Exmark Lazer Z S 000 Higher, Lazer Z S 312, Lazer Z S User Manual

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LAZERZ®S-SERIES

ForSerialNos. 312,000,000&Higher LazerZ(LZS)Units

PartNo.4501-199Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered, orgrass-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

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Figure1

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

Ifadditionalinformationisneeded,orshould yourequiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com

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

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Contents

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

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

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

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

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

Specications........................................................16

ModelNumbers.............................................16

Systems..........................................................16

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

TorqueRequirements.....................................20

ProductOverview.................................................21

Operation..............................................................21

Controls.........................................................21

Pre-Start.........................................................24

OperatingInstructions...................................25

Transporting..................................................29

Maintenance..........................................................30

RecommendedMaintenanceSchedule(s)............30

PeriodicMaintenance........................................31

CheckEngineOilLevel..................................31

CheckMowerBlades......................................33

CheckSafetyInterlockSystem........................34

CheckRolloverProtectionsSystems(Roll

Bar)Knobs.................................................34

CheckSeatBelt...............................................35

CheckforLooseHardware.............................35

ServiceAirCleaner.........................................35

ChangeEngineOil.........................................35

CheckHydraulicOilLevel..............................35

CheckTirePressures......................................36

CheckConditionOfBelts...............................36

LubricateGreaseFittings................................36

LubricateDeckLiftPivot...............................37

CheckSparkPlugs..........................................37

ChangeHydraulicSystemFilterand

Fluid..........................................................38

WheelHub-SlottedNutTorque

Specication...............................................38

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

ThreadLockingAdhesives..............................39

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

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

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

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

PumpDriveBeltTension................................41

DeckBeltTension..........................................41

AdjustingtheParkingBrake............................41

ElectricClutchAdjustment.............................42

MotionControlLinkageAdjustment..............43

MotionControlDamperAdjustment..............44

MotionControlNeutralLockPivot

Adjustment................................................45

MotionControlHandleAdjustment...............45

MotionControlFullForwardTracking

Adjustment................................................45

CasterPivotBearingsPre-Load

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

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

CleanEngineandExhaustSystem

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

RemoveEngineShroudsandClean

CoolingFins...............................................47

CleanHydroFanCoolingFins........................47

CleanDebrisFromMachine...........................47

CleanGrassBuild-UpUnderDeck.................47

WasteDisposal...............................................47

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

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

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol( thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

SafetyAlertSymbol

Figure2)isusedbothin

Figure2

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.

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.

•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.

Safety

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

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengine oremissionsystem.

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Safety

CAUTION

Fueltankventislocatedinsidetheroll bartube.Removingormodifyingtheroll barcouldresultinfuelleakageandviolate emissionsregulations.

•DoNotremoverollbar.

•DoNotweld,drill,ormodifyrollbarin anyway .

•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erand enginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

•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,andsafetydevicesinplace andworkingproperly.

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

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhen makingturns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecaution whencrossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

Safety

•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).

(

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.

Safety

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.

•Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe 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.

•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.

•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.

•Carefullyreleasepressurefromcomponentswith storedenergy.

Safety

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagementof components.Sparkscouldcauseanexplosion ormovingpartscouldaccidentallyengage causingpersonalinjury.

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

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

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.

ForKohlerEFI(ElectronicFuelInjection)Units:

WARNING

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

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-633922

1-403005

98-5954

103-2076

Safety

109-7232

1.Fast3.Neutral

2.Slow

4.Reverse

109-7330

107-2102

109-3148

109-8483

AllUnitsExceptEFI

1.Throttle–fast3.Choke–on

2.Throttle–slow

4.Choke–off

DeckDriveBeltRouting

Safety

109-9361

116-0205

1.SeeOperator'sManual

116-0211

116-0090

116-0157

116-0752

1.Latch2.Unlatch

Safety

117–2718

116-1654

116-2643

116-5944

MessageDisplay

1.Fuel6.Hourmeter

2.Empty

116-2844

EFIUnitsOnly

1.Throttle–fast

2.Throttle–slow

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresence switch

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

116-3303

Safety

109-7069

Specications

ModelNumbers

SerialNos:312,000,000andHigher

LZS651KA484;LZS651KA484CA;LZS680KC524;LZS691KA524CA;LZS740KC524;LZS740KC604; LZS740KC604CA;LZS801KA724;LZS730EKC604;LZS749EKC724

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’ s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3750±50RPM(PTOnot engaged)Idle:1500+100/-250RPM

FuelSystem

•Capacity:

–AllUnitsExceptLZS730EKC604:12.0gal.

(45.4L)

–LZS730EKC604:8.0gal.(30.3L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher;containingnomorethan10% methanolorethanol.

•FuelFilter:

–Kohler:

KohlerP/N2405013

–Kawasaki:

KawasakiP/N49019-7005

–KohlerEFI:

KohlerP/N2505042

•FuelShut-OffValve:

AllUnits:1/4turnincrements(“ON”,“OFF”).

•Fuelleveleightsegmentdisplay—righthand controlpanel.

–KohlerandKawasaki:15amps

–KohlerEFI:20amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

Allunits:

–25ampmainfuse

–25ampchargingsystemfuse

–10ampPTOfuse

–15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearforthePTO ,parkbrake, drivelevers,andoperatorpresenceinthemessage displayontheRHcontrolpanel.

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

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

Specications

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engages/Disengages parkingbrake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

–Unlatchingposition:Deckdoesnotlatchat

thetransportposition.

Integratedseatswitch.Timedelayseatswitch eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

12ccParkeraxialpistonpump

240ccParkergerolermotor

•HydraulicOilType:ExmarkPremiumHydroOil.

•HydraulicOilCapacity:52oz(1.5L)perside

•HydraulicFilter:P/N116-0164

•Speeds:

–0-10mph(16.1km/hr)forward.

–0-5.5mph(8.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

TiresandWheels

Drive

Seat

•Type:Standardseatwithhighback,extra widefoampaddedseatcushionwithinternal suspension,thickbolstering,armrests,integral safetyswitch.

Optionalseataccessoriesforunitswithstandard seats:

–Customridesuspensionsystemtoenhance

StandardSeat.Addsapproximately3inches (7.6cm)toseatheight.

–Deluxesuspensionseatwithhighback,

(adjustablespringsuspension),armrests,and integralsafetyswitch.Addsapproximately 1/2inch(1.3cm)toseatheight.

–SeatIsolationSystemforreducedvibration,

toenhancerideofstandardseat,standardseat withCustomRideSeatSuspensionorDeluxe SuspensionSeat.Addsapproximately1inch (2.5cm)toseatheight.

•Mounting:Adjustableforeandaftonseattracks.

•Armrests:

–Standardseat:foampaddedadjustableip-up

armrests.

–Suspensionseat:foampaddedadjustable

ip-uparmrests.

•SeatSafetySwitch:

Pneumatic(Airlled)

DeckSize

Quantity

Tread

Size24x9.50-1224x12.00-12

PlyRating

Pressure

DeckSize

Quantity

Tread

Size13x5.00-6

PlyRating

Pressure

DeckSize

Quantity

Tread

48&5260&72

TurfMasterTurfMaster

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

48,52,&60(except LZS740KC604& LZS740KC604CA)

Smooth

N/A

72,LZS740KC604& LZS740KC604CA

Smooth

FrontCaster

Semi-Pneumatic

FrontCaster

Semi-Pneumatic

Specications

Size13x6.50-6

PlyRating

Pressure

N/A

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

–72inchDeck:(182.9cm)

•Discharge:Side

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•BladeSpindles:Solidsteelspindleswith1.00inch (25mm)I.D.bearings.

•DeckDrive:

Electricclutch:

•CuttingHeightAdjustment:

Footactivatedleverisusedtoadjustthecutting heightfrom1inch(2.5cm)to51/2inches(14 cm)in1/4inch(6.4mm)increments.

•MulchingKit:Optional.

Dimensions

OverallWidth:

48inchDeck52inchDeck

WithoutDeck45.7inches

(116.1cm)

DeectorUp51.8inches

(131.6cm)

DeectorDown59.6inches

(151.4cm)

60inchDeck72inchDeck

WithoutDeck53.0inches

(134.6cm)

DeectorUp62.5inches

(158.8cm)

DeectorDown72.8inches

(184.9cm)

45.7inches (116.1cm)

56.3inches (143.0cm)

64.8inches (164.6cm)

59.1inches (150.1cm)

73.5inches (186.7cm)

84.9inches (215.6cm)

–48and52inchDecks:“B”Sectionbeltwith

self-tensioningidler.

–60and72inchDecks:5VSectionbeltwith

self-tensioningidler.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport frame.Anti-scalprollersprovidemaximumturf protection.Deckdesignallowsforbagging, mulchingorsidedischarge.

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

–60inchDeck:4anti-scalprollers

–72inchDeck:6anti-scalprollers

•DeckDepth:

–48inchDeck:5.5inches(14cm)

–52inchDeck:5.5inches(14cm)

–60inchDeck:5.5inches(14cm)

OverallLength:

48inchDeck52inchDeck

RollBar-Up79.2inches

(201.2cm)

RollBar-Down80.9inches

(205.5cm)

60inchDeck72inchDeck

RollBar-Up83.1inches

(211.1cm)

RollBar-Down84.8inches

(215.4cm)

79.2inches (201.2cm)

80.9inches (205.5cm)

86.1inches (218.7cm)

87.8inches (223.0cm)

OverallHeight:

RollBar-UpRollBar-Down

70.5inches(179.1cm)46.8inches(118.9cm)

–72inchDeck:5.5inches(14cm)

Specications

TreadWidth:(CentertoCenterof Tires,Widthwise)

48inchDeck52inchDeck

DriveWheels36.2inches

(91.9cm)

CasterWheels32.8inches

(83.3cm)

60inchDeck72inchDeck

DriveWheels41.6inches

(105.7cm)

CasterWheels39.5inches

(100.3cm)

38.5inches (97.8cm)

32.8inches (83.3cm)

43.6inches (110.7cm)

47.1inches (119.6cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

48inch Deck

48.0inches (121.9cm)

52inch Deck

48.0inches (121.9cm)

60inch Deck

51.6inches (131.1cm)

72inch Deck

53.6inches (136.1cm)

CurbWeight:

48inch Deck

Kawasaki 651Units

Kawasaki 691Units

Kohler 680Units

Kohler EFI730 Units

Kohler 740Units

Kawasaki 801Units

Kohler EFI749 Units

1089lb (494kg)

—

——

—

———

52inch Deck

———

1066lb (484kg)

1088lb (494kg)

60inch Deck

——

1133lb (514kg)

72inch Deck

—

1208lb (548kg)

1191lb (540kg)

Specications

AccessoryWeightTableWorksheet:

Usethetablebelowtodetermineifextraweight isrequiredfortheunit.Identifytheaccessories andcorrectdecksizeandplacethecorresponding valuesintheAccessoryScorecolumn.IftheTotal AccessoryScoremeetsthefollowing,addthe recommendedweightkit.

Note:The72inchdeckdoesnotrequireaweightkit.

LightKit

Michigan Seat/CRSS

Bagger

Pneumatic CasterTires

MulchKit

StriperKit

OCD02-5

HitchKit

Sunshade Kit

48inch

Deck

1112

-3-4-5

-2

52inch

Deck

003

121

TotalAccessoryScore

-7

60inch

Accessory

Deck

-4

Score

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

BladeMountingBolt (lubricatewithanti-seize)

Anti-ScalpRollerNyloc NutSeeFigure18

Anti-ScalpRollerWhizlock NutSeeFigure18

EngineMountingBolts

(Kohler680&740)

(Kawasaki651&691)

(KohlerEFI)

(Kawasaki801)

WheelLugNuts

WheelMotorMounting Bolts

WheelHubSlottedNut211-260ft-lb

RolloverProtection System(RollBar)1/2 inchMountingBolts

Torque

130–160ft-lb(176-217 N-m)

50-60ft-lb(68-81N-m)

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

27-33ft-lb(37-45N-m)

17-23ft-lb(23-31N-m)

27-33ft-lb(37-45N-m)

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

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

(286-352N-m)

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

TotalAccessoryScoreRequiredWeightKit(s)

0–9

10–19

20andHigher*Two116-1173Undertoe

Nonerequired

*116-1173Undertoeboard mountweightkit

boardmountweightkitsor one116-1173Undertoe boardmountweightkit andone116-1238Front toeboardmountweightkit

*48and52inchunitsthatcomewithanundertoe boardweightasstandard,canaddanadditionaltoe boardweightforprimaryaccessoryweighting(scores 10-19);andfronttoeboardweightkitforsecondary accessoryweighting(scores20andhigher).Other unitsshouldinstallarstundertoeboardkitfor primaryaccessoryweighting(scores10-19);anda secondundertoeboardkitforsecondaryaccessory weighting(scores20andhigher).

ClutchRetainingBolt (securedwiththreadlocker)

HydroParkBrake CableAnchor1/2inch MountingBolt(secured withthreadlocker)

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

67-89ft-lb(91-121N-m)

Operation

ProductOverview

1.RolloverProtection System(ROPS)

2.EngineControls(right console)

3.Seatbelt

4.Motioncontrollevers

Figure4

5.Fuelcap

6.Heightofcutadjustment

7.Parkingbrake

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (Figure5).

Whenthemotioncontrolleversareintheneutral position,theLCDindicatorappearsinthemessage displayontheRHconsole(seeFigure8).

1.Neutrallockposition

2.Neutraloperateposition

3.FrontofUnit

Figure5

4.Forward

(handlesout)

5.Neutral(operate)

(handlesin)

6.Reverse

Operation

ChokeControl(AllUnitsExcept KohlerEFI)

Locatedonrightconsole(blacklever)(seeFigure6).

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

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

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

Figure6

RightConsole

1.Fuses

2.Messagedisplay5.Throttle

3.Ignitionswitch

4.PTOengagementswitch

6.Choke

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe RHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Figure7

1.Off3.Start

2.On

Note:Brakemustbeengaged,motioncontrol leversout(neutrallockposition)andPTOswitch disengagedtostartengine.(Itisnotnecessaryforthe operatortobeintheseattostarttheengine.)

HourMeter

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure8).

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Note:TheLCDindicatorappearsinthemessage displayontheRHconsolewhentheparkbrakeis engaged(seeFigure8).

Pulltheleverupandrearwardtoengagethebrake.

Figure8

Operation

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck,which couldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

1.LCDIndicators

2.Lowfuelindicatorlight

3.Fuellevelbardisplay

4.Lowvoltageindicatorlight

5.Hour/Voltagedisplay

Thehourmeterisrecordingwhenthedecimalpoint isashinginHour/Voltagedisplay.

Hoursaredisplayedwhenthekeyisofforwhenthe machineisrunning.

Note:Iftheignitionkeyisturnedtothe“ON” positionforafewsecondsbeforecrankingtheengine, thebatteryvoltagewilldisplayintheareawherethe hoursarenormallydisplayed.

Note:TheLCDindicatorsappearwheneachcontrol meetsthe“safetostart”mode(e.g.theindicator turnsonwhentheoperatorisintheseat.)

FuelShut-OffValve

WARNING

Theengineandhydraulicdriveunitscanbecome veryhot.T ouchingahotengineorhydraulic driveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrivewheel releasevalves.

Locatedonthebackoftheunitizedhydraulicdrive units,belowtheenginedeck.

Duringnormaloperatingconditions,thedrivewheel releasevalvesarepositionedhorizontally.Ifthe machinehastobepushedbyhand,thevalvesmust beinthe“released”position(seeFigure9).

Locatedbehindandbelowtheseat.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

FuelGauge

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure8).

Thefuellevelisshownonabardisplay.Theindicator lightappearswhenthefuellevelislow(approximately onegallonremaininginthetank).

Figure9

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure9), rotatethehandle1/4turntotheverticalposition untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2in

Figure9), rotatethehandle1/4turntothehorizontalposition untilithitsagainstthestop.

Operation

Note:Thehandlemustbehorizontalandagainst

thestopforoperation.

DoNottowmachine.

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isdisengaged(seeFigure8).

LowVoltageIndicator

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure8).

Alowvoltagecondition(lessthan12.3volts)exists whentheLCDindicatorappearsonthemessage displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

TransportLock

Figure10

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

ElectronicControlUnitMalfunction Indicator

KohlerEFIUnitsOnly:

Theelectroniccontrolunit(ECU)continuously monitorsoperationoftheEFIsystem.Ifaproblem orfaultwithinthesystemisdetected,themalfunction indicatorlight(MIL)isilluminated.TheMIListhe lightlocatedintherightconsolepaneltotherightof thethrottlecontrol.Followthetroubleshootingsteps outlinedintheKohlerengineoperator’smanualifthe MILisilluminated.

Pre-Start

Fillfueltankonlevelground.Forbestresultsuse onlyclean,freshregulargradeunleadedgasolinewith anoctaneratingof87orhigher.

Important:Neverusemethanol,gasoline containingmethanol,gasoholcontainingmore than10%ethanol,premiumgasoline,orwhite gasbecausethefuelsystemcouldbedamaged.

Locatedontheheightofcutadjustmentplatestothe rightoftheparkingbrake.

Positioninthetransportlatchingpositionto automaticallylatchthecuttingdeckwhenraisedto thetransportposition(seeitem1inFigure10).

Inthenon-latchingposition,thedeckwill automaticallyreturntothecuttingheightwhenthe pedalislowered(seeitem3inFigure10).

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

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

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

Operation

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Therollbarisanintegraland

effectivesafetydevice.Keeptherollbarinthe raisedandlockedpositionwhenoperatingthe mower.Lowertherollbartemporarilyonlywhen absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe tabsinterlockingasshownin therollbarintheraised,operateposition.

2.Applyforwardpressuretotheupperhoopofthe rollbar.

3.Pulltheknobandrotate90°toholdinthe unlatchedpositiontolowertherollbar.

4.Toreturntotheoperateposition,raisetheroll bar,andthenrotateknobs90°sothatthetabs interlockpartially.Applyforwardpressuretothe rollbarupperhoopandobservethattheknobs returntothecompletelylatchedposition.

Figure11tolock

pulledrearwardtogetbothknobsfullyengaged (seeFigure12).

Figure12

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

Important:Alwaysusetheseatbeltwiththe rollbarintheoperate(raised)position.Ensure thattherearpartoftheseatissecuredwiththe seatlatch.

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

StartingtheEngine

Figure11

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

5.Makesuretheknobsarefullyengagedwiththe rollbarintheraisedposition.Theupperhoopof therollbarmayneedtobepushedforwardor

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

5.Onacoldengine,pushthechokeleverforward intothe“ON”position(exceptKohlerEFIunits).

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

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

Operation

attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

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

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.PullthePTOswitchoutwardtoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

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

2.PushthePTOswitchintodisengagetheblades.

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.

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(

Note:The“N”LCDindicatorappearswhenboth leversareintheneutrallockposition.

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Figure13).

StoppingtheEngine

1.Bringtheunittoafullstop.

Figure14

Operation

Figure13

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

Figure15

Operation

Toturnright,releasepressureontheRHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheright.

Toturnleft,releasepressureontheLHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheleft.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from1to51/2inches(2.5cmto14cm)in1/4inch (6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Positionthetransportlockinthelatching position.

4.Raiseandlockthedecktothe51/2inch(14cm) transportposition(

Figure16).

Seethedecalonthesideofthedeckliftplatefor cutheights.

6.Pushthedeckliftpedal,releasethetransportlock andallowthedecktolowertothecuttingheight.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingthenylocnut, bushing,springdiscwasherandwhizlocknut.

6.Placetherollersinoneofthepositionsshown (Figure17).Rollerswillmaintain3/4inch(19 mm)clearancetothegroundtominimizegouging androllerwearordamage.

Thedeckisraisedbypushingthefootoperated deckliftpedalforward.Thepedalislocatedatthe frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure16

1.Deckfootpedal3.Heightofcutdecal

2.Heightadjustmentpin4.Transportlockcontrol

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Figure17

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Besurethewhizlocknutsareinstalledwiththe springdiscwasherbetweentheheadofthenut andthemountingbracket.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

Operation

8.Torquethe3/8–16whizlocknutto30-35ft-lb (41-47N-m)(Figure18).

9.Torquethe3/8nylocnutto30–35ft-lb(41-47 N-m).

Figure18

1.Springdiscwasher (conetowardsnut)

2.Frontrightanti-scalp bracketshown

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

4.3/8-16whizlocknut torqueto30-35ft-lb (41-47N-m)

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.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Aftertherst250hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Changethehydrauliclteranduid.

WARNING

Theenginecanbecomeveryhot.T ouchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Beforeeachuseordaily

Every50hours

Every100hours

Every200hours

Every250hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrofancoolingguards.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

•Checkthesparkplugs.

•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement;replaceif dirty.(Mayneedmoreoftenundersevereconditions.SeetheEngineOwner'sManualfor additionalinformation.)

Maintenance

MaintenanceService

Interval

Every500hours

Yearly

MaintenanceProcedure

•Replacethesecondaryaircleanerelement(Mayneedmoreoftenundersevereconditions. SeetheEngineOwner'sManualforadditionalinformation.)

•Changethehydrauliclteranduid.(Mayneedmoreoftenundersevereconditions.)

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Greasethedeckandpumpidlerpivots.

•Greasethefrontcasterpivots.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstick andwipeoiloff.Reinsertthedipstickaccording totheenginemanufacturer'srecommendations. Removethedipstickandreadtheoillevel.

4.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:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

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

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeterorwiththemessagedisplay.Iftheignition keyisturnedtothe“on”positionforafewseconds, thebatteryvoltagewillbedisplayedintheareawhere thehoursarenormallydisplayed.Locatethevoltage readingofthebatteryinthetableandchargethe batteryfortherecommendedtimeintervaltobring thechargeuptoafullchargeof12.6voltsorgreater.

Important:Makesurethenegativebatterycable isdisconnectedandthebatterychargerusedfor chargingthebatteryshouldhaveanoutputof 16voltsand7ampsorlesstoavoiddamaging thebattery(seechartforrecommendedcharger settings).ThisisespeciallyimportantonKohler EFI(ElectronicFuelInjection)units.Failureto dosomaydamagetheECU(ElectronicControl Unit).

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

Charging Interval

No Charging Required

30Minutes

1Hour

Maintenance

Voltage Reading

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

Maximum Charger Settings

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

2Hours

3Hours

6Hoursor More

Important:ForKohlerEFIunits:Unplugthe harnessfromtheECUbeforeperformingany weldingontheequipment.

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

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

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricaland/orEFIsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

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

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe engineorEFImayoccur.

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

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

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

Figure19.

Figure19

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

Maintenance

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

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

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK

Figure20).

(see

Figure21

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Makesurethesplinesonthebushingare engagedinthespindlebeforetighteningthe bolt.

Figure20

1.Engineblock

2.Negative(–)cable

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

Figure22

1.Usewrenchhereforbladeinstallation.Thisnuthas beentorquedto130–160ft-lb(176–217N-m)

2.Torqueto50-60ft-lb(68-81N-m)Applylubricantto threadsasneededtopreventseizing.Copper-based anti-seizepreferable.Greaseacceptablesubstitute.

Maintenance

C.Applylubricanttothreadsofbladeboltto

preventseizing.Copper-basedanti-seize preferable.Greaseacceptablesubstitute. Installbladeboltngertight.Placewrench onthetopspindlenutthentorquetheblade boltsto50-60ft-lb(68-81N-m).

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.

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)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe knobsareingoodworkingcondition.Makesurethe knobsarefullyengagedwiththeROPSintheraised position.Theupperhoopoftherollbarmayneed tobepushedforwardorpulledrearwardtogetboth knobsfullyengaged.

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).

Figure23

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

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:Every250hours—Replace

theprimaryaircleaner element—check secondaryaircleaner element;replaceifdirty. (Mayneedmoreoften undersevereconditions. SeetheEngineOwner's Manualforadditional information.)

Every500hours—Replace thesecondaryaircleaner element(Mayneedmore oftenundersevere conditions.Seethe

Maintenance

EngineOwner'sManual foradditionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.SeetheEngineOwner'sManualformaintenance instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseislocatedonrighthandside ofengineattherear.Placepanundermachine tocatchoil.Removeplugfromendofdrain hose.Allowoiltodrainandreplaceoildrainplug. Torqueplugto20-24ft-lb.

4.Replacetheoilltereveryotheroilchange.Clean aroundoillterandunscrewltertoremove. Beforereinstallingnewlter,applyathincoating ofExmark4–CyclePremiumEngineoilonthe surfaceoftherubberseal.Turnlterclockwise untilrubbersealcontactsthelteradapterthen tightenlteranadditional1/2to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

6.UseoilrecommendedintheCheckEngineOil Levelsection.DoNotoverll.Starttheengine andcheckforleaks.

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe hydraulicoil.

3.Slidetheseatalltheforwardtoaccessthecapson theLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand removecap.

Maintenance

5.Wipethedipstickcleanandre-insertthecapback intothehydro.Lightlytightenthecap.

6.Removethecapagainandcheckthelevelofthe oilonthedipstick.See

1.Full2.Add

Figure24foroillevels.

Figure24

Note:Theoillevelonthedipstickwillbe

incorrectiftheoilischeckedwhentheunitishot.

7.Ifthedipstickoillevelisatthe“add”markadd ExmarkPremiumHydroOil.

8.Replacehydraulicreservoircapandtightenuntil snug.DoNotovertighten.

2.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

3.Checkundermachinetoinspectthepumpdrive belt.

Note:Noadjustmentsarerequiredforbelt tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.Deckand PumpIdler Pivots

2.Front Caster Pivots

Initial

Pumps

Numberof

Places

Service

Interval

Yearly

*Yearly

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Semi-pneumaticcastertiresDoNotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

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

Maintenance

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure25

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthe spacernutstotheaxle.Removetheaxle(withthe otherspacernutstillassembledtoit)fromthe wheelassembly.

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.

LubricateDeckLiftPivot

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner's Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ForKohlerEFIUnits:

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

Maintenance

ReplacementFilters

Kohler

KawasakiKawasaki

KohlerEFI

Note:Itisimportanttoreinstallthefuellinehoses andsecurewithplastictiesthesameastheywere originallyinstalledatthefactorytokeepthefuelline awayfromcomponentsthatcouldcausefuelline damage.

KohlerP/N2405013

P/N49019-7005

KohlerP/N2505042

ChangeHydraulicSystem FilterandFluid

ServiceInterval:Aftertherst250hours

Every500hoursthereafter

Note:OnlyuseExmarkHydroFilter–PartNo.

116-0164forsummerorwinter.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

8.Installthenewltersandtorqueto14ft-lb(19 N-m).

9.FillthehydraulicsystemasstatedinCheck HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50Afterrst250hours

*Mayneedmoreoftenundersevereconditions.

10.Removethecatchpanandproperlydisposeof hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

12.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol leverstothefullspeedandrunforoneminute. Shutdownthemachine,allowthehydrostocool andrecheckoillevel.

13.Removethejackstands.

ServiceInterval

Afterrst250hours *Every500hours thereafter

*Every250hours thereafter

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem.

6.Usingasocket,unscrewlterstoremoveand allowoiltodrain.

7.Beforeinstallingthenewlters,applyathincoat ofExmarkPremiumHydroOilonthesurface ofthetworubberseals.

Note:DoNotchangethehydraulicsystemoil (exceptforwhatcanbedrainedwhenchanginglter), unlessitisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

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

Note:DoNotuseanti-seizeonwheelhub.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

Maintenance

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresult inpersonalinjuryorpropertydamage.

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:

•ROPSspringpinhousing.

•Hydropumpcontrolarm,linkagebolt,and attachmentbolt.

•Hydrocoolingfanscrew .

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof enginecrankshaft.

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.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper inationpressurefortiresis13psi(90kPa). Adjustifnecessary.

4.Positionthetransportlockinthelatching position.

5.Pushthefootpedalallthewayforwardandthe deckwilllatchatthe51/2inch(14cm)transport position(

Figure26).

Threadlockingadhesivesarerequiredforsome hardwareonengines—seetheEnginemanual.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact. Dielectricgreaseshouldnotbeappliedtosealed connectors.

Figure26

1.Footlever3.Transportlock

2.Heightofcutpin

6.Inserttheheightadjustmentpinintothe3inch (7.6cm)cuttingheightlocation.

Maintenance

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargedeector.

9.Measurefromthelevelsurfacetothefronttipof thecenterblade.Themeasurementshouldread 3inches(7.6cm).

Note:Inmostconditions,thebacktipsonthe sidebladesshouldbeadjusted1/4inch(6.4mm) higherthanthefront.

Figure28

1.Adjusterscrew2.Jamnut

11.Thebacktipsofthesidebladesshouldmeasure 31/4inches(8.3cm).Finetunerearadjusters asrequired.(Thesinglepointadjustmentcanbe utilizedtogainmoreadjustment.)

Figure27

1.31/4inches(8.3cm)4.3inches(7.6cm)

2.Backbladetip

3.Frontbladetip

5.Levelsurface

10.Finetunethefrontdeckliftassemblybyturning theadjusterscrewuntilitreachesthe3inch(7.6 cm)height(see

Figure28).Toincreasetheheight, turntheadjusterscrewclockwise;todecrease, turncounterclockwise.

12.Re-measureuntilallfoursidesarethecorrect height.Tightenallthenutsonthedeckliftarm assemblies.

13.Lowerdischargedeector.

14.Ifthefourdecklinksdonothaveenough adjustmenttoachieveaccuratecutheightwiththe desiredrake,thesinglepointadjustmentcanbe utilizedtogainmoreadjustment(seeFigure29).

Figure29

Maintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.This proceduremustbefollowedaftertherst100hours orwhenabrakecomponenthasbeenremovedor replaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey.

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

15.Toadjustthesinglepointsystem,rstloosenthe frontandrearheight-of-cutplatemountingbolts.

16.Ifthedeckistoolow,tightenthesinglepoint adjustmentboltbyrotatingitclockwise.If thedeckistoohigh,loosenthesinglepoint adjustmentboltbyrotatingitcounterclockwise.

Note:Loosenortightenthesinglepoint adjustmentboltenoughtomovetheheight-of-cut platemountingboltsatleast1/3thelengthof theavailabletravelintheirslots.Thiswillregain someupanddownadjustmentoneachofthe fourdecklinks.

17.Re-tightenfrontandrearheight-of-cutplate mountingbolts.

Important:Torquethefrontandrear height-of-cutplatemountingboltsto27-33 ft-lb(37-45N-m).

18.Repeatsteps

9through13.

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothe “released”position.RefertotheDriveWheel ReleaseV alvessectioninOperation.

8.Measuretheoveralllengthofthecompression spring.Thecorrectlengthshouldbebetween 11/2–19/16inches(3.8–4.0cm).Ifthespring lengthiswithinthisrange,noadjustmentis needed.Ifitisnot,proceedtostep9.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

9.Holdthethreadedrodendwithatoolandadjust thelocknutuntilthespringlengthisbetween 11/2–19/16inches(3.8–4.0cm)seeFigure30). DoNotallowthecabletoturnwhenthenutsare beingloosened.

Maintenance

Figure30

LeftHandBrakeShown

1.Cableanchor5.Caliper

2.Holdthreadedrodhere

3.Measure7.Threadedrod

4.Locknut8.Hub

10.Disengagetheparkbrake.Turnthewheelhub byhandinbothdirectionsrelativetothecaliper; nodragofthecaliperpadonthewheelhubis desired.

11.Ifthereisnomovementbetweenthehubandthe caliperthenrepeattheadjustment(driverelease valvesmustbeinthe“released”positiononthe hydros).

12.Afteradjustingthebrakesonbothsidesofthe mower,cyclethebrakehandleaminimumofsix timestoallowthecabletoseatintothesheath andmountingtabs.

13.Recheckthespringlength;engagetheparkbrake andrepeatsteps

8through11ifthelengthisnot

inthecorrectrange.

14.Rotatethedrivewheelreleasehandletothe “operating”position.RefertotheDriveWheel ReleaseV alvessectioninOperation.

15.Installthereartiresandtorquelugnutsto90-95 ft-lb(122-129N-m).

16.Removejackstands.

6.Compressionspring

longerengagesconsistently,theshimcanberemoved toextendtheclutchlife.

Figure31

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

Figure32).

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

ElectricClutchAdjustment

Noadjustmentnecessary.Howeverwhentheclutch brakehasworntothepointwheretheclutchno

Maintenance

G011733

Figure32

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.)

Figure34

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstep

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewith

thePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

1.Feelergauge

MotionControlLinkage Adjustment

Figure33

Locatedoneithersideofthefueltank,belowtheseat arethepumpcontrollinkages.Rotatingthepump linkagewitha1/2inchwrenchallowsnetuning adjustmentssothatthemachinedoesnotmovein neutral.Anyadjustmentsshouldbemadeforneutral positioningonly.

Maintenance

WARNING

Enginemustberunninganddrivewheelsmust beturningsoadjustmentscanbeperformed. Contactwithmovingpartsorhotsurfacesmay causepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift pedalandremovetheheightofcutpin.Lower decktotheground.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.Theswitchisapartoftheseat assembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

Figure35

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure36formountingoptions.

6.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulicoil uptooperatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengths byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse( controlleverstothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningor slightlycreepinreverse.

Figure35).Movethemotion

Figure36

RHMotionControlShown

1.Torquenylocnutto200in-lb(16.7ft-lb).Boltmust protrudepastendofnylocnutaftertorque.AT-40T orx bitwillbenecessarytoholdthestudfromturning.

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

MotionControlNeutralLock

Maintenance

MotionControlHandle Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

Figure38).

Figure38

PivotAdjustment

Theangednutcanbeadjustedtoobtainamore desiredmotioncontrolleverresistance(Figure37).

Figure37

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraft

Figure38.Tightenboth

boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

MotionControlFullForward TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthecoverplates.

1.Loosenthescrewsonacoverplate(seeFigure39).

Maintenance

2.Slidethecoverplatebackwardorforwardto adjustthetraveloftheleverandtightenthe screws.

3.Drivethemachineandcheckthefullforward tracking.

4.Repeatsteps1through3untildesiredtracking isobtained.

Figure39

RHMotionControlShown

Figure40

1.Springdiscwashers

1.Screw

2.Coverplate

3.Motioncontrollever

CasterPivotBearings Pre-LoadAdjustment

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

Figure40.

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea.

RemoveEngineShroudsand

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Slideseatallthewayforward.

3.Removeaccumulateddebrisfromthehydrofan coolingns.

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(51/2inch(14cm) cuttingheight)position.Liftthefrontofunit andsupportunitusingjackstandsorequivalent support.

CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean coolingns.Alsocleandust,dirtandoilfrom externalsurfacesofenginewhichcancause inadequatecooling.

3.Makesurecoolingshroudsarereinstalled. Operatingtheenginewithoutcoolingshroudswill causeenginedamageduetooverheating.

CleanHydroFanCooling Fins

ServiceInterval:Beforeeachuseordaily

Removingdebrisfromthehydrofancoolingnswill allowthehydrosystemtoruncoolerandimprovethe lifeofthehydrosystem.

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied

Maintenance

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.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank

Enginewillnotstart,startshard,orfailsto keeprunning

1.PTOisengaged.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

4.Batterydoesnothaveafullcharge.

5.Electricalconnectionsarecorroded,loose orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

8.Faultymodule.8.Replacemodule.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow .

4.Thethrottleandchokearenotinthe correctposition.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly.

9.Electricalconnectionsarecorroded,loose orfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.

13.Faultymodule.13.Replacemodule.

14.MILilluminatesandblinks14.ContactanAuthorizedServiceDealer

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral lockposition.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

11.Clean,adjustorreplacesparkplug.

12.Checkthesparkplugwireconnection.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Mowerpullsleftorright(withleversfully forward)

Machinedoesnotdrive

Unevencuttingheight.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.Dirt,water,orstalefuelisinthefuel system.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating” position.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

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

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

6.ContactanAuthorizedServiceDealer.

1.Positionhandlein“operating”position; seeDriveWheelReleaseValvessection inOperation.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration

Bladesdonotrotate.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

2.Deckbeltisoffpulley .2.Installbeltonclutchanddeckpulleys,

3.Brokenormissingidlerspring.

4.Drivebeltnotroutedcorrectly.4.Refertobeltroutingdecalondeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

idlers,andtensioningidlerperrouting decalondeck.

3.Replacethespring.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Clutchwillnotengage.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

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

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Replaceclutch.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Schematics

G016960

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

9 1 2 3 1 0 1 8 6 5 11 2 4 7

7 4 5 9 3 6 8 1 2

C A B

A B

26354

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—AllunitsexceptKohlerEFI

G017153

STARTER

ENGINE

INDICATOR

LED

MAIN HARNESS

RED

WHITE

BLUE

RED

BLACK

1 6 2 5 4 3

6 1 5 3 2 4

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

9 1 2 3 1 0 1 8 6 5 11 2 4 7

7 4 5 9 3 6 8 1 2

C A B

A B

26354

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

3. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—KohlerEFI

Schematics

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

REG

START

FUEL

SOLINIOD

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G008613

ElectricalLogicSchematic—AllunitsexceptKohlerEFI

ElectricalLogicSchematic—KohlerEFI

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

LAMP

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

ECU

REG

START

FUEL

SOLINIOD

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G012212

Schematics

HydraulicDiagram

General Warranty 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.

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.

Commercial Warranty Conditions

This warranty applies to Exmark Lazer Z X-Series, Lazer Z S-Series, and Vantage turf equipment sold in the U.S. or Canada for a period of three years for commercial usage.

This warranty includes the cost of parts and labor for a period of two years and the cost of parts for one additional year. This warranty does not cover pickup and delivery charges to and from any authorized Exmark Service Dealer.

Consumer Warranty Conditions

This warranty applies to Exmark Lazer Z X-Series, Lazer Z S-Series, and Vantage turf equipment sold in the U.S. or Canada for a period of five years or 750 hours (whichever occurs first) for residential usage.

Residential usage means use of the product on the same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty detailed above would apply.

This warranty only includes the cost of parts and labor. For the first warrantable service repair, Exmark will cover up to $45 for associated pick-up and delivery charges to and from any authorized Exmark Service Dealer. Additional transportation charges may apply, contact your Dealer for details.

Warranty Exceptions

 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.

Items and Conditions Not Covered

This warranty does not cover the following:

• 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 Lazer Z X-Series, Lazer Z S-Series, and Vantage Turf Equipment

3 Year Limited Commercial Warranty

5 Year or 750 Hours Limited Consumer Warranty

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MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

EXMARK 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

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT R IDING ACCESSORIES 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

*Some accessories and options not available for some models.

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

www.exmark.com

PartNo.4501-199Rev.A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

Exmark Lazer Z S 000 Higher, Lazer Z S 312, Lazer Z S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual