivetiresto13psi(90kPa).

6.Semi-pneumaticcastertiresdonotneedtobe
inated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checkunderenginedecktocheckpumpdrive
belt.

3.Removeleftandrightbeltshieldsondeckandlift
upoorpantoinspectdeckdrivebelt.

4.Forbeltadjustment,seethePumpDriveBelt
andDeckBeltT ensionAdjustmentsections.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Front
Casterwheel
hubs

*0

2

*Yearly

2.Front
Caster
Pivots

*0

2

*Yearly

3.Height
Adjustment
Shaft
Bearings

1

540Hours

4.Deck
DriveBelt
IdlerArm

11

Yearly

28

Maintenance

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

5.Brake
Brackets

12

200Hours

6.Pump
DriveBelt
IdlerArm

11

Yearly

7.Deck
RearStruts

12

40Hours

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.

Number6(PumpDriveBeltIdlerArm)Located

UnderEngineFrame-Greasethroughholeintop

ofengineframe,betweenpumps.

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

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Figure13

1.Sealguard2.Spacernutwithwrench
ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

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

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

9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

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

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

29

Maintenance

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

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully.

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

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandlepivot
withaspraytypelubricantorlightoil.

LubricateBrakeRod
Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake
rodshaftwithaspraytypelubricantoralightoil
(bushingsarelocatedtotheinsideoftheange
bearings).

LubricateMotionControl
BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings
securingthemotioncontrolarmshaftswitha
lightoiloraspraytypelubricant.

LubricateSeatSwitch
Actuator

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricateswitchactuatorrodwithspraytype
lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltanksandthe
engine.Replacewhennecessary.

ReplacementFilters

Kohler

KohlerP/N2405010

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

Yearlythereafter

Note:Summeruseabove32°F(0°C)useonly

ExmarkPartNo.109–4180.
Winterusebelow32°F(0°C)useonlyExmarkPart

No.1-523541.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Locatelterunderleftrearcornerofenginedeck.

3.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

4.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

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

30

Maintenance

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

5.FillreservoirasstatedinCheckHydraulicOil
Levelsection.

6.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely .

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

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

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

WheelHub-SlottedNut
TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor
taperedshaft:

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

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

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

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

5.Thentightennutuntilthenextsetofslotslineup
withthecrossholeinshaft.

6.Replacecotterpin.

Note:DoNotuseanti-seizeonwheelhub.

FuelTank—Mounting
HardwareSpecications

ServiceInterval:Asrequired

Wheninstallingthenutsonthefueltankstuds,fully
tightenthenylocnutandbackoff1/2turn.This

allowsfornormalfueltankexpansionandcontraction
withchangesintemperatureandfuellevels.

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol
arms.

•Sheaveretainingboltintheendofengine
crankshaft.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

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

Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or
Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
location:

OnthreadsofBladeBolts.SeeCheckMower
Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

31

Maintenance

Adjustments

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

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

3.Checktirepressureindrivetires.Properination
pressurefortiresis13psi(90kPa).Checktire
pressureincastertires.Properinationpressure
fortiresis13psi(90kPa).Adjustifnecessary.
Semi-pneumaticcastertiresdonotneedtobe
inated.

4.Setanti-scalprollerstotopholesorremovethem
completelyforthisadjustment.

5.Raisethedecktothe41/2inch(11.4cm)height
positionandtakeasmuchforceaspossibleoffof
thetwolargedeckliftspringsbylooseningthe
nutsatthefrontofeachspring.(Figure14).

6.Lowerthedecktothe11/2inch(3.8cm)
heightposition.Placetwo15/16inch(3.3cm)
thickblocksundertherearedgeofthecutting
deckskirt;oneoneachsideofthecuttingdeck
(Figure14).

7.Placea11/8inch(2.9cm)blockunderthecenter
frontedge,butnotundertheanti-scalproller
brackets

8.Loosenthetwotopchainboltsinslotsinthe
reardeckliftarms.Loosenjamnutsandbackoff
thesocketheadadjustingscrewsonthebottom
ofthearmsuntilthechainsarejustloosewhen
pressureisappliedtoforcereardecksupport
armsdown.Continuetopressdownonreardeck
supportarmsandturnthesocketheadadjusting
screwsinuntilslackistakenoutofeachchain.
Tightenthejamnuts.Tightenthechainboltsin
thedeckliftarmsmakingsuretheydonotmove
whiletightening.

9.Loosenfournutswhichsecurefrontswivels(two
perside),untilfrontchainsarelooseandfront
ofdeckissupportedbythe11/8inch(2.9cm)
block.Donotloosenfrontchainhardware.

10.Onleftside,adjustfrontswivelusingthelocking
nutbehindtheswiveluntilthefrontchainistight

andallslackisremovedfromlinkage.Donot
liftfrontofdeckoff11/8inch(2.9cm)block.
Securefrontswivelusinglockingnutinfrontof
swivel.Repeatforrightside.

Figure14

1.Swivel

2.Adjustfrontdeckheighthere

3.Adjustspringtensionhere

4.91/2inches(24.1cm)for52inchdeck

5.Applydownwardpressurehere

6.Jamnut

7.Socketheadadjustingscrew

8.Slottedhole

9.Frontoftheunit

11.Recheckthatblockstjustsnuglyunderthe
deckskirtandthatthetensiononallthechains
areapproximatelyequal.Makesureallchain
attachmentboltsaretight.

12.Raisedeckliftlevertothe41/2inch(11.4cm)
cuttingheightposition(alsotransportposition
(Figure8).Adjustspringcompressionuntil
properdistanceisobtainedbetweenthetwo
washersbyturningthenutatthefrontofeach
spring(Figure14).Locknutsinpositionwithjam
nuts.

13.Repositionanti-scalprollersandtightensecurely.

Note:Whenaboveadjustmentshavebeenmade,
thefrontofthedeckwillbeslightlylowerthanthe
rearofthedeck.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

BrakeLinkAdjustment

Checktomakesurebrakeisadjustedproperly .

32

Maintenance

1.Disengagebrakelever(leverdown).

2.Measurethelengthofthespring.Measurement
shouldbe23/4inches(7.0cm)betweenwashers.
(Figure15).

3.Ifadjustmentisnecessary,tightenthenutdirectly
belowtheyokeandloosenthebottomnut
(bottomoneofthetwotightenedtogether)below
thespring.Turnthenutdirectlybelowthewasher
(topnutofthetwotightenedtogether)untilthe
correctmeasurementisobtained.Tightenthetwo
nutstogetherandrepeatonoppositesideofunit.
Turnclockwisetoshortenspringlengthandturn
counterclockwisetolengthenthespring.

Figure15

1.Leverdown
(disengaged)

6.Yoke

2.Leverup(engaged)

7.Locknut

3.1/4to5/16inch(6.4to

7.9mm)

8.Springadjustment

4.Collar9.2.75inches(7.0cm)

5.Trunnionroller

BrakeAdjustment

1.Checkforbrakelink23/4inches(7.0cm)
measurementasdescribedintheBrakeLink
Adjustmentsection.

2.Engagethebrakelever(leverup).Thespace
betweenthetrunnionrollerandtherodcollar
shouldmeasure1/4inchto5/16inch(6.4–7.9
mm).

3.Ifadjustmentisnecessary,loosennutabovethe
trunnionroller.Adjustthenylocnutunderthe
trunnionrolleruntildistancelistedaboveexists
betweenthespringretainerbracketandthe

adjacentnylocnut.Tightenthejamnutabove
thetrunnionroller.

4.Ifadjustmentisnecessary,loosenthenut
directlybelowtheyoke.Turnthebottomnut
(belowwasher)untilthecorrectmeasurement
isobtainedseeFigure15turnnutclockwiseto
lengthenthegap(screwsrodintoyoke)andturn
counterclockwisetoshortenthegap(screws
rodoutofyoke).Tightennutagainstyokeand
checkoppositesideofunit,repeatifnecessary.
Lengthen(orshorten)thebrakeroduntilthe
correctgapcanbeachievedbyfollowingsteps
2and3.

ElectricClutchAdjustment

Noadjustmentnecessary.

ReverseIndicator
Adjustment

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatforward.

3.Beginwitheithertheleftorrightmotioncontrol
lever.Movelevertotheneutralpositionandpull
leverbackuntiltheclevispin(onarmbelowpivot
shaft)contactstheendoftheslot(justbeginning
toputpressureonspring).(Figure16).

4.Checkwhereleverisrelativetonotchinconsole
(shouldbecenteredallowinglevertopivot
outwardtotheneutrallockposition).

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

6.Repeatonoppositesideofunit.

33

Maintenance

MotionControlLinkage
Adjustment

WARNING

Enginemustberunninganddrive
wheelsmustbeturningsomotioncontrol
adjustmentcanbeperformed.Contactwith
movingpartsorhotsurfacesmaycause
personalinjury

Keepngers,hands,andclothingclearof
rotatingcomponentsandhotsurfaces.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport

1.Thisadjustmentmustbemadewiththedrive
wheelsturning.Firstraisetheframeandblockup
sothatdrivewheelscanrotatefreely .

2.Removetheelectricalconnectionfromtheseat
safetyswitch,locateddirectlytotheleftoftheseat
switchassemblybesidethehydraulicoilreservoir.

3.Temporarilyinstallajumperwireacrossthe
terminalsintheconnectorofthemainwiring
harness.

4.Runtheunitatleast5minuteswiththedrive
leversatfullforwardspeedtobringhydraulic
systemoiluptooperatingtemperature.

5.Unhookseatlatchandtiltseatforward.

6.Loosenlocknutsfromtheballjointsateachend
oftheRHpumpcontrollinkage(Figure16).

Note:Thenutstotherearoftheunitoneach
rodhaveleft-handthreads.

Figure16

1.Turnbolthere

5.Endofslot

2.Reverseindicator

6.Loosenhere(right-hand
thread)

3.Loosenhere7.Turnheretoadjust

4.Yoke

8.Loosenhere(left-hand
thread)

7.Startengine.Brakemustbeengagedand
motioncontrolleversouttostartengine.
Operatordoesnothavetobeintheseat
becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

8.Thereverseindicatorspringmustbecorrect
beforethefollowingadjustmentscanbemade.
SeetheReverseIndicatorAdjustmentsection.

Note:Themotioncontrolleverneedstobein
neutralwhilemakinganynecessaryadjustments.

9.Bringthemotioncontrolleverintotheneutral
position.AdjustRHpumpcontrolrodlength
byrotatingthedoublenutsontherodinthe
appropriatedirectionuntilthewheelsslightly
creepinreverse(Figure16).Movethemotion
controllevertothereversepositionandwhile
applyingslightpressuretothelever,allowthe
reverseindicatorspringtobringtheleversbackto
neutral.Thewheelmuststopturningorslightly
creepinreverse.

Theleftrodassemblycontrolstheleftwheeland
therightrodassemblycontrolstherightwheel.

10.AdjustmentfortheRHmotioncontrollever:
BringtheRHmotioncontrolleverintothe
neutralposition.

BringtheLHmotioncontrolleverintothe
neutralposition.AdjusttheLHpumpcontrolrod
lengthbyrotatingthetrackingadjustmentknobin
theappropriatedirectionuntilthewheelsslightly
creepinreverse.Movethemotioncontrollever
tothereversepositionandwhileapplyingslight

34

Maintenance

pressuretotheleverallowthereverseindicator
springtobringtheleversbacktoneutral.The
wheelmuststopturningorslightlycreepin
reverse(Figure17).

Figure17

Left-HandSideofUnit

1.TurnLHtrackingadjustmentknob.(Donotloosenany
nutsonLHside)

11.Shutoffunit.Removejumperwirefromwire
harnessconnectorandplugconnectorintoseat
switch.

AdjustSeatSwitch

1.Ifnecessary,adjusttheseatactuatorrodlength
towherethemachinewillshutoffwhenthe
operatorraisesofftheseat(withbrakedisengaged
orPTOengaged)butwillcontinuetorunwith
operatorinseat(aslightshiftinweightshould
notshutmachineoff).

Normaladjustmentiswhenlengthofspringis

2.09inches(5.3cm)(withseatup).

Note:Topreventtheenginefromcuttingout
whenoperatingoverroughground,theunitis
equippedwithatime-delayedseatswitch.When
theoperatorraisesofftheseatwitheitherthe
brakedisengagedorthePTOengaged,theengine
shouldstopafter1/2secondhaselapsed.

2.Toadjustseatswitch,loosenlocknutonbottom
oftheactuatorrod(5/16x7inchbolt)andadjust
thenutstomovetheactuatorplateupordown
ontherod.

CasterPivotBearings
Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut
untilwashersareatandbackoff1/4ofaturn

toproperlysetthepre-loadonthebearings.If
disassembled,makesurethespringdiscwashersare
reinstalledasshowninFigure18.

Figure18

1.Springdiscwashers

35

Maintenance

Cleaning

CleanEngineCooling
System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore
oftenindryordirty
conditions.)

CAUTION

Excessivedebriscancausetheengineand
hydraulicsystemtooverheatwhichcan
createarehazard.

Cleanalldebrisfromaroundtheengineand
hydraulicpumpsdaily.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake
screenandfromaroundengineshrouding.

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removecoolingshroudclean-outcoversfrom
engineandcleancoolingns.Alsocleandust,dirt
andoilfromexternalsurfacesofenginewhich
cancauseimpropercooling.

3.Makesurecoolingshroudclean-outcoversare
reinstalled.Operatingtheenginewithoutcooling
shroudclean-outcoverswillcauseenginedamage
duetooverheating.

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raisedecktothetransport(maximumcutting
height)position.Liftthefrontofunitandsupport
unitusingjackstandsorequivalentsupport.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.

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

36

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock
position.

3.Ensurethedriveleversareintheneutral
lockposition.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

Starterdoesnotcrank

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Thethrottleandchokearenotinthe
correctposition.

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

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

6.Dirt,water,orstalefuelisinthefuel
system.

6.ContactanAuthorizedServiceDealer.

7.Aircleanerisdirty.

7.Cleanorreplacetheaircleanerelement.

8.Seatswitchisnotproperlyadjusted.8.Adjusttheseatswitch.

9.Electricalconnectionsarecorroded,loose
orfaulty.

9.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

11.Clean,adjustorreplacesparkplug.

Enginewillnotstart,startshard,orfailsto
keeprunning

12.Sparkplugwireisnotconnected.

12.Checkthesparkplugwireconnection.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe
engineareplugged.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.Ventholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

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

Enginelosespower

7.Dirt,water,orstalefuelisinthefuel
system.

7.ContactanAuthorizedServiceDealer.

37

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

Engineoverheats

3.Coolingnsandairpassagesforthe
engineareplugged.

3.Removetheobstructionsfromthecooling
nsandairpassages.

1.Trackingneedsadjustment1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

Mowerpullsleftorright(withleversfully
forward)

3.Reverseindicatorandmotioncontrol
linkageneedadjustment.

3.Adjustthereverseindicatorandthe
motioncontrollinkage.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

2.Changethebelt.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

4.Replacethespring.

Machinedoesnotdrive

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

cooldown.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

front-to-rear.

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

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

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley ,orblade
pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

Abnormalvibration

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley .2.Installdrivebeltandcheckadjusting

shaftsandbeltguidesforcorrectposition.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

pulley,idlerarmandspringforcorrect
positionandfunction.

Bladesdonotrotate.

5.Brokenormissingidlerspring.

5.Replacethespring.

38

Schematics

Schematics

ElectricalDiagram

VIOLET

DK GREEN

STARTER

SOLENOID

ENGINE

CONNECTOR

KILL

RELAY

SEAT DELAY

MODULE INPUT

START

RELAY

FUSE

FUSE

GROUND

ELECTRIC

CLUTCH

(PTO)

SEAT DELAY

MODULE CONTROL

VIOLET

VIOLET

RED

RED

RED

DK

. BLUE

WHITE

BLACK

BLACK

BLACK

BLACK

TAN

TAN

TAN

LT. BLUE

BROWN

BROWN

GREY

LT. BLUE

LT. BLUE

LT. BLUE

LT. BLUE

LT. BLUE

LT. GREEN

LT. GREEN

DK. GREEN

PINK/BLK STRIPE

DK. GREEN

DK. GREEN

DK. GREEN

DK. GREEN

DK. GREEN

YELLOW

DK. GREEN/WHT STRIPE

DK. GREEN/WHT STRIPE

ORANGE/BLK STRIPE

BLACK

BLACK

WHITE

ORANGE/BLK STRIPE

BLACK

DK BLUE

ORANGE

PINK/BLACK STRIPE

ORANGE

ORANGE

ORANGE

GREY

GREY

GREY

VIOLET

RED

YELLOW

TAN

ORANGE

ORANGE

ORANGE

ORANGE

GREY

SEAT DELAY

MODULE DIODE

GREY

BLACK

DK. GREEN

SEAT

SWITCH

SWITCH IN - ORANGE TO PINK/BLACK

SWITCH OUT - ORANGE TO GREY

SWITCH IS CLOSED WITH

OPERATOR iIN SEAT

PTO

SWITCH

HOUR

METER

IGNITION

SWITCH

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM WIRE END

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, PTO SWITCH

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

B + I + A

2. RUN

1. OFF

POSITION

3. START

TERMINAL A

TERMINAL B

TERMINAL Y

TERMINAL X

TERMINAL S

TERMINAL I

G006774

BRAKE

RH MOTION

CONTROL

LH MOTION

CONTROL

BOTH MOTION CONTROL SWITCHES

ARE CLOSED WITH CONTROL LEVERS

IN NEUTRAL LOCK POSITION

CLOSED WITH

BRAKE ENGAGED

OPEN WITH

BRAKE ENGAGED

39

Schematics

HydraulicDiagram

FRONT
OF UNIT

HIGH PRESSURE

CHARGE PUMP INLET

CASE DRAIN

HYDRAULIC
TANK

FILTER

BYPASS
VALVE

BYPASS
VALVE

HIGH PRESSURE
FORWARD

HIGH PRESSURE
REVERSE

HIGH PRESSURE
FORWARD

HIGH PRESSURE
REVERSE

G006765

40

Conditions and Products Covered

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

This warranty applies to Exmark turf equipment purchased on
or after October 1, 2004 sold in the US or Canada. This
warranty may only be assigned or transferred to a second (or
third) owner by an authorized Exmark dealer. The warranty
period commences upon the date of the original retail
purchase.

 Products Warranty Period

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

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series  1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

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

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
of defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall have any liability for any
other cost, loss or damage, including but not limited to, any
incidental or consequential loss or damage.

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

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

Some states do not allow exclusions of incidental or
consequential damages, so the above exclusions and
limitations may not apply to you.

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

2-Year Limited Warranty

Exmark Turf Equipment

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

G006117

41

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

42

43

MI D-MOUNT RIDIN G ACCESSO RIES

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES

WALK-BEHIND ACCESSORIES

GRASS CATCHER

LAZERLOCKER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LAZERLOCKER

LIGHT KIT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT RID ING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

ROTARY BROOM

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

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

PartNo.4500-257Rev.A
[phone]
Fax[phone]
PrintedintheUSA.

www.exmark.com