Exmark Lazer Z XP LZ27DD604, Lazer Z XP LZ27DD724 Operator's Manual

For Serial Nos.

510,000 & Higher

Part No. 103-7372 Rev. B

WARNING

POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating practices can result in serious

operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condition.
♦ Stop engine and wait for all moving parts to stop. Remove key

before adjusting, servicing, or performing maintenance.
♦ If mower deck becomes clogged, stop engine and wait for all

moving parts to stop. Remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts.
♦ Keep off mower unless seat platform is provided.
♦ Keep others off mower.

IMPORTANT

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

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regulation
of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual
become damaged or illegible, replace immediately. Replacements may be ordered
through the engine manufacturer.

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

i

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995
Program

If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or
the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as

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

6. Who pa ys for the pa rt
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

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

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

the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus® shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.

®

order, he contacts Exmark by

3:00 p.m., central time, with an Exmark Parts Plus

®

order of six (6) line items or less.

requested by distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping
charges, where applicable.

accordance to the program.

and freight if it fails to arrive overnight in accordance to the program?

®

1. The dealer not submitting the Exmark Parts Plus

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating
Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus
service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to
many areas of the continental United States and can be requested for an overnight shipment on Friday to be
delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the
purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark
Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or
less. Exclusions from the Exmark Parts Plus

®

Program are: Any wholegood or accessory in its entirety, engines
and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic
wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight
restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS
next day or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can
be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program

®

order

- ii -

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

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety
instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong
the life of your mower, maintain its maximum efficiency, and promote safe operation.

If additional information is needed, or should you require trained mechanic
service, contact your authorized Exmark equipment dealer or distributor.

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

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

- iii -

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Ale rt Symbol...............................................................................1

1.2 Trainin g.................................................................................................1

1.3 Preparation........................................................................................ 1-2

1.4 Operation.......................................................................................... 3-6

1.5 Maintenance & Storage..................................................................... 6-7

1.6 Safety Sign s.................................................................................... 8-10

2. SPECIFICATIONS

2.1 Model Numb e rs...................................................................................11

2.2 Engine.................................................................................................11

2.3 Fuel System........................................................................................11

2.4 Electrical System.................................................................................11

2.5 Cooling System...................................................................................11

2.6 Operator Con trols...........................................................................11-12

2.7 Seat.....................................................................................................12

2.8 Hydrostatic Ground Drive System........................................................12

2.9 Tires & Wheels....................................................................................12

2.10 Cutting Deck...................................................................................12-13

2.11 Dimensions..........................................................................................13

2.12 Torque Requirements .........................................................................13

3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate Mower....................................................................................14

3.2 Install Rollover Protection System (Roll Bar)..................................14-15

3.3 Install Drive Wheels.............................................................................15

3.4 Check Tire Pressure............................................................................15

3.5 Service Battery

3.6 Install Motion Control Levers...............................................................17

3.7 Position Discharge Chute....................................................................17

3.8 Service Engine ....................................................................................17

3.9 Service Engine Coolant..................................................................17-18

3.10 Service Hydraulic Oil........................................................................... 18

..............................................................................15-16

4. OPERATION INSTRUCTIONS

4.1 Controls..........................................................................................18-22

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

4.3 Mowing...........................................................................................22-23

4.4 Transporting...................................................................................23-25

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance.....................................................................25-36

5.2 Adjustments....................................................................................36-43

6. WASTE DISPOSAL

6.1 Motor Oil Di sp o s a l...............................................................................44

6.2 Engine Coo l a nt Disposal.....................................................................44

6.3 Mercury Sw itch Disposal.....................................................................44

6.4 Battery Disp o s a l..................................................................................45

7. TROUBLE SHOOTING .....................................................................

8. ELECTRICAL DIAGRAMS

9. HYDRAULIC DIAGRAM
10

.

WARRANTY

................................................................................................50

..........................................................................48

..............................................................................49

45-47

- iv -

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This
symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering/Red background. Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or serious injury.

WARNING: Black lettering/Orange background. Indicates a potentially hazardous situation

which, if not avoided, COULD result in death or serious injury.

CAUTION: Black lettering/Yellow background. Indicates a potentially hazardous situation

which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

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

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

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

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

1.3 PREPARATION

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

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

CAUTION

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

dBA at the operator’s ear when in operation.

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

extended periods of time can cause hearing loss.

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

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

- 1 -

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

POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.

WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.

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

where dangerous carbon monoxide fumes can collect.

POTENTIAL HAZARD
♦ In certain conditions gasoline and diesel fuel are

flammable and can be highly explosive.

WHAT CAN HAPPEN
♦ A fire or explosion from gasoline or diesel fuel can

burn you, others, and cause property damage.

WARNING

DANGER

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

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

♦ Refuel only outdoors.
♦ Store fuel in an approved container and keep it out of

the reach of children.

♦ Add fuel before starting the engine. Never remove the

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

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

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

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

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

♦ Do not operate without entire exhaust system in place

and in proper working condition.

- 2 -

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

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

WARNING

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

extremely hot.

WHAT CAN HAPPEN

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

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

touching.

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

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

WARNING

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

entangled in rotating parts.

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

or severe lacerations.

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

safety devices in place and working.

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

rotating parts.

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

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

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

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

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction
and/or tip-over could occur. The operator is responsible for safe operation on
slopes.

- 3 -

DANGER

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

loss of control.
WHAT CAN HAPPEN
♦ Wheels dropping over edges, ditches, steep banks, or

water can cause rollovers, which may result in serious

injury, death or drowning.
HOW TO AVOID THE HAZARD

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

• See inside the back cover to determine the approximate slope angle of the

area to be mowed.

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

Figure 1

SAFE ZONE FOR MOWING

• Progressively greater care is needed as the slope increases.

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

disengage the blades and proceed slowly off the slope.

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

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

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

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

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

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

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

1.4.5 A Rollover Protection System (roll bar) is installed on the unit.

- 4 -

WARNING

POTENTIAL HAZARD
♦ There is no rollover protection when the roll bar is down.

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

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

HOW TO AVOID THE HAZARD
♦ Keep the roll bar in the raised and locked position and use

seat belt.

♦ Lower the roll bar only when absolutely necessary.
♦ Do not wear seat belt when the roll bar is down.
♦ Drive slowly and carefully.
♦ Raise the roll bar as soon as clearance permits.

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

rolls into ponds of water.

• Check carefully for overhead clearances (i.e. branches, doorways, and
electrical wires) before driving under any objects and do not contact them.

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

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

1. 4. 8 Never operate the mower with damaged guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper
working condition.

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

1. 4. 10 Disengage PTO before starting engine.

1.4.11 Start

1. 4. 12 Keep hands, feet, and clothing away from rotating parts while the mower is being

1. 4. 13 Stop engine, wait for all moving parts to stop, and remove key:

• Before checking, cleaning, or working on the mower.

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

• Before clearing blockages.

• Whenever you leave the mower.

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

1.4.14 Before stopping the engine, move the throttle control to the “SLOW” position.

1. 4. 15 The fuel system is provided with a shut-off valve. Shut off the fuel:

1. 4. 16 This mower was designed for one operator only. Keep all others away from

the engine carefully with feet well away from the blades.

operated.

repairs before restarting and operating the mower).

• Before refueling.

• Before dumping the grass catcher.

Keep on running at idle for a short time, (approximately one minute) then stop the
engine.

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

• During transport to and from the job.

• When parked inside a building.

mower during operation.

- 5 -

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

1. 4. 18 Be Aware of the mower discharge and direct discharge away from others.

1.4.19 DO NOT operate the mower under the influence of alcohol or drugs.

1. 4. 20 Use extra care when approaching blind corners, shrubs, trees or other objects
that may obscure vision.

1.4.21 If jump starting is required:

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

battery to the positive post on the battery.

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

booster battery to the engine block as far away from the battery as possible.

c) disconnect batt ery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

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

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

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

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

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

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

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

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

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

1.5.9 Check all bolts freq uently to maintain proper tightness.

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

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

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

- 6 -

POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrate

skin and cause injury.

WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin must be

surgically removed within a few hours by a doctor
familiar with this form of injury or gangr ene may result.

HOW TO AVOID THE HAZARD
♦ Make sure all hydraulic fluid hoses and lines are in

good condition and all hydraulic connections and
fittings are tight before applying pressure to hydraulic
system.

♦ Keep body and hands away from pinhole leaks or

nozzles that eject high pressure hydraulic fluid.

♦ Use cardboard or paper and not hands to find

hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic system, by

placing the motion control levers in neutral and
shutting off the engine, before performing any work on
the hydraulic system.

WARNING

POTENTIAL HAZARD

♦ Engine coolant is hot and pressurized.
♦ Radiator and surrounding parts are hot.

WHAT CAN HAPPEN
♦ Spray or steam from hot, pressurized liquid in the

engine cooling system or touching a hot radiator may
cause severe burns.

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

the radiator cap or servicing any component of the
cooling system.

POTENTIAL HAZARD
♦ Engine coolant is toxic.

WHAT CAN HAPPEN
♦ Swallowing coolant can cause poisoning.

HOW TO AVOID THE HAZARD

♦ Do not swallow
♦ Keep out of reach of children and pets.

WARNING

CAUTION

- 7 -

1.6 SAFETY SIGNS

1. 6. 1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety
signs and instructional labels.

1. 6. 2 Saf ety signs must be replaced if they are missing or illegible.

1. 6. 3 When new components are installed, be sure that current safety signs are affixed
to the replaced components.

1. 6. 4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or from Exmark Mfg. Co. Inc.

1. 6. 5 Saf ety signs may be affixed by peeling off the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

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

PART NO. 103-3794
LOCATION: LH Side of Console

PART NO. 103-3979
LOCATION: RH Side of Console

PART NO. 103-5455
LOCATION: Top Front of RH

Fuel Tank

PART NO. 103-3679
LOCATION: Right of Throttle

Control on RH
Fuel Tank

PART NO. 1-303508
LOCATION: RH Side on Top

Rear of Mower Deck

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

Belt Shields, Left and
Right Sides

Type A Anti-Scalp Rollers –
See Figure 12
PART NO. 1-323540
LOCATION: Left Rear Corner
Top of Mower Deck

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

- 8 -

DO NOT OPERATE
WITHOUT GUARD

IN PLACE.

PART NO. 1-513748
LOCATIONS: Bottom Side

1-513748

of Floorpan

PART NO. 1-513746
LOCATION: Rear RH Side of

Engine Deck

PART NO. 1-633313
LOCATION: RH Side on Top
Front Mower Deck

PART NO. 1-643222
LOCATION: Left of Center on Mower

Deck, Under Floor Pan

PART NO. 103-1636
LOCATION: Top of Fuel

Tanks

PART NO. 1-633706

LOCATION: LH Side of Cutting

Height Adjustment Plate

PART NO. 1-523552
LOCATION: Top of Hydraulic

Reservoir

PART NO. 1-633922
LOCATION: Front Center on

Top of Mower Deck

PART NO. 1-643401
LOCATION: On Tilt Switch

PART NO. 103-0261
LOCATION: RH Front of

PART NO. 1-643253
LOCATION: LH and RH Sides of Radiator Mount Plate

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

next to Stiffener

- 9 -

Console

PART NO. 103-0223
LOCATION: LH Side on Top of

Radiator

PART NO. 103-5881
LOCATION: Engine Access Panel
Behind the Seat

p

For Units with S/N 465,000 and Higher
PART NO. 103-6320
LOCATION: Bottom Side of Floorpan

PART NO. 107-2102
LOCATION: Inside Surface of

PART NO. 103-3276
LOCATION: Engine Access Panel

behind seat, LH Side
next to Buzzer

PART NO. 107-2112
LOCATION: Top Center of

Floorpan

Upper Roll bar

PART NO. 103-1596
LOCATION: Center Inside of the

Rear Bumper

PART NO. 103-5304
LOCATION: Engine Access Panel Behind Seat

PART NO. 103-5200
LOCATION: Top of console

PART NO. 103-2076
LOCATION: Top of Radiator Trim

Plate, LH & RH Sides

PART NO. 98-5954
LOCATION: - Under LH and RH Belt Shields

- Radiator Fan Pump Idler Arm

- On Engine Belt Guard behind Seat

-On Pum

Mounting Plate behind Seat

- 10 -

2. SPECIFICATIONS

2.1 MODEL NUMBER:

LZ27DD604; LZ27DD724

2.2 ENGINE:

2. 2. 1 Engine Specifications: See your Engine Owner’s Manual

2.2.2 RPM: Full Speed: 3850 RPM (No Load) Idle: 1750 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity: 15.5 gal. (56.8 L.)

2.3.2 Type of Fuel: Diesel fuel, 40 cetane or higher

2. 3. 3 Fuel Filter: Replaceable Canister -10 micron
Briggs & Stratton P/N 820311

2. 3. 4 Fuel Shut-Off Valve: 1/4 turn increments
(Left tank, Ri ght tank, “OFF”)

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: External Alternator

2. 4. 2 Charging Capacity: 40 Amps

2. 4.3 Battery Type: BCI Group Size 26

2. 4. 4 Batt ery Voltage: 12 Volt

2. 4. 5 Polarity: Neg at ive Ground

2.4.6 Fuses: One 40 amp and one 20 amp blade type

2.4.7 Safety Interlock System:
PTO must be disengaged, brake engaged, and motion control levers out

(neutral lock) to start engine. (It is not necessary for the operator to be in the
seat to start the engine.)

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

motion control levers are moved in or engine will stop.

Engine will stop if either the left, the right, or both levers are moved from neutral

lock position while brake is engaged.

Note: Do not use kerosene or gasoline instead of diesel fuel.

Failure to observe this caution will damage the engine.

2. 4. 8 Tilt Switch: Shuts off the engine when the unit is tilted more than 60° from
horizontal.

2.5 COOLING SYSTEM

2.5.1 Fan: Hydraulic, continuous operation with engine running

2. 5. 2 Coolant Liq uid: 50/50 mix of Dex-Cool © extended life antifreeze and water.

2. 5. 3 Coolant Capacity: 2 gallons (7.6 L)

2.6 OPERATOR CONTROLS

2. 6. 1 Steering and Motion Control:

Separate levers, on each side of the console, control speed and direction of

travel of the respective drive wheels.

St eer ing is controlled by varying the position of the levers relat ive to each other.
Moving motion control levers outward
NOTE: Motion control levers are adjustable to two heights.

2. 6. 2 PTO Engagement Switch
mower blades.

(in slots) locks the drive system in neutral.

: Engages electric clutch (to drive belts) which engage

- 11 -

2. 6. 3 Parking Brake Lever: Engag es parking brake.

2. 6. 4 Deck Height Adjustment Lever

: Sets cutting height to desired position.

2. 6. 5 Deck Lift Assist Lever: Foot pedal that assists in raising the deck.

2.7 SEAT

2. 7. 1 Type: Deluxe suspension seat with high back, low profile foam-in-place cushion
(dampened, adjustable spring suspension) and armrests.

2. 7. 2 Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other
components. Held in tilted position with prop rod. Adjustable fore and aft seat track.

2. 7. 3 Armrests: Molded adjustable flip-up

armrests.

2.7.4 Seat Safety Switch: Incorporated into the Safety Interlock System. Time delay
seat switch eliminates rough ground cut-outs.

2.8 HYDROSTATIC GROUND DRIVE SYSTEM

2. 8. 1 Hydrostatic Pumps: Two Hydro Gear BDP-21L variable displacement piston pumps.

2. 8. 2 Wheel Motors: Two Parker/Ross with 1 1/4” tapered shafts.

2. 8. 3 Hydraulic Oil T ype: Synthetic Mobil 1 15W-50.

2. 8. 4 Hydraulic Oil Capacit y: 4 qt. (3.8 L.)

2. 8. 5 Hydraulic Filter: Replaceable cartridge type.

P/N 103-2146: 25 microns, No bypass

2. 8. 6 Speeds: 0 - 12.0 mph (19.3 km/hr) forward.

0 – 8.0 mph (12.9 km/hr) reverse.

2. 8. 7 Drive wheel release valves allow machine to be moved when engine is not running.

2.9 TIRES AND WHEELS

2.9.1 Tires
Pneumatic (Air-Filled)

Drive Front Caster

Semi-Pneumatic

Quantity 2 2
Tread Multi-Trac C/S Smooth
Size 26 x 12.0-12 13 x 6.50-6
Ply Rating 4
Pressure 10 psi (69 kPa)

2.10 CUTTING DECK

2. 10. 1 Cutting Width: 72 in. (182.9 cm)
60 in. (152.4 cm)

2. 10. 2 Discharge: Side

2. 10. 3 Blade Size: (3 each) w/60” Deck 20.5 in. (52.1 cm)
w/72” Deck 24.5 in. (62.2 cm)

2. 10. 4 Blade Spindles: Solid steel spindles with 1” I.D. bearings.

2. 10. 5 Deck Drive: Electric clutch mounted on horizontal engine shaft. 2 – “A” Section
belts (with self-tensioning idlers) from electric clutch to transfer shaft mounted on
deck.

Blades ar e driven by one “B” Section belt (w/self-tensioning idler ) from transfer

shaft on deck to blade spindles.

2. 10. 6 Deck: Full floating deck is attached to out-front support frame. Six anti-scalp
rollers provide maximum turf protection. Deck design allows for bagging, mulching
or side discharge.

2.10.7

Deck Depth: 5.5” (14.0 cm)

- 12 -

2. 10. 8 Cutting Height Adjustment: an extr a-long cushioned lever is used to adjust the
cutting height from 1 1/2” (3.8 cm) to 5” (10.2 cm.) in 1/4”(6.4 mm) increments.
The cutting height adjustment handle has a transport position and all adjustments
can be made while the operator remains seated. Units also have a foot operated
deck lift assist lever to aid in raising the deck.

2. 10. 9 Mulching Kit : O ptional.

2.11 DIMENSIONS

2.11.1 Overall Width:

60” Deck 54.5 in. (138.4 cm) 61.4 in. (156.0 cm) 72.2 in. (183.4 cm)
72” Deck 58.5 in. (148.6 cm) 73.2 in. (185.9 cm) 84.3 in. (214.1 cm)

without deck deflector up deflector down

2.11.2 Overall Length:

60” Deck 82.2 in. (208.8 cm) 92.3 in. (234.4 cm)
72” Deck 86.0 in. (218.4 cm) 96.1 in. (244.1 cm)

Roll Bar – Up Roll Bar - Down

2.11.3 Overall Height:

60” Deck 73.7 in. (187.2 cm) 55.6 in. (141.2 cm)
72” Deck 73.7 in. (187.2 cm) 55.6 in. (141.2 cm)

Roll Bar - Up Roll Bar - Down

NOTE: Height will vary slightly depending on seat setting

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

Drive Wheels Casters
60” Deck 42.8 in. (108.7 cm) 38.9 in. (98.8 cm)
72” Deck 46.8 in. (118.9 cm) 47.6 in. (120.9 cm)

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

60” Deck 54.0 in. (137.2 cm)
72” Deck 56.8 in. (144.3 cm)

2.11.6 Curb Weight:

60” Deck 1639 lbs. (743 kg)
72” Deck 1657 lbs. (752 kg)

2.12 TORQUE REQUIREMENTS

Bolt Location

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

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

Jack Shaft Spindle Nut................................................... 75-80 ft-lbs. (102-108 N-m)

Engine Deck/Front Frame Mount ................................... 30-35 ft-lbs. (41-48 N-m)

Anti-Scalp Roller (See Figure 12)

Type A – Whizlock Nut.......................................... 40-45 ft-lbs. (54-61 N-m)

Type B – Nyloc Nut................................................ 30-35 ft-lbs. (41-47 N-m)

Type B – Hex Capscrew........................................ 50-55 ft-lbs. (68-75 N-m)

Starter Mounting Bolts (M10).......................................... 22-27 ft-lbs. (30-37 N-m)

Water Separator Mounting Bolts (M8)............................ 11-14 ft-lbs. (15-19 N-m)

Hydraulic Oil Filter Head Mounting Bolts (M6)................ 60-72 in-lbs. (7-8 N-m)

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

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

Wheel Hub Slotted Nut................................................... minimum125 ft-lbs. (169 N-m)

Rollover Protection System (Roll Bar) Mounting Bolts.... 30-35 ft-lbs. (41-47 N-m)

Clutch Retaining Bolt (secured with threadlocker).......... 55-60 ft-lbs. (75-81 N-m)

- 13 -

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE MOWER

3.2 INSTALL ROLLOVER PROTECTION SYSTEM (ROLL BAR)

3. 2. 1 Disassemble roll bar from the crate.

a) Remove roll bar tubes from sides of crate and remove screws that attach the

wheel hub retaining plate to the bottom of the crate.

b) Remove the two brackets used to mount the bottom of the upper roll bar tube

to the crate. Remove the 1/2-13 x 3 1/4 capscrews and 1/2-13 hex flange
lock nuts from the two brackets at each end of the upper roll bar tube and
retain for later use.

3. 2. 2 Raise the rear of the unit and support it with jack stands or equivalent support.

POTENTIAL HAZARD
♦ Raising the rear of the unit for assembly relying solely

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

support or may malfunction allowing the unit to fall,

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

for support. Use adequate jack stands or equivalent

support.

3. 2. 3 Remove the wheel nuts from both sides of the unit and retain for later use.

3.2.4 Install the two lower roll bar tubes.
a) Locate the left and right lower roll bar tubes.
b) Align lower roll bar tubes along the rear engine frame as shown in Figure 2.
c) LOOSELY install lower roll bar hardware (four 3/8-16 x 1 capscrews, four

spring disk washers and four 3/8-16 whizlock nuts) from the bolt bag to the
tubes on each side as shown in Figure 2.

NOTE: Be sure the spring disk washer cone is installed towards the head of

the capscrew.

LOWER ROLL BAR INSTALLATION

3.2.5 Install the upper u-shaped section of the roll bar. (Reference Figure 3 for
alignment and installation instructions below):

CAUTION

FIGURE 2

- 14 -

a) Locate the latch pin assemblies (pin and hairpin connected with a lanyard).
b) Install a 1/2-13 x 3 1/4 capscrew in the washer on the lanyard of each pin assembly.
Note: Make sure the bent tab in the washer is towards the head of the bolt.

b)

Lightly oil the inside surfaces of the ear-shaped plates at the upper end of the
lower roll bar tubes.

c) Locate the upper u-shaped section of the roll bar. Install the upper roll bar

section using the two 1/2-13 x 3 1/4 capscrews from step b and two 1/2-13 hex
flange lock nuts. Do not over tighten. Make sure upper roll bar can pivot freely.

Notes:

• Make sure the capscrew and nuts are installed with the nut to the inside of

the roll bar.

• Make sure the tab on the lanyard washer is installed as shown and points

toward the front of the unit.

d) Raise the roll bar into the upright position and secure with the latch pin

assemblies on each side. Install the latch pin from the outer surface of the
roll bar assembly and secure with the hairpin to the inside.

e) Tighten the front knobs against the upper roll bar ends.

f) Torque all lower roll bar hardware attached to the machine frame to 30-35 ft-

lbs. (41-47 N-m).

FIGURE 3

UPPER ROLL BAR INSTALLATION

3.3 INSTALL DRIVE WHEELS

3. 3. 1 Mount drive wheels with the valve stem to the outside of the unit. Secure using
four (4) 1/2-20 wheel nuts (removed in step 3.2.3) for each wheel. Torque to 95
ft-lbs (128 Nxm). Lower the unit from jackstands.

3.4 CHECK TIRE PRESSURE.

3.4.1 Check tire pressure in drive tires. Proper inflation pressure for tires is 10 psi (69
kPa). Adjust if necessary.

Semi-pneumatic caster tires do not need to be inflated.

3.5 SERVICE BATTERY.

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

to the State of California to cause cancer and reproductive harm. Wash hands after handling.

The machine is shipped with a filled lead acid battery.

.

- 15 -

3.5.1 Tilt seat up to gain access to the battery.

DANGER

POTENTIAL HAZARD
♦ Charging the battery may produce explosive gases
WHAT CAN HAPPEN
♦ Battery gases can explode causing serious injury.
HOW TO AVOID THE HAZARD

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

enclosed space.

♦ Make sure venting path of battery is always open once

battery is filled with acid.

3. 5. 2 Check the voltage of the battery with a digital voltmeter. Locate the voltage reading
of the battery in the table below and charge the battery for the recommended time
interval to bring the charge up to a full charge of 12.6 volts or greater.

IMPORTANT: When charging the battery, make sure the negative battery

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

Voltage

Reading

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

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

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

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

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

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

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

for sparks and engagement of components.

WHAT CAN HAPPEN
♦ Sparks could cause an explosion or moving parts

could accidentally engage causing personal injury.

HOW TO AVOID THE HAZARD
♦ Be sure ignition switch is in the “OFF” position before

charging the battery.

3. 5. 3 Connect the negative battery cables.

NOTE: If the positive cable is also disconnected, connect the positive (red) cable

to the positive terminal on the battery first, then connect the negative (black) cable
to the negative terminal. Slip insulator boot over the positive terminal.

NOTE: If time does not permit charging the battery, or if charging equipment is

not available, connect the negative battery cables and run the vehicle
continuously for 20 to 30 minutes to sufficiently charge the battery.

Percent

Charge

Maximum

Charger Settings

CAUTION

Charging Interval

- 16 -

3.6 INSTALL MOTION CONTROL LEVERS

3.6.1 Loosen and remove the two (2) 3/8”x1” bolts and spring disk washers which attach
the motion control levers to the control arm shafts for shipping and the two (2) 3/8”
x 1” bolts and spring disk washers which are screwed into the control arm shafts.

a) Install the left motion control lever onto the control arm shaft (See Figure 5) on

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

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

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

If the levers do not align with each other when in the neutral position (See Figure

6), loosen the hardware and make the appropriate adjustment by sliding/tilting the
lever(s) forward or backward until properly aligned and tighten hardware.

MOTION

CONTROL

LEVER

MOUNT PLATE TO

THE REAR & OUTSIDE

OF ARM SHAFT

FIGURE 5 FIGURE 6

CONTROL ARM SHAFT LEVER ALIGNMENT

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

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

LEVERS IN

ALIGNMENT

3.7 POSITION DISCHARGE CHUTE.

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

3.8 SERVICE ENGINE.

Engine is shipped with oil; check oil level and if necessary and fill to the

appropriate level with oil as specified in Engine Owner’s Manual.

3.9 SERVICE ENGINE COOLANT

Machine is shipped filled with engine coolant.

- 17 -

POTENTIAL HAZARD

♦ Engine coolant is hot and pressurized.
♦ Radiator and surrounding parts are hot.

WHAT CAN HAPPEN
♦ Spray or steam from hot, pressurized liquid in the

engine cooling system or touching a hot radiator may

cause severe burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before removing

the radiator cap or servicing any component of the

cooling system.

WARNING

POTENTIAL HAZARD
♦ Engine coolant is toxic.

WHAT CAN HAPPEN
♦ Swallowing coolant can cause poisoning.
HOW TO AVOID THE HAZARD

♦ Do not swallow
♦ Keep out of reach of children and pets.

With machine on level surface and with cool engine, remove radiator cap (under

hood) and add a 50/50 mix of water and Dex-Cool© extended life coolant until liquid
level is as high as possible without overflowing. Reinstall radiator cap, making sure
that the cap is completely seated by pressing down firmly while turning until the cap
stops. Add 50/50 coolant mix to overflow bottle on the left side of the engine as
required to bring the level up to the indicator line on the bottle.

NOTE: Units should only be filled with Dex-Cool© extended life coolant, which can

be identified by its orange color.

CAUTION

3.10 SERVICE HYDRAULIC OIL

NO TE: The baffle has two levels. The upper level represents the “HOT” level and

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

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

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4. 1. 2 Motion Control Levers: Located on each side of the console. The left lever

4.1.1 Familiarize yourself with all controls befor e operating the mower.

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

- 18 -

IMPORTANT: To begin movement (forward or backward) the operator must

be in the seat, the brake lever must be disengaged (pushed down) before
the motion control levers can be moved in or the engine will kill.

When levers are centered in the T-slot the drive system is in the neutral position.

With levers moved out in the T-slot the drive system is in the neutral lock
position (See Figure 7).

FIGURE 7

MOTION CONTROL POSITIONS

By moving both levers an equal amount forward or back from the neutral position

the machine can be caused to move forward or backward in a straight line.

Movement of the left lever forward will cause the left drive wheel to rotate in a

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

To turn left while moving forward, move the left lever back toward neutral to

slow the left drive wheel.

To turn right while moving forward, move the right lever back toward neutral to

slow the right drive wheel.

To make a zero turn to the left, pull the left lever back beyond neutral while

holding the right lever slightly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutral while

holding the left lever slightly ahead of neutral.

Pulling the levers back from the neutral position will cause the respective drive

wheels to rotate in a reverse direction (spring tension can be felt when moving
into reverse from neutral).

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

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

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

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

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

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

4. 1. 3 Tracking Adjustment Knob: Located under the seat on the LH pump control link.
Rotating this knob allows fine tuning adjustments so that the unit tracks straight
with the drive levers in the full forward position.

CAUTION

- 19 -

Stop machine and wait for all moving parts to stop. Engage park brake. Tilt seat

forward to gain access to the tracking knob. Rotate the knob clockwise (as
viewed from the rear of the machine) to cause the machine to track more to the
right and counterclockwise to cause the machine to track more to the left. Adjust
in quarter-turn increments until the machine tracks straight. Check that the
machine does not creep when in neutral with the park brakes disengaged.

IMPORTANT: Do not rotate the knob too far, as this may cause the unit to

creep in neutral. Refer to section 5.2.13 for control linkage adjustment.

4. 1. 4 PTO Engagement Switch

: Located on right fuel tank.

Swit ch m u st be pulled out to the “ROTATE” position to engage the blades.

Switch is pushed in to the “STOP” position to stop the blades.

4.1.5 Throttle Control

: Located on right fuel tank.

Throttle is used to control engine speed. Moving throttle lever forward will increase

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

4.1.6 Brake Lever

: Located on left side of unit, just to the front of the console.
The brake lever engages a parking brake on the drive wheels.
Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.
T he unit must be tied down and brake engaged when transporting.

4.1.7 Ignition Switch

: Located on the right fuel tank.

The ignition switch is used to start and stop the engine. The switch has three

positions “OFF”, “ON” and “START”. Insert the key into switch and rotate
clockwise to the “ON” position. Rotate clockwise to the next position to engage
the starter (key must be held against spring pressure in this position).

NOTE: A glow plug light, locate d to the right of the ignition switch, will illum inat e

when the switch is turned to the “ON” position. The glow plug light indicates the
glow plugs are preheating the combustion chamber. Wait until the light goes out
before rotating the key to the “START” position.

Brake must be engaged, motion control levers out (neutral lock position)

and PTO switch “OFF” to start engine. (It is not necessary for the operator to
be in the seat to start the engine.)

4.1.8 Hour Meter

: Located on the right fuel tank.

The hour meter records the number of hours that the engine has run. If the ignition

switch is left “ON” without engine running, the hour meter will continue to run.

4. 1. 9 Fuel Shut-Off Valve

: Located directly below right of console. The fuel shut-off
valve is used to shut off the fuel when the machine will not be used for a few days,
during transport to and from the job site, and when parked inside a building. The
valve has three positions. Each position is made in 1/4 turn increments.

Reference the table below for the correct locations.

FUEL FLOW VALVE POSITION

“OFF” RIGHT

RIGHT TANK “ON” DOWN

LEFT TANK “ON” LEFT

Note: The operator must prime the fuel system when the fuel tanks have gone

empty. The primer pump is the gold button located under the seat next to the
console in the front left-hand corner. To prime the system, push down on the
primer pump until the tension becomes firm (approximately 10-15 pushes).

- 20 -

4.1.10 Fuel Gauge: Located on the left fuel tank.
The fuel gauge monitors the amount of fuel in the left tank only. Use the fuel

from the right fu e l tank first. When th e right fuel tan k is e mp ty switch to the left
fuel tank. Fuel gauge will monitor the remaining fuel.

4. 1. 11 Drive Wheel Release Valves

: Located on the top right front corner of hydrostatic

pumps.

Drive wheel release valves are used to release the hydrostatic drive system to

allow the machine to be pushed without the engine running. Tilt seat up to gain
access to pumps.

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

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

4.1.12 Coolant Temperature Gauge:

Located at the front of the left fuel tank.

The coolant temperature gauge monitors the temperature of the engine coolant.

An engine overheating condition is indicated by the red area on the gauge and
an alarm will sound (See Section 4.1.17).

4.1.13 Voltmeter:

Located next to the Coolant Temperature Gauge at the front of the

left fuel tank.

The voltmeter measures the voltage output of the alternator. Both high and low

voltages will potentially damage the battery.

4. 1. 15 W ater in Fuel Light:

Located on the right fuel tank.

An illuminated water in fuel light signals water in the diesel fuel. Water should be

drained from the fuel filter if the light is on.

IMPORTANT: Water or other contaminants in fuel can severely damage fuel

pump and/or other engine components.

4. 1. 16 Glow Plug Light:

Located on the right fuel tank. The glow plug light comes on
when the ignition switch is turned to the ON position. The glow plug light
indicates the glow plugs are preheating the combustion chamber. Wait for the
glow plug light to go out before starting the engine.

4.1.17 Warning Buzzer:

Located behind the seat on the left hand side of the engine air

deflector. The buzzer is a warning signal for the following circumstances:

a) When the engine is not running and the ignition switch is turned to the ON

position, the buzzer emits intermittent beeps. The intermittent beeps remind
the user that the switch is ON and the hourmeter is running. A switch left ON
could also drain the battery.

b) When the engine is running and the buzzer emits a continuous beep, the

buzzer is warning the user that the engine is overheating. Perform the
following steps.

1. Disengage the mower blades, and idle down the engine.

2. Look at the temperature gauge to determine if temperature continues to
increase. If it does, turn the unit off and allow the engine and engine
components to cool.

3. Check the coolant level. If necessary fill with coolant as described in
Section 5.1.2.

4. Remove any debris on or around the radiator that may restrict airflow.

5. Check to see if the water pump/alternator belt is intact. If belt is
missing, do not run unit, as unit can overheat and damage the engine.
See Engine Service Dealer.

- 21 -

c) When the engine is running and the buzzer emits intermittent beeps, the

buzzer is warning the user that the engine oil pressure is low or

the alternator

is not charging. Perform the following steps.

1. Turn the unit off, allow the engine and engine components to cool.

2. Check the oil level and fill, if necessary, as described in Section 5.1.1.

3. Check for oil leaking from engine. If the engine is leaking, see Engine
Service Dealer.

4. Check to see if the water pump/alternator belt is intact. If belt is present,
there could be a charging problem, see Engine Service Dealer. If belt is
missing, do not run, as unit can overheat and damage the engine. See
Engine Service Dealer.

4.2 PRE-START

4. 2.1 Fill fuel tanks.

For best results use only clean, fresh diesel fuel, with a cetane rating of 40 higher.
NOTE: Do not use kerosene or gasoline instead of diesel fuel. Failure to

observe this caution will damage the engine.
DO NOT add oil to fuel.
DO NOT overfill fuel tank. Never fill the fuel tank so that the fuel level rises

above a level that is 1/2” below the bottom of the filler neck to allow for fuel

expansion and prevent fuel spillage.

4. 2. 2 Make sure you understand the controls, their locations, their functions, and their

safety requirements.

4. 2. 3 Refer to Maintenance, Section 5, and perform all the necessary inspection and

maintenance steps.

4.3 MOWING

4. 3. 1 Operate units with the roll bar in the raised and locked position and use seat belt.

There is no rollover protection when the roll bar is down. If it is necessary to lower

roll bar do not wear the seat belt. Raise the roll bar as soon as clearance permits.

4. 3. 2 Open fuel shut-off valve

4.3.3 Starting Engine

:

a) Brake must be engaged, motion control levers out (neutral lock

position) and PTO switch “OFF” to start engine. (It is not necessary for
the operator to be in the seat to start the engine.)

b) On a warm engine, place the throttle in the “SLOW” position.

On a cold engine (below 14° F (-10° C)), place the throttle in the “FAST” position.
Note: Do not use fuel left over from summer.
c) T urn the ignit ion switch to the “ON” posit ion. The glow plug lig ht will tur n

on. Wait for the glow plug light to turn off and turn the ignition switch to the
“START” position. Release the switch as soon as the engine starts.

IMPORTANT:

ten (10) seconds at a time. If the engine does not start, allow a 60
second cool-down period between starting attempts. Failure to follow
these guidelines can burn out the starter motor.

c) Move the throttle t o the “SLOW” (if in “FAST”) and let the engine warm up a

few minutes before moving the throttle to the “FAST” position.

(left or right tank).

DO NOT crank the engine continuously for more then

- 22 -

4.3.4 Engaging PTO:

POTENTIAL HAZARD
♦ The rotating blades under the mower deck are

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

deck when the blades are engaged.

POTENTIAL HAZARD
♦ An uncovered discharge opening will allow objects to

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

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

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

removed, or altered unless there is a grass collection

system or mulch kit in place and in proper working

condition.

DANGER

DANGER

The PTO push-pull switch engages the cutting blades. Be sure that all persons

are clear of the mower deck and discharge area before engaging PTO.

IMPORTANT

Set throttle to "midway" position. Pull outward on the switch to the “ROTATE”

position. Accelerate to full throttle to begin mowing.

4.3.5 Stopping PTO
“STOP” position stopping the cutting blades.

4.3.6 Stopping Engine

a) Bring unit to a full stop. Disengage the PTO, move motion control

levers out to the neutral lock position and engage parking brake.

b) Before stopping the engine, move the throttle control to the “SLOW”

position. Keep on running at idle for a short time, (approximately one
minute) then stop the engine.

c) Rot a t e ignit ion switch to “OFF” position. Remove the key to prevent

children or other unauthorized persons from starting engine.

d) Close fuel shut-off valve when machine will not be used for a few days,

when transporting, and when the unit is parked inside a building.

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

: Set throttle to the “midway” position. Push in on the switch to the

:

4.4 TRANSPORTING

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

- 23 -

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

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

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

is dangerous and can lead to accidents causing

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

may also be a violation of State laws and the operator

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

CAUTION

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

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

injury or death.
HOW TO AVOID THE HAZARD

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

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

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

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

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

ramp to avoid tipping backward.

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

Ramp should be long enough so that the angles between the ramp and the

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

WARNING

- 24 -

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

drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration

when backing down a ramp. Both maneuvers can cause the unit to tip backward.

5. MAINTENANCE & ADJUSTMENTS

POTENTIAL HAZARD
♦ While maintenance or adjustments are being made,

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

you or other bystanders.
HOW TO AVOID THE HAZARD
♦ Remove the key from the ignition switch before you do

any maintenance.

POTENTIAL HAZARD
♦ The engine can become very hot.

WHAT CAN HAPPEN
♦ Touching a hot engine can cause severe burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before service or

making repairs around the engine area.

WARNING

WARNING

5.1 PERIODIC MAINTENANCE

5. 1. 1 Check engine oil level:
Service Interval: Daily
a) Stop engine and wait for all moving parts to stop. Make sure machine is on

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

dipstick and push it all the way down into the tube. Remove the dipstick

and read the oil level.
d) If the oil level is low, wipe off the area around the oil fill cap, remove cap

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

Owner’s Manual. DO NOT overfill.

IMPORTANT: DO NOT operate the engine with the oil level below the

“LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

5. 1. 2 Check engine coolant level

Service Interval: Daily

a) Stop engine and wait for all moving parts to stop. Make sure machine is on

a level surface.

b) Tilt seat up and tilt hood forward to gain access to the cooling area.
c) Check with engine cold.

d) View coolant level in overflow bottle on the left side of the engine. Coolant

level should be at the indicator line on the overflow bottle.

- 25 -

e) If the coolant level is low, remove the cap to the overflow bottle and fill to

the indicator line. Use coolant specified in Section 2.5.2.
NO TE: Units should only be filled with Dex-Cool© extended life coolant, which

can be identified by its orange color.

POTENTIAL HAZARD

♦ Engine coolant is hot and pressurized.
♦ Radiator and surrounding parts are hot.

WHAT CAN HAPPEN
♦ Spray or steam from hot, pressurized liquid in the

engine cooling system or touching a hot radiator may
cause severe burns.

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

the radiator cap or servicing any component of the
cooling system.

POTENTIAL HAZARD
♦ Engine coolant is toxic.

WHAT CAN HAPPEN
♦ Swallowing coolant can cause poisoning.

HOW TO AVOID THE HAZARD

♦ Do not swallow
♦ Keep out of reach of children and pets.

WARNING

CAUTION

5. 1. 3 Check battery charge:
Service Interval: Monthly
Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and service life. To preserve optimum
battery performance and life, recharge batteries in storage when the open circuit
voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before

putting away for winter storage.

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

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

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

volts or greater.
IMPORTANT: When charging the battery, make sure the negative battery

cables are disconnected and the battery charger has an output of 16 volts

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

recommended charger settings).

- 26 -

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

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

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

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

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

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

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

5. 1. 4 Clean engine cooling system:
Service Interval: Daily or more often in dry conditions
a) Wipe debris from screen in engine cover. Rotate engine cover forward and

wipe debris from radiator core as required. Inspect seals in engine cover
and replace as necessary.

5. 1. 5 Clean grass build-up under deck.
Service Interval: Daily
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Raise deck to the transport (5” (12.7cm) cutting height) position. Lift the

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

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or maintenance

relying solely on mechanical or hydraulic jacks could
be dangerous.

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

support or may malfunction allowing the unit to fall,
which could cause injury.

HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or hydraulic jacks

for support. Use adequate jack stands or equivalent
support.

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

5. 1. 6 Check mower blades

.
Service Interval: Daily
a) Stop engine, wait for all moving part s to stop, and remove key.
b) Lift deck and secure in raised position as stated in Section 5.1.5.
c) Inspect blades and sharpen or replace as required.

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

between the front or rear baffles and the blade then torquing the blade bolts
to 115-120 ft-lbs. (156-13 N-m). Be sure the spring disc washer cone is
installed toward the bolt head (See Figure 8).

- 27 -

CAUTION

POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened

blade bolts can be dangerous.

WHAT CAN HAPPEN
♦ A loose or weakened blade bolt could allow a blade

rotating at a high speed to come out from under the
deck, causing serious injury or property damage.

HOW TO AVOID THE HAZARD
♦ Replace the blade bolt after striking a foreign object.

(Use only Exmark replacement parts PN 103-0862 –
blade bolt and PN 103-0865 – spring disk washer).

♦ DO NOT lubricate the threads of the bolt or spindle

before assembly.

♦ Torque the blade bolt to 115-120 ft-lbs. (156-163 N-m).

FI GURE 8
BLADE BOLT INSTALLATION

5.1.7 Check safety interlock system

.

Service Interval: Daily
a) Check starting circuit. Starter should crank with, parking brake engaged, PTO

disengaged and motion control levers moved out in the neutral lock position.

The operator does not need to be in the seat to start the engine.

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

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

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

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

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

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

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

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

Run engine at one-third throttle, engage PTO and raise off of seat (but do not

get off of machine) engine must stop after 1/2 second has elapsed.

G0084

- 28 -

Run engine at one-third throttle, with brake disengaged, move levers in and

raise off seat (but do not get off of machine) engine must stop after 1/2
second has elapsed.

Again, run engine at one-thir d thrott le, brake engaged, and move left

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

NOTE: If machine does not pass any of these tests, do not operate.

Contact your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that operator safety mechanisms be connected

and in proper operating condition prior to use for mowing.

5.1.8 Check rollover protections systems (roll bar) pins

Service Interval: Daily
a) Make sure latch pin and hair pin are fully installed and lanyard is in good

condition.
b) Check that the seat latch closes and latches securely.
c) Check the operation and condition of seat belt. If seat belt webbing is worn

or frayed, replace immediately (Part Number 103-4469).

5. 1. 9 Check for loose hardware

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

problem. Tighten hardware or correct the problem before operating.

5. 1. 10 Service air cleaner

.

Canister type, 2 stage cleaner:
Service Intervals:

F irst ser vice int erval – 50 h rs.
Normal service interval – 100 hrs.
Replacement interval – 600 hrs.
(more often under heavy load or high temperatures).

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

b) Unhook seat latch and tilt seat up to gain access to the air cleaner.
c) Remove engine access panel.
d) Loosen retaining clips and remove air cleaner compartment cover.
e) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damaged.

f) Check the condition of the inner element. Replace whenever it appears dirty,

typically every other time the paper element is replaced. Clean the base
around the inner element before removing, so dirt does not get into the engine.

g) DO NOT wash or use pressurized air to clean paper element or inner

element.

h) Reinstall paper element. Position the cover so that the rubber dust ejector

is pointing downward and secure with retaining clips.

5. 1. 11 Change engine oil

:

Service Intervals:
First service interval – 50 hrs.
Normal service interval – 100 hrs.
(yearly if operated less than 100 hrs.)
(m ore often under heavy load or high temperatures).

- 29 -

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tilt seat up and tilt hood forward to gain access to the engine area.
c) Dr ain oil while engine is warm from operation.
d) Remove the oil drain plug. There are two oil drain plugs available. One drain

plug is located at the front of the engine; the other is located on the right side.

Either drain plug can be used. Allow oil to drain then replace the drain plug.
e) Replace the oil filter every other oil change.
f) Clean around oil filter and unscrew filter to remove.
g) Before reinstalling a new filter, apply a thin coating of fresh clean oil on the

surface of the gasket.
h) Turn filter clockwise until rubber seal contacts the filter adapter, then tighten

filter an additional 1 full turn.
i) Clean around oil f ill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NOT overfill.
j) Star t t he engine at idle for 5 minutes. Stop engine and wait three minutes,

then check the oil level. If required, add oil to bring level to the “FULL” mark

on the dipstick. DO NOT overfill.
k) Check f or leaks, including ar ound the oil filt er.

5. 1. 12 Change engine coolant
Service Interval: 4 years/4000 hours* - Dex-Cool© extended life

* It is recommended to service at whichever interval happens first.
a) Stop engine, wait f or all moving parts to stop, and remove key. Machine

must be positioned on level surface.
b) Tilt seat up and tilt hood forward to gain access to the cooling area.

:

coolant (orange color)

POTENTIAL HAZARD

♦ Engine coolant is hot and pressurized.
♦ Radiator and surrounding parts are hot.

WHAT CAN HAPPEN
♦ Spray or steam from hot, pressurized liquid in the

engine cooling system or touching a hot radiator may
cause severe burns.

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

the radiator cap or servicing any component of the
cooling system.

POTENTIAL HAZARD
♦ Engine coolant is toxic.

WHAT CAN HAPPEN
♦ Swallowing coolant can cause poisoning.

HOW TO AVOID THE HAZARD

♦ Do not swallow
♦ Keep out of reach of children and pets.

WARNING

CAUTION

- 30 -

Drain coolant when engine is cool. Coolant may be drained from the radiator by
loosening the drain cock in the right rear corner. The engine block may be
drained by removing the rear radiator hose and/or by removing the drain plug
from the engine block. The plug may be accessed from the right side of the unit
and are located as shown in Figure 9. The engine has a socket head bolt for the
drain plug.

FIGURE 9

COOLANT PLUG LOCATION

a) Re-install dr ain plug and hoses and tighten drain cock.
b) Fill radiat or with a 50/50 mix of water and Dex-Cool © coolant, allowing

some room (approximately 1/2” (1.27 cm)) for expansion. Add 50/50

coolant mix to overflow bottle on the left side of the engine as required to

bring the level up to the indicator line on the bottle.

WARNING

POTENTIAL HAZARD

♦ Engine compartment contains open belt drives and fans.
♦ Rotating components can cause injury

WHAT CAN HAPPEN
♦ Fingers, hands, loose clothing or jewelry can get caught

by the rotating fan and drive shaft.

HOW TO AVOID THE HAZARD

♦ Do not operate machine without the covers in place.
♦ Keep fingers, hands, and clothing clear of rotating

components.

♦ Shut off engine, wait for all moving parts to stop, and

remove the ignition key before performing maintenance.

e) With the cap off the radiator, start the engine. Refer to Section 4.3.3.
f) Operate engine until the engine thermostat opens and coolant is circulating

through the radiator core. As air is purged from the engine block and the

coolant level drops, add additional coolant to the radiator.
g) W hen the radiator is completely full and no additional coolant can be

added, continue running the engine and install the radiator cap. Make sure

that the cap is completely seated by pressing down firmly while turning until

the cap stops. Once the cap is installed, the engine may be stopped.

- 31 -

5. 1. 13 Check hydraulic oil level:
Service Interval: 40 hr.

a) Stop engine and wait for all moving parts to stop.
b) Clean area around hydraulic reservoir cap and remove cap. Oil level should

be to the top of the baffle inside the tank. If not, add oil. Use only Mobil 1

15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten

until snug. DO NOT overtighten.
NOTE: The baffle has two levels. The upper level represents the “HOT”

level and the lower level represents the “COLD” level. The oil level varies

with the temperature of the oil. The “HOT” level shows the level of oil when it

is a 225°F (107°C). The “COLD” level shows the level of the oil when it is at

75°F (24°C). Fill to the appropriate level depending upon the temperature of

the oil. For example: If the oil is about 150°F (65°C), fill to halfway between

the “HOT” and “COLD” levels. If the oil is at room temperature (about 75°F

(24°C)), fill only to the “COLD” level.

5. 1. 14 Check tire pressures

:
Service Interval: 40 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Check tire pressure in drive tires.

c) Inflate drive tires to 10 psi (69 kPa).
d) Caster tires do not need to be inflated.
NOTE: Do not add any type of tire liner or foam fill material to the tires.

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

5. 1. 15 Check condition of belts

:
Service Interval: 40 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tilt seat up. Lift the rubber flaps on front side of the engine to check pump

drive belt and alternator drive belt.

c) Rem ove left and right belt shields on deck and lift up floor pan to inspect

deck drive belt.

d) Remove bumper and check under machine to inspect the two mule drive belts

and fan pump drive belt.

e) See Sections 5.2.3, through 5.2.7 for belt adjustments.

5.1.16 Lubricate grease fittings

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

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

- 32 -

LUBRICATION CHART

FITTING

LOCATIONS

1. Front Caster wheel hubs

2. Front Caster Pivots

3. Height Adj. Shaft Bearings 1 5 40 hours

4. Deck Drive Belt Idler Arm

5. Brake Brackets 1 2 200 hours

6. Fan Pump Belt Idler Arm

7. Wheel Drive Pump Belt Idler Arm

8. Deck Rear Struts 1 2 40 hours

9. Mule Drive Belt Idler Arms 1 2 Yearly

INITIAL
PUMPS

∗0
∗0

1 1

1 1
1 1

NO. of

PLACES

2
2

SERVICE

INTERVAL

∗Yearly
∗Yearly

Yearly

40 hours

Yearly

∗ See Section 5.1.16 c) for special lubrication instructions on the front caster pivots and

Section 5.1.17 for special lubrication instructions on the front casters wheel hubs.

No. 6 (Fan Pump Belt Idler Arm)
Access through hole in bumper plate

No. 7 (Pump Drive Belt Idler Arm)
Located Under Seat

c) Lubricate front caster pivots once a year. Remove hex plug and cap. Thread

grease zerk in hole and pump with grease until it oozes out around top
bearing. Remove grease zerk and thread plug back in. Place cap back on.

Service Interval: Once Yearly
a) Stop engine, wait for all moving parts to

b) Remove caster wheel from caster forks.
c) Remove seal guards from the wheel hub.

d) Remove one of the spacer nuts from the

e) Pry out seals, and inspect bearings for

f) Pack the bearings with a NGLI grade #1 multi-purpose grease.
g ) Insert (1) bearing, (1) new seal into the wheel.
NOTE: Seals (Exmark PN 103-0063) must be replaced.
h) If the axle assembly has had both spacer nuts removed (or broken loose),

5.1.17 Lubricate caster wheel hubs:

stop, and remove key.

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

wear or damage and replace if necessary.

apply a thread locking adhesive to (1) spacer nut and thread onto the axle
with the wrench flats facing outward. Do not thread spacer nut all of the way

FIGURE 10

CASTER WHEEL ASSEMBLY

- 33 -

onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer
surface of the spacer nut to the end of the axle inside the nut.

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

with the new seal and bearing.

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

around the axle full of NGLI grade #1 multi-purpose grease.
k) I nsert the second bearing and new seal into the wheel.
l) Apply a thread locking adhesive to the 2

nd

spacer nut and thread onto the axle

with the wrench flats facing outward.
m) Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to 20-25

in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.
n) Re-install the seal guards over the wheel hub and insert wheel into caster

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

IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin the caster tire. The tire should not spin freely (more

than 1 or 2 revolutions) or have any side play. If the wheel spins freely,

adjust torque on spacer nut until there is a slight amount of drag. Re-apply

threadlocking adhesive.

5. 1. 18 Lubricate brake handle pivot

:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant

or light oil.

5. 1. 19 Lubricate brake rod bushings

:

Service Interval: 160 hrs.

a) Stop eng ine, wait for all moving parts to stop, and remove key.
b) Lubricat e bronze bushings on each end of brake rod shaft with a spray type

lubricant or a light oil (bushings are located to the inside of the flange
bearings).

5.1.20 Lubricate motion control bronze bushings

:

Service Interval: 160 hrs.

a) Stop eng ine, wait for all moving parts to stop, and remove key.
b) T ilt seat up.
c) Lubricate bronze bushings on flange bearings securing the motion control

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

5.1.21 Drain fuel filter

:

Service Interval: When Water in Fuel warn in g light is “ON”

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Place a drain pan under the fuel filter and loosen the drain plug

approximately 1 turn.
c) Water should drain.
d) When fuel begins to flow from the filter, tighten the drain plug.

e) Prime the fuel system (See Section 5.1.23).
f) Start engine. Make sure warning light goes out. Check for leaks.
I MPORT ANT: W ater or other contaminants in fuel can severely damage fuel

pump and/or the other engine components.

- 34 -

5.1.22 Replace fuel filter:
Service Interval: 800 hrs.

A fuel filter is installed between the fuel tank and the injector pump and is

located under the seat in the left hand front corner of engine deck.
a) Close fuel shut off valve.
b) Disconnect the sensor wire, remove the drain plug and discard the o-ring.
c) Remove fuel filter with a filter wrench.
d) Screw new filter on by hand until gasket contact the housing, then tighten

1/3 turn more.

e) Install the drain plug with new O-ring and connect the sensor wire.

f) Bleed air fr om f uel line, by using the priming pump, (See section 5.1.23)

then start the engine to check for leaks.

Replacement Components
27 HP Daihatsu Diesel Fuel Filter
27 HP Daihatsu Diesel Drain Plug O-ring

Briggs & Stratton P/N 820311
Briggs & Stratton P/N 820348

5. 1. 23 Fuel priming procedure:
Service Interval: As required

The primer pump is the gold button located under the seat next to the console in

the front left-hand corner.

a) Repeatedly push down on the primer pump until the resistance becomes

firm (approximately 10-15 pushes).

5. 1. 24 Change hydraulic system filter

:

Service Interval: After First 250 hrs.
Then yearly thereafter

NOTE: Use only Exmark Part No. P/N 103-2146.
a) Stop eng ine, wait for all moving parts to stop, and remove key.
b) Raise seat.
c) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system.

d) Unscrew f ilter to remove and allow oil to drain from reservoir.
IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and

apply a thin coat of clean oil on the surface of the rubber seal.

Turn filter clockwise until rubber seal contacts the filter adapter, then tighten

the filter an additional 2/3 to 3/4 turn.

e) Fill reser voir as stat ed in Section 5.1.13.
f) Raise the rear of machine up and support with jack stands (or equivalent

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

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

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

Do not change hydraulic system oil (except for what can be drained when

changing filter), unless it is felt the oil has been contaminated or been
extremely hot.

Changing oil unnecessarily could damage hydraulic system by

introducing contaminates into the system.

5.1.25 Wheel hub

- slotted nut torque specification.

Service Interval: 500 hrs
When tightening the slotted nut on the wheel motor tapered shaft:

- 35 -

a) Torque the slotted nut to 125 ft-lbs. (169 N-m).
b) Check distance from bottom of slot in nut to inside edge of hole. Two

threads (0.1” (.25 cm)) or less should be showing.

c) If more than two threads (0.1” (2.5 mm)) are showing remove nut and

install washer (PN 1-523157) between hub and nut.
d) Torque the slotted nut to 125 ft-lbs. (169 N-m).
e) Then tighten nut until the next set of slots line up with the cross hole in shaft.
f) Replace cotter pin.
Note: Do not use antisieze on wheel hub.

5.1.26 Fuel Tank

– mounting hardware specification.

When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and

back off 1/2 turn. This allows for normal fuel tank expansion and contraction with
changes in temperature and fuel levels.

5. 1. 27 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type”

are used on the following fasteners:
a) Pump drive sheave set screws.
b) Square head setscrews on Hydro pump control arms.
c) Sheave retaining bolt in the end of engine crankshaft.
d) Engine mount retaining bolts.
e) Stub shaft-to-flywheel retaining bolts.
f) Front engine crankshaft hub retaining bolts.
g) Fuel tank bulkhead fitting threads.
h) Caster wheel spacer nuts.
i) Cutter housing spindle nut.

Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro

Pro-Lock Retaining I

or Retaining II” are used on the following:
a) Fuel tank studs, where studs are inserted into tank.

5. 1. 28 Mobil HTS grease (or a food-grade antisieze) is used in the following locations
a) Between the jackshaft and bearings
b) Between the jackshaft and sheaves.
c) Between the cutter housing spindle and bearings.
d) Between the cutter housing spindle and sheaves.
e) Under top cutter housing bearing guard.
f) On the fan pump shafts and motor shafts next to the seal.

5.1.29 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

:

5.2 ADJUSTMENTS

I M PORT ANT: Disengage PTO, shut off engine and remove key before servicing,

cleaning or making any adjustments to the unit.

5. 2. 1 Cutting Height Adjustment
a) Stop machine and move drive levers out to neutral lock position.
b) Disengage PTO.
c) Raise the deck lever to the transport position (also the 5” (12.7 cm) cutting

height position). See Figure 11.

The deck can be raised by pulling the deck lever up and/or by pushing on

the deck lift assist lever.

.

- 36 -

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

complete stop and disengage the PTO.

FIGURE 11

CUTTING HEIGHT POSITION

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

height and install hairpin cotter. See decals on the side of deck lift plate.

e) Move lever out of the transport (or 5” (12.7 cm) cutting height) position and

down onto height

adjustment pin to mow at selected height.

f) To transport, move lever back up to transport (or 5” (12.7 cm) cutting

height) position.

Note: The foot operated deck lift assist lever can be used to momentarily

lift the deck to clear objects. Be sure the PTO is disengaged.

g) Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one

of the positions shown in Figure 12. Rollers will maintain 3/4 in. (19 mm)
clearance to the ground to minimize gouging and roller wear or damage.

For Maximum Deck Flotation, place rollers one hole position lower.

Rollers should maintain 1/4 in. (6.4 mm) clearance to ground. Do Not
adjust rollers to support the deck. Be sure roller bolts and nuts are installed
with the spring disc washer between head of the bolt and mounting bracket.

Two types of anti-scalp roller assemblies are available. See Figure 12 to

determine which assembly has been installed on the unit. Torque hardware
as specified, or loss of roller may result.

Type A – Torque the 3/8 whizlock nut to 40-45 ft-lbs. (54-61 N-m)
Type B – Torque the 3/8 nyloc nut to 30-35 ft-lbs. (41-47 N-m)
Torque the 3/8-24x2 Gr 8 hex capscrew to 50-55 ft-lbs (68-75 N-m)

FIGURE 12

ANTI-SCALP ROLLER ADJUSTMENT

5.2.2 Deck Leveling
a) Position mower on a flat surface.

- 37 -

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

j

c) Check tire pressure of drive tires. If needed, adjust to 10 psi (69 kPa).
Semi-pneumatic caster tires do not need to be inflated.

d) Set ant i-scalp rollers to top holes or remove them completely for this

adjustment.

e) Raise the deck to the 5” height position (also transport position) and take all

force off of the two large deck lift springs by loosening the nuts at the front
of each spring. See Figure 13.

f) Lower the deck to the 1-1/2” height position. Force the left rear deck

support arm downward about 1/4” to get the deck to rest at the 1-1/2” height
position. Place locking pliers between the rear swivel and spring stop to
hold the deck in this position. See Figure 13.

g) Place a 3/4” thick block of wood under each of the two (2) rear anti- scalp

roller brackets and place one under one of the front center anti-scalp
roller brackets.

h) Loosen the two (2) top chain bolts in slots in the rear deck lift arms. Loosen

jam nuts and back off the socket head adjusting screws on the bottom of
the arms until the chains are just loose. Turn the socket head adjusting
screws in until slack is taken out of each chain. Tighten the jam nuts.
Tighten the chain bolts in the deck lift arms making sure they don’t move
while tighte n ing.

i) Loosen the four (4) nuts which secure the front swivels (two per side) until

the front chains are loose and front of deck is supported by the 3/4” block.
Do not loosen the front chain hardware.

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

the front chain is tight and all slack is removed from linkage. Do not lift front
of deck off 3/4” block. Secure front swivel using locking nut in front of
swivel. Repeat for right side.

k) Recheck that the 3/4” blocks fit just snugly under the brackets and that the

tension on all the chains are approximately equal. Make sure all chain
attachment bolts are tight. Reposition anti-scalp rollers and tighten securely.

Apply downward

pressure here

Place locking pliers

here to hold spring

11 1/2”

Remove force on

deck springs by

loosening nuts here

Jam nut

Socket head

ad

usting screw

FIGURE 13

Front of Unit

Swivel

SWIVEL ADJUSTMENT

SPRING COMPRESSION ADJUSTMENT

l) Raise deck lift lever t o the 5” cutting height position See Figure 8. Adjust

spring compression until proper distance is obtained between the two large
washers (See Figure 10). Adjustment is made by turning the nut at the front
of each spring (clockwise will shorten the spring, counter-clockwise will
lengthen the spring). Lock in position with jam nuts.

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

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

G0122

- 38 -

5. 2.3 Wheel Drive Pump Belt Tension.
Self-tensioning - No adjustment necessary.

5.2.4 Fan Pump Belt Tension.
Self-tensioning – No adjustment necessary.

5. 2. 5 Mule Drive Belts Tension Adjustment

.
Self-tensioning idlers, adjust as follows:
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Check to make sure the coils of the spring on the spring-loaded idler pulley

measures as listed below. See Figure 14.

Left Side Spring – 5 3/4” ± 1/8” (14.8 ± 0.3 cm)
Right Side S pring – 5 1/2” ± 1/8” (14.0 ± 0.3 cm)

c) If the spring does not have the correct measurement, loosen the nut holding the

adjustable idler pulley on each side so they can move up and down in the slot.
d) Relieve pressur e on the spring-loaded idler pulleys.
e) Reposition t he adjusting pulleys lower in the slot and tighten the nut.
f) Re-check to make sure the coils of the spring on the spring-loaded idler pulley

have the correct measurement. Repeat as necessary on both sides of the unit.

FIGURE 14

MULE DRIVE BELTS ADJUSTMENT

5.2.6 Deck Belt Tension

.

a) The deck belt is tensioned by a self-tensioning idler, no adjustment is

necessary.

5. 2. 7 Alternator belt tension.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Remove engine access panel and rubber flap assembly located behind

seat.
c) To tighten alternator belt, loosen both upper and lower alternator mounting

bolts. Rotate alternator out, away from engine and re-tighten hardware to

secure in place.
d) When properly tensioned, the alternator belt will deflect 3/8”-1/2” (9-13 mm)

while applying 22 pounds of force to the belt midway between fan and

alternator.

5. 2. 8 Belt Guide Adjustment

.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Remove the belt shield on the right side of mower deck.
c) Locat e belt guide bolted to deck near the shield support stud and right-hand

pulley. Guide should be 1/8” (3 mm) away from the belt, with bolt-end of
guide near end of slot (See Figure 15).

- 39 -

d) If adjustment is necessary, loosen the bolt securing the belt guide and

make proper adjustment. Tighten hardware.

FIGURE 15

BELT GUIDE POSITIONING

5.2.9 Br ake Link Adjustm e nt

.
Check to make sure brake is adjusted properly.
a) Disengage brake lever (lever down).
b) Measure the length of the spring. Measurement should be 2.75” (7 cm)

(See Figure 16).

c) If adjustment is necessary, adjust the nyloc nut at the bottom of the spring to

achieve 2 3/4” (7 cm).
d) Engage the brake lever (lever up).
e) The space between the brake spring bracket and the nyloc nut under the

spring should measure 3/16” to 1/4” (4.8 – 6.4 mm).
f) If adj ustment is necessary, loosen jam nut above the trunion roller. Adjust

the nyloc nut under the trunion roller until 3/16” to 1/4” (4.8 – 6.4 mm) exists

between the spring retainer bracket and the adjacent nyloc nut. Tighten the

jam nut above the trunion roller.

g) If a 3/16” to 1/4” (4.8 – 6.4 mm) gap can no longer be achieved because there

is no clearance between nyloc nut below the spring and the jam nut above the

trunion or there are no threads left on the bottom nyloc nut, the length of the

brake rod can be adjusted. Remove a pin from a yoke at either end of the

brake rod and lengthen (or shorten) the brake rod until 3/16” to 1/4” (4.8 – 6.4

cm) gap can be achieved by following steps e) and f).

FIGURE 16

BR AK E AD J U S T M E N T

- 40 -

5.2.10 Adjust Throttle Lever Tension.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tension in throttle lever can be adjusted by adjusting the tightness of the

lever pivot bolt, which is located under the console (See Figure 17).

FIGURE 17

THROTTLE TENSION

5. 2. 11 Electric Clutch Adjustment

:

No adjustment is necessary.

5. 2. 12 Reverse Indicator Adjustment

:

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tilt seat forward.
c) Begin with either the left or right motion control lever. Move lever to the

neutral position and pull lever back until the clevis pin (on arm below pivot
shaft) contacts the end of the slot (just beginning to put pressure on spring),
See Figure 18.

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

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

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

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

f) Repeat on opposite side of unit.

FIGURE 18

REVERSE INDICATOR ADJUSTMENT

- 41 -

5. 2. 13 Motion control linkage adjustment.

WARNING

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

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

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

components and hot surfaces.

POTENTIAL HAZARD
♦ Raising the mower deck for service or maintenance

relying solely on mechanical or hydraulic jacks could be

dangerous.
WHAT CAN HAPPEN

♦ The mechanical or hydraulic jacks may not be enough

support or may malfunction allowing the unit to fall, which

could cause injury.
HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or hydraulic jacks for

support. Use adequate jack stands or equivalent support.

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

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

b) Disconnect the electrical connection from the seat wire harness from the main

harness. The electrical connection is below the seat hold up rod just above
the left wheel drive pump.

Temporarily install a jumper wire across the terminals in the connector of

the main wiring harness.

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

bring hydraulic system oil up to operating temperature. Return the drive

levers to the neutral position.
d) Tilt seat forward.
e) Loosen lock nut from the ball joints at the pump end of the RH pump control

linkage (See Figure 19).

CAUTION

- 42 -

NOTE: The nuts to the front of the unit on RH rod has left-hand threads.

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

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

NOTE: The motion control lever needs to be in neutral while making

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

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

i) When adjustment is complete, re-tighten lock nuts to the ball joints at rear

j) Bring t he LH motion control lever into the neutral position. Adjust the LH

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

5. 2. 14 Caster pivot bearings pre-load adjustment
a) Remove dust cap from caster and tighten

FIGURE 19

MOTION CONTROL ADJUSTMENT

start engine. Operator does not have to be in the seat. Run engine at

full throttle and release brake.

adjustments can be made. See Section 5.2.12.

any necessary adjustments.

controls the right wheel.

control rod length by rotating the double nuts on the rod in the appropriate

direction until the wheels slightly creep in reverse. (See Figure 19) Move

the motion control lever to the reverse position and while applying slight

pressure to the lever allow the reverse indicator spring to bring the levers

back to neutral. The wheel must stop turning or slightly creep in reverse.

of the RH pump control linkage (See Figure 19).

pump control rod length by rotating the tracking adjustment knob in the

appropriate direction until the wheels slightly creep in reverse. Move the

motion control lever to the reverse position and while applying slight

pressure to the lever allow the reverse indicator spring to bring the levers

back to neutral. The wheel must stop turning or slightly creep in reverse.

See Figure 19.

connector into seat switch.

.

nyloc nut until washers are flat and back

off 1/4 of a turn to properly set the pre-

load on the bearings. If disassembled,

make sure the spring washers are

reinstalled as shown in Figure 20.

CASTER ADJUSTMENT

FIGURE 20

- 43 -

6. WASTE DISPOSAL

6.1 MOTOR OIL DISPOSAL

Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at

a certified recycling center or according to your state and local regulations.

6.2 ENGINE COOLANT DISPOSAL

POTENTIAL HAZARD
♦ Engine coolant is toxic.

WHAT CAN HAPPEN
♦ Swallowing coolant can cause poisoning.
HOW TO AVOID THE HAZARD

♦ Do not swallow
♦ Keep out of reach of children and pets.

Engine coolant is a 50/50 mixture of Dex-Cool© (ethylene glycol (anti-freeze) with

addititives) and water. Ethylene glycol is a pollutant. Dispose of used engine coolant
according to your state and local regulations.

6.3 MERCURY SWITCH DISPOSAL

POTENTIAL HAZARD
♦ The mercury contained in the tilt switch is poisonous.

WHAT CAN HAPPEN
♦ Exposure to mercury can cause severe illness.

HOW TO AVOID THE HAZARD

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

CAUTION

CAUTION

The tilt switch (PN 1-633782) on this unit contains mercury, a hazardous material. Mercury

that is outside a sealed container vaporizes at room temperature. The vapors are harmful.
Mercury can be absorbed through the skin. Do not attempt to open or repair this switch.

A very small amount of mercury is contained in a hermetically sealed body. The steel

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

Several states have passed laws concerning the disposal of devices containing mercury.

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

Return the switch to your Exmark dealer if it is faulty and is being replaced or if the unit

containing the switch is no longer operating and is being scrapped. If the switch is
damaged or broken open use extreme caution in handling. Call your local waste
management authority or Exmark Customer Service for instructions.

- 44 -

6.4 BATTERY DISPOSAL

POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric acid, which is

poisonous and can cause severe burns
WHAT CAN HAPPEN
♦ Swallowing electrolyte can be fatal or if it touches skin

can cause severe burns.
HOW TO AVOID THE HAZARD
♦ Wear safety glasses to shield eyes, and rubber gloves

to protect skin and clothing when handling electrolyte.
♦ Do not swallow electrolyte.

Federal law states that batteries should not be placed in the garbage. Management and

disposal practices must be within relevant federal, state, or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating and

is being scrapped, take the battery to a local certified recycling center. If no local recycling
is available return the battery to any certified battery reseller.

7. TROUBLE SHOOTING

DANGER

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

a) Refer to Tracking Adjustment Section 4.1.3.
b) Check air pressure in drive tires;10 psi.
Sem i- pneum atic casters do not require inflation.

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

section 5.2.12 and 5.2.13.

7.2 MOWER CUTS UNEVENLY.

a) Check air pressure in drive tires; 10 psi.
Semi-pneumatic casters do not require inflation.
A more uniform cutting height may be obtained with higher tire pressure on

rough terrain.
A lower tire pressure provides more flotation.
b) Check deck support chains.
c) Check deck leveling (See Adjustments Section 5.2.2.)
Note: The front of the mower deck will be approximately 1/4” (6.4 mm)

lower than the back of the mower deck. This is the “rake” of the deck.
d) Check blades tip to tip for straightness (they should be within 3/16" or one

blade width from being in line.)

7.3 ENGINE WILL NOT START.

a) Make sure the battery has a full charge. See section 5.1.3 for charging

instructions.
b) Be sure the throttle control is in the correct position. See section 4.3.3.
c) Make sure there is fuel in the fuel tank and that the fuel valve is open.
d) Make sure the parking brake is set and motion control levers are moved out

(neutral lock position).
e) Check that the PTO is disengaged.
f) Check for loose or faulty wiring connections.

- 45 -

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

cause a faulty connection. Clean connector terminals thoroughly with

electrical contact cleaner; apply dielectric grease and reconnect.

NOTE: When disconnecting electrical connectors DO NOT pull on the

wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the

engine. If it does not start, contact your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be

connected and in proper operating condition prior to mower use.

When a problem occurs, do not overlook the simple causes. For example,

starting problems could be caused by an empty fuel tank.

The following table lists some of the common causes of trouble. Do not attempt

to service or replace major items or any items that call for special timing of
adjustment procedures (such as valves, governor, etc.). Have this work done by
your Engine Service Dealer.

TROUBLESHOOTING TABLE

PROBLEM

Will not start

Hard starting

Stops suddenly

Lacks power

Operates erratically

Skips or misfires

Overheats

High fuel consumption

7.4 ENGINE WARNING SYSTEMS

7. 4. 1 Water in Fuel Light:

NO

FUEL

FUEL

IMPROPER

DIRT IN

WATER OR

FILTER

ENGINE

DIRTY AIR

FUEL LINE

OVERLOADED

FUEL

FILTER

BLOCKED

CORE

OIL LEVEL

INCORRECT

INSUFFICIENT

FAN PUMP

CHARGE

BATTERY

DIRTY

BELT MISSING

RADIATOR

X X X X X X
X X X X X X
X X X X X

X X X X X
X X X X X
X X X
X X X X X
X X

Located on the right fuel tank. An illuminated water in fuel
light signals water in the diesel fuel. Water should be drained from the fuel filter if
the light is on.

IMPORTANT: Water or other contaminants in the fuel can severely damage fuel

pump and/or other engine components.

7. 4. 2 Glow Plug Light:

Located on the right fuel tank. The glow plug light comes on
when the ignition switch is turned to the ON position. The glow plug light
indicates the glow plugs are preheating the combustion chamber. Wait for the
glow plug light to go out before starting the engine.

7.4.3 Warning Buzzer:

Located behind the seat on the left hand side behind the
engine access panel. The buzzer is a warning signal for the following
circumstances:

a) When the engine is not running and the ignition switch is turned to the ON

position, the buzzer emits intermittent beeps. The intermittent beeps remind
the user that the switch is ON and the hourmeter is running. A switch left ON
could also drain the battery.

b) When the engine is running and the buzzer emits a continuous beep, the

buzzer is warning the user that the engine is overheating. Perform the
following steps.

1. Disengage the mower blades, and idle down the engine.

- 46 -

2. Look at the temperature gauge to determine if temperature
continues to increase. If it does, turn the unit off and allow the
engine and engine components to cool.

3. Check the coolant level. If necessary fill with coolant as described
in Section 5.1.2.

4. Remove any debris on or around the radiator that may restrict airflow.

5. Check to see if the water pump/alternator belt is intact. If belt is
missing, do not run unit, as unit can overheat and damage the
engine. See Engine Service Dealer.

c) When the engine is running and the buzzer emits intermittent beeps, the

buzzer is warning the user that the engine oil pressure is low, OR the
alternator is not charging. Perform the following steps.

1. Turn the unit off, wait for all moving parts to stop, and remove key.
Allow the engine and engine components to cool.

2. Check the oil level and fill, if necessary, as described in Section 5.1.1.

3. Check for oil leaking from engine. If the engine is leaking, see
Engine Service Dealer.

4. Check to see if the water pump/alternator belt is intact. If belt is
present, there could be a charging problem, see Engine Service
Dealer. If belt is missing, do not run unit, as unit can overheat and
damage the engine. See Engine Service Dealer .

- 47 -

8. ELECTRICAL DIAGRAM

- 48 -

9. HYDRAULIC DIAGRAM

- 49 -

10.

2-Year Limited Warranty
Exmark Turf Equipment

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

Conditions and Products Covered

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

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

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

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

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused or

• Any repairs necessary due to use of parts, accessories or

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

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

2. Bring the product and your proof of purchase (sales
receipt) to the Exmark Service Dealer.

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

Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310

402-223-6375 or
[e-mail]

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer.
and tear, or exposure.
filters, fuel, lubricants, tune-up parts, and adjustments.
required replacement or repair due to normal wear,

accidents, or lack of proper maintenance.
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.

Instructions for Obtaining Warranty Service

Owner’s Responsibilities

The Exmark turf equipment, including any defective part,
must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to
turf equipment operated under normal conditions. You
must 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.

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
as set forth herein. Neither Exmark nor Exmark Warranty

Company shall have any liability for any other cost, loss
or damage, including but not limited to, any incidental or
consequential loss or damage.

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

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge relating to
repairs or replacements out side 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.

There are no understandings, agreements, representations,
or warranties, express or implied, including but not limited to
any regarding the merchantability (that product is fit for
ordinary use) or fitness for use (that product is fit for a
particular purpose), not specified herein, respecting the
equipment which is the subject of this 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 leg al rights, and you may
also have other rights which vary from state to state.

- 50 -

NOTES

- 51 -

NOTES

- 52 -

SERVICE RECORD

Date

Description of Work Done Service
Done By

- 53 -

- 54 -

M

©

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.

2004 EXMARK MFG. CO. INC. PART NO. 103-7372 Rev. B

INDUSTRIAL PARK BOX 808 [phone]
BEATRICE, NE 68310 FAX [phone]

ALL RIGHTS RESERVED PRINTED IN U.S.A.

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproducti ve harm.

WARNING

CALIFORNIA

Proposition 65

®

FG. CO. INC.