Exmark LAZER Z D-SERIES, lazer Z DS series, LAZER Z LZD25KD605, LAZER Z LZD25KD725 Operator's Manual

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Page 1

LAZERZ®D-SERIES

ForSerialNos. 920,000&Higher LazerZ(LZD)Units

PartNo.4500-919Rev.A

Page 2

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered,or grass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilar laws.

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe CanadianstandardICES-002.Cesystèmed’allumage parètincelledevèhiculeestconformeàlanorme NMB-002duCanada.

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

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

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

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Page 3

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

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

Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm

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.

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Contents

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

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

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

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

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

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

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

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

Dimensions...................................................19

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

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

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

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

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

OperatingInstructions..................................23

Transporting.................................................27

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

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

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

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

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

CheckMowerBlades.....................................31

CheckSafetyInterlockSystem.......................32

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................32

CheckSeatBelt..............................................32

CheckforLooseHardware............................32

ServiceAirCleaner........................................32

ChangeEngineOil........................................33

CheckHydraulicOilLevel.............................33

CheckTirePressures.....................................33

CheckConditionOfBelts..............................34

LubricateGreaseFittings...............................34

WheelHub-SlottedNutTorque

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

LubricateBrakeHandlePivot........................35

LubricateBrakeRodBushings.......................35

LubricateMotionControlBronze

Bushings...................................................36

DrainFuelFilter/WaterSeparator..................36

ChangeFuelFilter/WaterSeparator...............36

ChangeHydraulicSystemFilter.....................36

CheckEngineCoolantLevel..........................37

ChangeEngineCoolant.................................37

CheckSparkArrester(ifequipped).................38

ThreadLockingAdhesives.............................38

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................39

Copper-BasedAnti-seize..............................39

DielectricGrease...........................................39

Adjustments.....................................................39

DeckLeveling...............................................39

PumpDriveBeltTension...............................40

DeckBeltTension.........................................40

MuleDriveBeltTensionAdjustment.............40

AlternatorBeltTension.................................41

BeltGuideAdjustment..................................41

ParkingBrakeAdjustment.............................41

ElectricClutchAdjustment............................43

ReverseIndicatorAdjustment........................44

MotionControlLinkageAdjustment.............44

MotionControlDamperAdjustment.............46

CasterPivotBearingsPre-Load

Adjustment...............................................46

Cleaning...........................................................47

CleanEngineCoolingSystem........................47

CleanEngineandExhaustSystem

Area..........................................................47

CleantheRadiator.........................................47

CleanDebrisFromMachine..........................48

CleanGrassBuild-UpUnderDeck................48

WasteDisposal..............................................48

Troubleshooting...................................................49

Schematics...........................................................52

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Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

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.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

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Safety

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

DANGER

Incertainconditionsdieselfuelisextremely ammableandvaporsareexplosive.

Areorexplosionfromdieselfuelcanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanydieselfuelthatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows dieselfueltoexpand.Overllingmay resultinfuelleakageordamagetothe engineoremissionsystem.

•Neversmokewhenhandlingdieselfuel, andstayawayfromanopenameor wheredieselfuelfumesmaybeignitedby spark.

•Storedieselfuelinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Dieselfuelisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Operation

WARNING

Operatingengineparts,especiallythemufer, becomeextremelyhot.Severeburnscanoccur oncontactanddebris,suchasleaves,grass, brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

•Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields,

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Safety

guards,switchesandotherdevicesinplaceandin properworkingcondition.

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

DANGER

Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.Wheelsdroppingover edges,ditches,steepbanks,orwatercancause rollovers,whichmayresultinseriousinjury, deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

Figure3).

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Safety

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

2.DangerZone-Useawalkbehindmowerand/orhand trimmeronslopesgreaterthan15degrees,near drop-offsandwater.

3.Water

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

WARNING

Thereisnorolloverprotectionwhentherollbar isdown.Wheelsdroppingoveredges,ditches, steepbanks,orwatercancauserollovers,which mayresultinseriousinjury,deathordrowning.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbaris down.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

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

•Keepengineandengineareafreefrom accumulationofgrass,leaves,excessivegrease oroil,andotherdebriswhichcanaccumulate intheseareas.Thesematerialscanbecome combustibleandmayresultinare.

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe

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Safety

negativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

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

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagement ofcomponents.Sparkscouldcausean explosionormovingpartscouldaccidentally engagecausingpersonalinjury.

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty,traction, andsafetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.Makingunauthorizedchangestothe engine,fuelorventingsystem,mayviolateEP A andCARBregulations.

Replaceallpartsincluding,butnotlimitedto, tires,belts,blades,andfuelsystemcomponents withoriginalExmarkparts.

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Safety

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

•Ifequipped,makesureallhydraulicuid hosesandlinesareingoodconditionandall hydraulicconnectionsandttingsaretight beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,fuelleakageandpossible explosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

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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

1-513748

1-633706

98-5954

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Safety

103-0223

103-0261

103-1798

103-2076

103-7218

107-2102

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Safety

109-0872

109-1214

109-1215

109-1399

109-2219

109-2263

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Safety

109-2264

109-2478

109-2951

109-3148

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Safety

116-0127

116-0404

116-0997

116-2643

116-3303

116-5074

116-5185

1.PTO–engage2.PTO–disengage

117–2718

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Safety

19426-87881

19426-87903

107-9866

1.Fast3.Neutral

2.Slow

4.Reverse

Page 17

Specications

ModelNumbers

SerialNos:920,000andHigher

LZD25KD605;LZD25KD725

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3850±50RPM(PTOnot engaged)Idle:1400±100RPM

FuelSystem

•Capacity:15.5gal.(58.6L)

•TypeofFuel:Dieselfuel,40cetaneorhigheror biodieseluptoB20(20%biodiesel,80%petro diesel).

•FuelFilter:In-line113Micron ExmarkP/N112-7836.

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

•Fuelgaugeinlefthandfueltank.

ElectricalSystem

•ChargingSystem:ExternalAlternator

•ChargingCapacity:60amps

•BatteryType:BCIGroup26

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:One20ampbladetype;One30ampblade type

SafetyInterlockSystem

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

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

EngineOverheatProtectionSystem

PTOwilldisengage,analarmwillsound,andthe coolanttemperaturegaugewillbeintheredarea whentheenginetemperaturereachesanoverheat condition.ThePTOwillnotre-engageuntilthe enginehascooledandthePTOswitchismanually shut-offandre-engaged.

Note:Iftheenginecoolantlevelisbelowthe indicatorlineontheoverowbottlewhenthe engineiscold,thecoolanttemperaturegaugemay notregistercorrectlyduringoperationand/or thewarningbuzzermaynotsoundiftheengine overheats.RefertoCheckEngineCoolantLevel inMaintenance.

CoolingSystem

•Fan:Electricwithcontinuousoperationwith enginerunning.

•CoolantLiquid:50/50mixofDexCool© extendedlifeantifreezeandwater.

•CoolantCapacity:4quarts

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

Page 18

Specications

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftAssistPedal:Footpedalthatassistsin raisingthedeck.

Seat

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

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

•Armrests:Moldedadjustableip-uparmrests.

•SeatSafetySwitch:Integratedseatswitch. Timedelayseatswitcheliminatesroughground cut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearPW variabledisplacementpistonpumps.

•WheelMotors:TwoParker/Rosswith11/4inch taperedshafts.

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:5.5qt.(5.2L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–0-12.0mph(19.3km/hr)forward. –0-8.0mph(12.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

Pneumatic (Air-Filled)

Semi-Pneumatic

DeckSize

60,66,&72

AllDecks

Quantity

DriveFrontCaster

TreadSize

“Multi-Trac C/S”

Smooth

Size26x12.00-1213x6.50-6

PlyRating

Pressure

10psi(69kPa)

CuttingDeck

•CuttingWidth:

–60inch(152.4cm)

–72inch(182.9cm)

•Discharge:Side

•BladeSize:(3ea.)

–60inchDeck:20.75inches(52.7cm)

–72inchDeck:24.75inches(62.9cm)

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

•DeckDrive:

–Electricclutchmountedonhorizontalengine

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

–Bladesaredrivenbyone“B”Sectionbelt

(w/self-tensioningidler)fromtransfershaft ondecktobladespindles.

•Deck:

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

•DeckDepth:

–60inchDeck:6.0inches(15.2cm)

–72inchDeck:6.0inches(15.2cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

Page 19

Specications

Dimensions

OverallWidth:

60inchDeck72inchDeck

WithoutDeck53.5inches

(135.9cm)

61.5inches (156.2cm)

DeectorUp61.4inches

(156.0cm)

74.3inches (188.7cm)

DeectorDown72.8inches

(184.9cm)

85.8inches (217.9cm)

OverallLength:

60inchDeck72inchDeck

RollBar-Up81.9inches

(208.0cm)

85.8inches (217.9cm)

RollBar-Down92.5inches

(235.0cm)

96.4inches (244.9cm)

OverallHeight:

RollBar-UpRollBar-Down

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

TreadWidth:(CentertoCenterof Tires,Widthwise)

60inchDeck72inchDeck

DriveWheels41.9inches

(106.4cm)

45.9inches (116.6cm)

CasterWheels37.3inches(94.7

cm)

47.3inches (120.1cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

60inchDeck72inchDeck

56.0inches(142.2cm)60.2inches(152.9cm)

CurbWeight:

60inchDeck72inchDeck

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

TorqueRequirements

BoltLocation

Torque

BladeDriveSheave MountingNut

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

CutterHousingSpindle Nut

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

BladeMountingBolt (lubricatewithanti-seize)

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

EngineDeck/FrontFrame MountBolts

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

Anti-ScalpRollerNyloc NutSeeFigure11

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

Anti-ScalpRollerHex CapscrewSeeFigure11

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

EngineMountingBolts 1/2-13inchscrews M10screws

67-83ft-lb(99-113N-m) 30ft-lb(41N-m)

WheelLugNuts

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

WheelMotorMounting Bolts

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

WheelHubSlottedNut211-260ft-lb

(286-352N-m)

RolloverProtectionSystem (RollBar)MountingBolts

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

DeckDriveJackshaftNut

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

ClutchRetainingBolt (securedwiththreadlocker)

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

Page 20

Operation

ProductOverview

Figure4

1.Motioncontrollevers

5.EngineControls(right console)

2.Parkingbrake

6.Seatbelt

3.Heightofcutadjustment

7.RolloverProtection System(ROPS)

4.Fuelcap(bothsides)

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (

Figure5).

Figure5

1.Neutrallockposition (handlesout)

5.Neutral(operate)

2.Neutraloperateposition (handlesin)

6.Reverse

3.FrontofUnit

7.Neutrallock

4.Forward

ThrottleControl

Locatedonrightfueltank.

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed

Page 21

Operation

andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonleftsideofunit,justtothefrontofthe console.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightfueltank.

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

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

HourMeter

Locatedontherightfueltank.

Thehourmeterisconnectedtoapressureswitch installedintheengineblockanditrecordsthe numberofhoursthattheenginehasrun.Ifthe ignitionswitchisleftonwithoutenginerunning, hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locateddirectlybelowtherightsideofconsole,next tothecubby.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Thevalvehasthreepositions,eachpositionmade in1/4turnincrements.

FuelFlowValveHandlePosition

“Off”Right

RightTank

Down

LeftTankLeft

FuelGauge

Locatedontheleftfueltank.

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

DriveWheelReleaseValves

Locatedonthetoprightfrontcornerofhydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe pushedwithouttheenginerunning.Unhookseat latchandtiltseatuptogainaccesstopumps.

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

Nottowmachine.

TrackingAdjustmentKnob

LocatedundertheseatontheLHpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso thatthemachinetracksstraightwiththedrivelevers inthefullforwardposition.

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

Important:DoNotrotatetheknobtoofar,as thismaycausethemachinetocreepinneutral. RefertotheMotionControlLinkageAdjustment sectioninMaintenance.

Page 22

Operation

PTOEngagementSwitch

Locatedonrightfueltank.

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

Note:Iftheengineoverheats,thePTOwill automaticallydisengage.ThePTOcannotbe engageduntiltheenginehascooleddown.To re-engagethePTO,pushPTOswitchinto thedisengagedpositionandthenpulloutto engage.RefertotheEngineoverheatsinthe Troubleshootingsection.

CoolantTemperatureGauge

Locatedatthefrontoftheleftfueltank.

Thecoolanttemperaturegaugemonitorsthe temperatureoftheenginecoolant.Anengine overheatingconditionisindicatedbytheredarea onthegauge.AnalarmwillsoundandthePTO willdisengage.RefertotheWarningBuzzerinthe Troubleshootingsection.

Note:Iftheenginecoolantlevelisbelowthe indicatorlineontheoverowbottlewhentheengine iscold,thecoolanttemperaturegaugemaynot registercorrectlyduringoperation.RefertoCheck EngineCoolantLevelinMaintenance.

Voltmeter

LocatednexttotheCoolantTemperatureGaugeat thefrontoftheleftfueltank.

Thevoltmetermeasurethevoltageoutputofthe alternator.Bothhighandlowvoltageswillpotentially damagethebattery.

GlowPlugSwitchandLight

Locatedontherightfueltank.

Depressandholdtheswitchtoheattheglowplugs. Theglowpluglightcomesonwhentheglowplug switchisdepressed.Theglowpluglightindicatesthe glowplugsarepreheatingthecombustionchamber.

LowOilPressureLight

Locatedontherightfueltank.

Lightwillcomeonwhenengineoilpressureislow orlost.

WarningBuzzer

Locatedbehindtheseatundertheairdeectoron theelectricalpanel.

Thebuzzerisawarningsignalthattheengine isoverheatingortheoilpressureislow .Seethe Troubleshootingsection.

Note:Iftheenginecoolantlevelisbelowthe indicatorlineontheoverowbottlewhentheengine iscold,thewarningbuzzermaynotsoundifthe engineoverheats.RefertoCheckEngineCoolant LevelinMaintenance.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

Pre-Start

Fillfueltankonlevelground.

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

DeterminingFuel

Theenginerunsonclean,freshdieselfuelwith aminimumoctaneratingof40.Purchasefuelin quantitiesthatcanbeusedwithin30daystoensure fuelfreshness.

Usesummergradedieselfuel(No.2-D)at temperaturesabove20°F(-7°C)andwintergrade dieselfuel(No.1-DorNo.1-D/2-Dblend)below 20°F(-7°C).Useofwintergradedieselfuelatlower temperaturesprovideslowerashpointandpour pointcharacteristics,thereforeeasingstartabilityand lesseningchancesofchemicalseparationofthefuel duetolowertemperatures(waxappearance,which maypluglters).

Useofsummergradedieselfuelabove20°F(-7°C) willcontributetowardlongerlifeofthepump components.

Page 23

Operation

Important:DoNotusekeroseneorgasoline

insteadofdieselfuel.Failuretoobservethis cautionwilldamagetheengine.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsthefueltoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system.

Ifpossible,llthefueltankaftereachuse.Thiswill minimizepossiblebuildupofcondensationinsidethe fueltank.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuel ofuptoB20(20%biodiesel,80%petrodiesel).The petrodieselportionshouldbeloworultralowsulfur.

Observethefollowingprecautions:

•Thebiodieselportionofthefuelmeets specicationASTMD6751orEN14214.

•Theblendedfuelcompositionshouldmeet ASTMD975orEN590.

•Paintedsurfacesmaybedamagedbybiodiesel blends.

•UseB5(biodieselcontentof5%)orlesserblend incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuel astheymaydegradeovertime.

•Fuellterpluggingmaybeexpectedforatime afterconvertingtobiodieselblends.

•Contactyourdistributorifyouwishformore informationonbiodiesel.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe tworollbarpins(Figure6).

2.Raisetherollbartotheuprightpositionand installthetwopinsandsecurethemwiththe hairpincotterpins(Figure6).

Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.Ensurethatthe

rearpartoftheseatissecuredwiththeseat latch.

Figure6

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

TurnthevalvetotheLHorRHtank.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

5.Onawarmengine,placethethrottleinthe “SLOW”position.

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

Note:DoNotusefuelleftoverfromsummer.

Page 24

Operation

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

GlowPlugChart

AmbientT emperature

HoldGlowPlugsOn

Above50°F(10°C)

NONEED

50°F(10°C)to23°F(-5°C)

Approximately5seconds

Below23°F(-5°C)

Approximately10seconds

Limitofcontinuoususe

20seconds

Theglowpluglight,locatedneartheglow plugswitch,willilluminatewhentheswitchis depressed.Theglowpluglightindicatestheglow plugsarepreheatingthecombustionchamber.

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

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

1.Setthethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

2.PullthePTOswitchoutwardtoengagethe blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

1.Setthethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

2.PushthePTOswitchintodisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Movethemotioncontrolleversouttotheneutral lockposition.

3.Engagetheparkingbrake.

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

5.DisengagethePTO.

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

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

Page 25

Operation

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

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

Whenthemotioncontrolleversarepositionedfully outward(apart)intheT-slot,thedrivesystemisin theneutrallockposition(

Figure7).

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Figure7

1.Neutrallockposition (handlesout)

5.Neutral(operate)

2.Neutraloperateposition (handlesin)

6.Reverse

3.FrontofUnit

7.Neutrallock

4.Forward

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

Figure8

1.FrontofUnit

3.Neutral

2.Forward4.Reverse

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

Toturnright,releasepressureontheRHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheright.

Toturnleft,releasepressureontheLHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheleft.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheCuttingHeight

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

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Raisethedeckheightlevertothetransport position(alsothe5inch(12.7cm)cuttingheight position)(Figure9).

Page 26

Operation

Thedeckcanberaisedbypullingthedecklever upand/orbypushingdownonthefootoperated deckliftassistleverlocatedatthefrontright corneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure9

1.Leverintransportand5inch(12.7cm)cuttingheight position

4.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheightand installthehairpincotterpin.

Seethedecalonthesideofthedeckliftplatefor cutheights.

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

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingtheboltandspring discwasher.

6.Placetherollersinoneofthepositionsshown (

Figure10).Rollerswillmaintain3/4inch(19 mm)clearancetothegroundtominimizegouging androllerwearordamage.

Figure10

Forcuttingheightsabove4.0inches(102mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Besuretherollerboltsareinstalledwiththe springdiscwasherbetweentheheadofthebolt andthemountingbracket.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

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

Figure11).

Page 27

Operation

Figure11

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)

9.Ifthe3/8nylocnuthasbeenremoved, re-installandtorqueto30–35ft-lb(41–47N-m) (Figure11).

Transporting

TransportingaUnit

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

CAUTION

Thisunitdoesnothaveproperturnsignals, lights,reectivemarkings,oraslowmoving vehicleemblem.Drivingonastreetorroadway withoutsuchequipmentisdangerousand canleadtoaccidentscausingpersonalinjury. Drivingonastreetorroadwaywithoutsuch equipmentmayalsobeaviolationofStatelaws andtheoperatormaybesubjecttotrafctickets and/ornes.

DoNotdriveaunitonapublicstreetorroadway.

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•DoNotexceeda15°anglebetweenrampand groundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

LoadingaUnit

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

Rampshouldbelongenoughsothattheangles betweentherampandthegroundandtherampand thetrailerortruckDoNotexceed15°.Asteeper anglemaycausemowerdeckcomponentstoget caughtastheunitmovesfromramptotraileror truck.Steeperanglesmayalsocausetheunittotip backward.Ifloadingonornearaslope,position thetrailerortrucksoitisonthedownsideofthe slopeandtherampextendsuptheslope.Thiswill minimizetherampangle.Thetrailerortruckshould beaslevelaspossible.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Page 28

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

WARNING

Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkenginecoolantlevel.

•Cleantheenginecoolingsystem.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheheightadjustmentshaftbearings.

•Greasethereardeckstruts.

•Drainfuellter/waterseparator.

Every50hours

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

•Checksparkarrester(ifequipped).

•Cleantheenginecoolingsystem.

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

Every160hours

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

Page 29

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Every200hours

•Greasethebrakebrackets.

Every400hours

•Replacethefuellter/waterseparator(moreoftenindirtyordustyconditions).

Every500hours

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checktheparkbrakeadjustment.

Every600hours

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

Every4,000hours

•

Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)

Monthly

•Checkthebatterycharge.

Yearly

•Changetheengineoilifoperatedlessthan100hours.

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

•Greasethemuledrivebeltidlerarm.

•Greasethepumpdrivebeltidlerarm.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Raiseradiatortogainaccesstodipstick.

CAUTION

Iftheradiatorproprodisnotsecurely positionedinthenotchtheradiatormayfall. Fallingradiatorcouldcauseseriousinjury.

Besuretheproprodisengagedsecurelyin thenotchatthefarrightsideoftheslot.

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

5.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner’smanualforanacceptablealternative.Do Notover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.T opreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Page 30

Maintenance

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

Important:Makesurethenegativebatterycable isdisconnectedandthebatterychargerusedfor chargingthebatteryhasanoutputof16voltsand 7ampsorlesstoavoiddamagingthebattery(see chartforrecommendedchargersettings).

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

12.6or greater

100%

16volts/7 amps

No Charging Required

12.4–12.675–100%

16volts/7 amps

30Minutes

12.2–12.450–75%

16volts/7 amps

1Hour

12.0–12.225–50%

14.4volts/4 amps

2Hours

11.7–12.00–25%

14.4volts/4 amps

3Hours

11.7orless

14.4volts/2 amps

6Hoursor More

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

1.Checktheweakbatteryforterminalcorrosion (white,green,orblue“snow”),itmustbecleaned offpriortojumpstarting.Cleanandtighten connectionsasnecessary.

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

DANGER

Jumpstartingaweakbatterythatiscracked, frozen,haslowelectrolytelevel,oran open/shortedbatterycell,cancausean explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6AWG)with shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity.

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Note:Thefollowinginstructionsareadapted fromtheSAEJ1494Rev .Dec.2001–Battery BoosterCables–SurfaceVehicleRecommended Practice(SAE–SocietyofAutomotive Engineers).

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel. Placeadampcloth,ifavailable,overanyvent capsonbothbatteries.Besurethevehiclesdo nottouchandthatbothelectricalsystemsare offandatthesameratedsystemvoltage.These instructionsarefornegativegroundsystemsonly.

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure12.

Page 31

Maintenance

Figure12

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe reverseorderofconnection(theengineblock (black)connectionisthersttodisconnect).

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated intheCleanGrassBuild-UpUnderDeck procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure13

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Figure14

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

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

C.Applylubricanttothreadsofbladeboltas

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

Page 32

Maintenance

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith, parkingbrakeengaged,PTOdisengagedand 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 onesecondhaselapsedifthehandlesarein.The delaywillbe1/2secondifthehandlesareout.

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

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

Repeatagainmovingtherightleverin,then movingbothleversin-enginemustinitiate shutdownafter1/2secondhaselapsedwhether operatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckRolloverProtections Systems(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

Makesurelatchpinandhairpinarefullyinstalled andlanyardisingoodcondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See

Page 33

Maintenance

theEngineOwner’s Manualforadditional information.)

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhooktwoairltercanisterlatchestogain accesstotheaircleanerelement.

3.Removeaircleanercanistercoverandremove outerelement.

4.Checktheconditionofthepaperelement. Replaceifdirty,bentordamaged.

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

6.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

Yearlyifoperatedless than100hours.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Fastendeckbeltspanstogetherwithmechanics wireortiewraptopreventoilfromdrainingonto belt.

4.Placepanundermachinetocatchoil.Remove theoildrainplug.Allowoiltodrainandreplace oildrainplug.

5.Replacetheoilltereveryotheroilchange.Clean aroundoillterandunscrewltertoremove. Beforereinstallingnewlter,applyathincoating ofExmark4-CyclePremiumEngineOilonthe surfaceoftherubberseal.Turnlterclockwise untilrubbersealcontactsthelteradapterthen tightenlteranadditional1fullturn.

6.Unlatchradiatorandliftituptoaccessoilll. Cleanaroundoilllcapandremovecap.Fill tospeciedcapacityandreplacecap.Useoil recommendedintheCheckEngineOilLevel section.DoNotoverll.Starttheengineand checkforleaks.

7.Removewireortiewrapfrombeltspans

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

9.Checkforleaks,includingaroundtheoillter.

10.Wipeupanyspilledoil.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

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

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.

Page 34

Maintenance

2.Checktirepressureindrivetires.

3.Inatedrivetiresto10psi(69kPa).

4.Semi-pneumaticcastertiresdonotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.Removethe airdetectorpanelonfrontsideoftheengine compartmenttocheckpumpdrivebeltand alternatorbelt.

3.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

4.Checkundermachinetoinspectthemule drivebelt.RefertoMuleDriveBeltTension AdjustmentsectioninAdjustments.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Front Casterwheel hubs

*Yearly

2.Front Caster Pivots

*Yearly

3.Height Adjustment Shaft Bearings

540Hours

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

4.Deck DriveBelt IdlerArm

Yearly

5.Brake Brackets

200Hours

6.Mule DriveBelt IdlerArm

Yearly

7.Pump DriveBelt IdlerArm

Yearly

8.Deck RearStruts

40Hours

*Seestep3forspeciallubricationinstructionson thefrontcasterpivotsandtheLubricateCaster WheelHubssectionforspeciallubrication instructionsonthefrontcasterswheelhubs.

Number6(MuleDriveBeltIdlerArm)Located

UnderEngineFrame

Number7(PumpDriveBeltIdlerArm)Located

UnderEngineFrame

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

Page 35

Maintenance

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Torquetheslottednutto211-260ft-lb(286-352 N-m).

Note:DoNotuseanti-seizeonwheelhub.

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure15

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.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

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

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandlepivot withaspraytypelubricantorlightoil.

LubricateBrakeRod Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake rodshaftwithaspraytypelubricantoralightoil

Page 36

Maintenance

(bushingsarelocatedtotheinsideoftheange bearings).

LubricateMotionControl BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings securingthemotioncontrolarmshaftswitha lightoiloraspraytypelubricant.

DrainFuelFilter/Water Separator

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Placeadrainpanunderthefuellterandloosen thedrainplugapproximately1turn.

3.Watershoulddrain.

4.Whenfuelbeginstoowfromthelter,tighten thedrainplug.

Important:Waterorothercontaminantsinfuel canseverelydamagefuelpumpand/ortheother enginecomponents.

ChangeFuelFilter/Water Separator

ServiceInterval:Every400hours/Yearly

(whichevercomesrst) (moreoftenindirtyor dustyconditions).

DANGER

Useofimpropercomponentscanresultinsystem failure,fuelleakageandpossibleexplosion.

•EnsurethatanAuthorizedServiceDealer replacethefuellterandanycomponentsfor thefuelsystem.

•Useonlyapprovedfuellines,hoseclamps andfuelltersforhighpressuresystems.

ChangeInlineFuelFilter

ServiceInterval:Asrequired

Aninlinefuellterisinstalledbetweenthefueltank andthefuelpump.Replacewhennecessary.

ReplacementFilters

ExmarkP/N112-7836

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

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

Note:UseonlyExmarkP/N103-2146.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raiseseat.

3.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

4.Unscrewltertoremoveandallowoiltodrain fromreservoir.

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

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

5.FillreservoirasstatedinCheckHydraulicOil Levelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ChangeInterval

ExmarkPremiumHydro Oil(Preferred)

500Hours

Mobil115W50

250Hours

Page 37

Maintenance

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .

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

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

CheckEngineCoolantLevel

ServiceInterval:Beforeeachuseordaily

Note:Iftheenginecoolantlevelisbelowthe

indicatorlineontheoverowbottlewhenthe engineiscold,thecoolanttemperaturegaugemay notregistercorrectlyduringoperationand/or thewarningbuzzermaynotsoundiftheengine overheats.

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

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

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Sprayor steamfromhot,pressurizedliquidintheengine coolingsystemandtouchingahotradiatormay causesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolantcan causepoisoning.

•DoNotswallow .

•Keepoutofreachofchildrenandpets.

ChangeEngineCoolant

ServiceInterval:Every4,000hours/Every4

years(whichevercomes rst)Dex-Cool© ©

extended

lifecoolant(orangecolor)

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

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

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Spray orsteamfromhot,pressurizedliquidinthe enginecoolingsystemandtouchingahot radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant cancausepoisoning.

•DoNotswallow .

•Keepoutofreachofchildrenandpets.

3.Draincoolantwhenengineiscool.Coolantmay bedrainedfromtheradiatorbyremovingthe drainplugintherightrearcorner.Theengine blockmaybedrainedbyremovingtherear radiatorhoseand/orbyopeningthedraincock ontheright-handsideoftheengineblock(see Figure16).

Page 38

Maintenance

Figure16

1.Oildipstick

2.Draincock

4.Reinstallalldrainplugsandhosesandtighten draincock.

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

WARNING

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

•DoNotoperatemachinewithoutthe coversinplace.

•Keepngers,hands,andclothingclearof rotatingcomponents.

•Shutoffengine,waitformovingpartsto stop,engageparkingbrakeandremove key,beforeperformingmaintenance.

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

7.Operateengineuntiltheenginethermostatopens andcoolantiscirculatingthroughtheradiator

core.Asairispurgedfromtheengineblockand thecoolantleveldrops,addadditionalcoolantto theradiator.

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

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignitefuel vaporsevenaftertheengineisstopped.Hot particlesexhaustedduringengineoperationmay igniteammablematerials.Firemayresultin personalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

4.Ifpluggingofthescreenisobserved,remove arresterandshakelooseparticlesoutofthe arresterandcleanscreenwithawirebrush(soak insolventifnecessary).Reinstallarresteron exhaustoutlet.

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol arms.

•Sheaveretainingboltintheendofengine crankshaft.

•Casterwheelspacernuts.

Page 39

Maintenance

•Fueltankbulkheadttingnuts.

•Boltsretainingstubshafttoengineywheel.

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

Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

•Betweenthejackshaftandbearingsandthe jackshaftandsheaves.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Adjustments

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

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbeenough supportormaymalfunctionallowingtheunitto fall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

4.Setanti-scalprollerstotopholesorremovethem completelyforthisadjustment.

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

Figure17).

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

Figure17).

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

8.Loosenthetwotopchainboltsinslotsintherear deckliftarms.Loosenjamnutsandbackoffthe socketheadadjustingscrewsonthebottomof thearmsuntilthechainsarejustloose.Turnthe socketheadadjustingscrewsinuntilslackistaken outofeachchain.Tightenthejamnuts.Tighten

Page 40

Maintenance

thechainboltsinthedeckliftarmsmakingsure theydon’tmovewhiletightening.

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

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

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

Figure17

1.Applydownwardpressurehere

2.Placelockingpliersheretoholdspring

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

4.Removeforceondeckspringsbylooseningnutshere

5.Swivel

6.Frontofunit

7.Socketheadadjustingscrew

8.Jamnut

12.Raisedeckliftlevertothe5inch(12.7cm) cuttingheightposition(Figure9).Adjustspring compressionuntilproperdistanceisobtained betweenthetwolargewashers(Figure17). Adjustmentismadebyturningthenutatthe frontofeachspring(clockwisewillshortenthe spring,counterclockwisewilllengthenthespring). Lockinpositionwithjamnuts.

Note:Whenaboveadjustmentshavebeenmade, thefrontofthedeckwillbeslightlylowerthanthe rearofthedeck.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

MuleDriveBeltTension Adjustment

Self-tensioningidler,adjustasfollows:

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktomakesurethecenterofthebolthead inthecenterofthespringloadedpulley,onleft sideenginedecksupport,ispositionedbetween thecentersofthetwoalignmentholesinthe leftsupportplate(

Figure18andFigure19).It isnecessarytoadjustthebelttensionwhenthe centeroftheboltheadisatorbelowthecenter ofthebottomalignmenthole.

3.Whenadjustmentisnecessary,loosentheidler pulleyontheright-handsidesoitcanmoveup anddownintheslot.

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

Repositiontheadjustingpulleytothebottomof theslot.

Note:Wheninstallinganewbelt,itisnecessary torepositiontherightadjustingpulleyupwardin theslotinordertopositionthecenterofthespring loadedpulleybetweenthealignmentholes.

Page 41

Maintenance

Figure18

1.Frontofunit

2.Alignmentholes

Figure19

1.Springidlerpulley

3.Rightsideidlerpulley (adjustable)

2.Frontofunit

AlternatorBeltTension

Stopengine,waitforallmovingpartstostopand removekey.Engageparkingbrake.

Tiltseatandremoveairdeectorpanel

Totightenalternatorbelt,loosenbothupperand loweralternatormountingbolts.Rotatealternator out,awayfromengineandretightenhardwareto secureinplace.

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

BeltGuideAdjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethebeltshieldontherightsideofmower deck.

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

Figure20).

4.Ifadjustmentisnecessary,loosentheboltsecuring thebeltguideandmakeproperadjustment. Tightenhardware.

Figure20

1.Endofslot

2.Beltguide

ParkingBrakeAdjustment

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.This proceduremustbefollowedaftertherst100hours orwhenabrakecomponenthasbeenremovedor replaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey .

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

Page 42

Maintenance

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Engagetheparkingbrake(leverup).

8.Loosenthejamnut(item9inFigure21)just abovethetrunnionroller2-3turns.

Figure21

1.Leverdown (disengaged)

6.Removepintoadjust rodlengthforadditional brakeadjustment

2.Leverup(engaged)

7.Trunnionroller

3.Nylocnutbelowtrunnion roller

8.Springretainerbracket

4.Nylocnutbelowspring9.Jamnutabovetrunnion

roller

5.1/8to3/16inch(3.2to

4.8mm)

9.Tightenthebottomnylocnut(item3inFigure21) untilthebrakespringiscompletelycompressed, thenloosenone-halfturn.

10.Tightenthejamnutagainstthetrunnionroller

11.Checktheclearancebetweenthebottomofthe brakebracketandthenylocnutjustunderthe spring.Clearanceshouldmeasure1/8to3/16

inch(3.2-4.8mm).Ifnecessary,adjustthenyloc nutaccordingly.

12.Ifthecorrectgapcannolongerbeachieved becausethereisnoclearancebetweenthenyloc nutbelowthespringandthejamnut,orthere arenothreadsleftinthebottomnylocnut,the lengthofthebrakerodcanbeadjusted.Remove apinfromayokeateitherendofthebrakerod andlengthen(orshorten)thebrakeroduntilthe correctgapcanbeachieved.

13.Ifabrakecomponenthasbeenremovedor replaced,seethestepsbelow;otherwiseproceed tostep

14.

BurnishingtheBrakeProcedure:

A.Cleartheareaofanyammablematerial

beforestartingtheburnishingprocess.

B.Whilesittingintheoperator’sseat,startthe

engine,andreleasetheparkbrake.

WARNING

Enginemustberunninganddrivewheels mustbeturningsoadjustmentscanbe performed.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

C.Increasethethrottletohighidle.

D.Bringbothdriveleversoutofneutraland

pushthemintofullforwardposition.

E.Pulltheparkbrakeleverupuntiltheengine

rpmstartstodrop.Holdtheparkbrakelever inthispositionfor15seconds.

F.Releasethebrakelever.

G.Movethedriveleversintothefullreverse

position.RepeatstepsEandF.

H.Movethedriveleversbacktotheneutrallock

position.

I.Returnthethrottletolowidle,andstopthe

engine.

J.Allowthebrakebandsanddrumstocool.

Repeatsteps7through11.

14.Installthetiresandtorquethelugnutsto90-95 ft-lb(122-129N-m).

15.Removethejackstands.

Page 43

Maintenance

ElectricClutchAdjustment

Noadjustmentnecessary.Howeverwhentheclutch brakehasworntothepointwheretheclutchno longerengagesconsistently,theshimcanberemoved toextendtheclutchlife.

Figure22

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

1.Stopengine,waitforallmovingpartstostop, andremovekey .Engageparkingbrake.Allow themachinetocoolcompletelybeforestarting theseinstructions.

2.Usingapneumaticline,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers.

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature. Ifthegapisgreaterthan.04inch(1mm),proceed withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-half

toonefullturn(see

Figure23).

Note:DoNotremovethebrakepolefrom theeldshell/armature.Thebrakepolehas worntomatchthearmatureandneedsto continuetomatchaftertheshimisremoved toensureproperbraketorque.

Figure23

1.Brakemountingbolt

2.Shim

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13

N-m)+/-0.5ft-lb(0.7N-m).

E.Usinga0.010inchthickfeelergauge,verify

thatagapispresentbetweentherotorand armaturefaceonbothsidesofthebrakepole asshown.(Duetothewaytherotorand armaturefaceswear(peaksandvalleys)itis sometimesdifculttomeasurethetruegap.)

G011733

Figure24

1.Feelergauge

Page 44

Maintenance

Figure25

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstep

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengage

withthePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly ,referencethe Troubleshootingsection.

ReverseIndicator Adjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatforward.

3.Beginwitheithertheleftorrightmotioncontrol lever.Movelevertotheneutralpositionandpull leverbackuntiltheclevispin(onarmbelowpivot shaft)contactstheendoftheslot(justbeginning toputpressureonspring).(Figure26).

4.Checkwhereleverisrelativetonotchinconsole (shouldbecenteredallowinglevertopivot outwardtotheneutrallockposition).

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

6.Repeatonoppositesideofunit.

Figure26

1.Turnbolthere4.Yoke

2.Levercenteredinnotch5.Loosenhere

3.Endofslot

6.Reverseindicator

MotionControlLinkage Adjustment

WARNING

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

Page 45

Maintenance

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

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

2.Unhookseatlatchandtiltseatforward.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locateddirectlytotheleftoftheseat switchassemblybesidethehydraulicoilreservoir.

Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

4.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulic systemoiluptooperatingtemperature.

5.Loosenlocknutsfromtheballjointsateachend ofthepumpcontrollinkage(

Figure27).

Figure27

Right-HandSideofUnit

1.Turnheretoadjust

2.Loosenhere(right-hand thread)

6.Startengine.Brakemustbeengagedand motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat

becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

7.Thereverseindicatorspringmustbecorrect beforethefollowingadjustmentscanbemade. SeetheReverseIndicatorAdjustmentsection.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

Theleftrodassemblycontrolstheleftwheeland therightrodassemblycontrolstherightwheel.

8.Bringthemotioncontrolleverintotheneutral position.AdjustRHpumpcontrolrodlength byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(

Figure27).Movethemotion controllevertothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringtobringtheleversbackto neutral.Thewheelmuststopturningorslightly creepinreverse.Whenadjustmentiscomplete, tightenlocknutsontoballjoints.

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

Figure28).

Figure28

Left-HandSideofUnit

1.TurnLHtrackingadjustmentknob.(DoNotloosenany nutsonLHside)

10.Shutoffunit.Removejumperwirefromwire harnessconnectorandplugconnectorintoseat switch.

Page 46

Maintenance

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. See

Figure29formountingoptions.

Figure29

1.Motioncontrolbracket

2.Leastresistance(softestfeel)

3.Mediumresistance(mediumfeel)

4.Mostresistance(rmestfeel)

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

6.Damper

7.Dampermustmovefreelyonbolt.

CasterPivotBearings Pre-LoadAdjustment

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

Figure30.

Figure30

1.Springdiscwashers

Page 47

Maintenance

Cleaning

CleanEngineCooling System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundtheenginecooling airintakeandinsideofthepumpdrivebelt compartmentanddamagedormissingrubber bafescancausetheengineandhydraulic systemtooverheatwhichcancreatearehazard.

•Cleanalldebrisfrominsideofpumpdrive beltcompartmentdaily.

•Cleandebrisfromradiatorscreenandcore daily.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfrominsideofpumpdrivebelt compartment.

3.Wipedebrisfromscreeninenginecover.

4.Rotateenginecoverforwardandwipedebris fromradiatorcoreasrequired.

5.Cleandebrisfromradiatornswithcompressed air.

Important:Ifdebrisoraircannotbeblown throughtheradiator,seeCleaningofthe Radiatorsection.

6.Inspectsealsinenginecoverandreplaceif necessary.

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundengineandexhaust systemareacancauseengine,exhaustarea,and hydraulicsystemtooverheatwhichcancreate arehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removeairdeectorpanelfrombehindseat.

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

4.Cleanalldebrisfromtheexhaustsystemarea.

5.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustarea.

6.Reinstalltheairdeectorpanel.

Important:DoNotusewatertoclean engine.Uselowpressurecompressedair.See EngineOwner’sManual.

CleantheRadiator

ServiceInterval:Every50hours(Maybe

requiredmoreoftenindry ordirtyconditions.)

1.Stopengine,waitforallrotatingpartstostopand removekey.Engageparkingbrake.

2.Allowenginetocool.

3.Rotateseatandenginecoverforward.

4.Whileholdingfanup,removethefourscrews attachingthefantotheshroud.Disconnectand removethefan.

5.Usingcompressedair,blowoutdebrisstuck betweenthensoftheentireradiator,bothfrom thetopdownandfromthebottomup.

6.Ifdebrisremains,itmaybenecessarytousewater fromalowpressurehose.Iftheradiatorisclean, proceedtostep

7.Covertheenginewithapieceofcardboard,ora plasticsheet.Squirtwaterdownthroughthens. Blowthroughwithlowpressureairfromboth directions.Ifdebrisremains,repeatuntilclean.

8.Re-assemblethefantotheradiator.Reconnect thefan.

9.Starttheenginetoensurethefanisfunctioning properly.

Page 48

Maintenance

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe machineandcuttingdeck,especiallyunderdeck beltshields,aroundthefueltank,aroundengine andexhaustarea.

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

Page 49

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO .

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

3.Ensurethedriveleversareintheneutral lockposition.

4.Batterydoesnothaveafullcharge.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

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“F AST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

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

6.Dirt,water,orstalefuelisinthefuel system.

6.ContactanAuthorizedServiceDealer.

7.Aircleanerisdirty.

7.Cleanorreplacetheaircleanerelement.

8.Seatswitchisnotfunctioningproperly.

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Electricalconnectionsarecorroded,loose orfaulty.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

Enginewillnotstart,startshard,orfailsto keeprunning

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe engineareplugged.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.V entholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

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

Enginelosespower

7.Dirt,water,orstalefuelisinthefuel system.

7.ContactanAuthorizedServiceDealer.

Page 50

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

3.Dirtyairlter.

3.Cleanorreplacetheaircleanerelement.

4.Coolantlevelislow .

4.Addcoolant.

5.Debrisonoraroundradiator.

Removedebris(seeCleantheRadiator sectioninMaintenance).

Engineoverheats.

6.W aterpumporalternatorbeltisworn, loose,orbroken.

6.ContactanAuthorizedServiceDealer.

1.Trackingneedsadjustment.1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

Mowerpullsleftorright(withleversfully forward)

3.Reverseindicatorandmotioncontrol linkageneedadjustment.

3.Adjustthereverseindicatorandthe motioncontrollinkage.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

2.Changethebelt.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

4.Replacethespring.

Machinedoesnotdrive

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

cooldown.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

front-to-rear.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

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

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley ,orblade pulley.

4.Tightentheappropriatepulley .

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

Abnormalvibration

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley .2.Checkbeltfordamage;replaceif

necessary.Installdrivebeltandcheckbelt guideforcorrectposition.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

pulley,idlerarmandspringforcorrect positionandfunction.

5.Brokenormissingidlerspring.

5.Replacethespring.

Bladesdonotrotate.

6.Clutchhasdisengaged.6.Enginehasoverheated;determinecause

ofoverheat(seeEngineoverheats).

Page 51

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.T emperatureisincreasingoncoolant temperaturegauge.

1.Turnunitoffandallowengineandengine componentstocool.

2.Coolantlevelislow .

2.Addcoolant.

3.Debrisonoraroundradiator.3.Removedebris.

Warningbuzzeremitscontinuousbeep.(See alsoEngineoverheats).

4.W aterpumporalternatorbeltisworn, looseorbroken.

4.ContactAuthorizedServiceDealer.

1.Oillevelislow .1.Checkoillevel.

Warningbuzzeremitsintermittentbeep.

2.Oilleakingfromengine.

2.ContactAuthorizedServiceDealer.

1.Fuseisblown.

1.Replacefuse.Checkcoilresistance, batterycharge,chargingsystem,and wiringconnectionsandreplaceif necessary.

2.Lowvoltagesupplyattheclutch.

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Damagedcoil.

3.Replaceclutch.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor electricalsystem.Cleanconnector contacts.

5.Rotor/armatureairgapistoolarge.

5.Removeshimorreplaceclutch.

Clutchwillnotengage.

6.Enginehasoverheated.

6.Determinecauseofoverheat(seeEngine overheats).

Page 52

Schematics

ElectricalDiagram

Page 53

Schematics

ElectricalSchematic

Page 54

Conditions and Products Covered

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

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

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine *

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

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

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

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

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-589_C

Page 55

Notes:

Page 56

Notes:

Page 57

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

Page 58

Page 59

G011841

Figure31

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan15degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

Page 60

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

PartNo.4500-919Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark LAZER Z D-SERIES, lazer Z DS series, LAZER Z LZD25KD605, LAZER Z LZD25KD725 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual