Exmark LAZER Z X Series, LAZER Z S Series, LAZER Z E Series Operator's Manual

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Page 1

LAZERZ®

ForSerialNos. 316,000,000&Higher LazerZ(LZE,LZS,LZX)Units

PartNo.4502-754Rev.A

Page 2

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

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

noresponsibilityforvariationswhichmaybe evidentintheactualspecicationsofitsproducts andthestatementsanddescriptionscontained inthispublication.

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

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

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

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

Labeledpowerratingsaresuppliedbytheengine manufacturerinaccordancewithSAEtesting andgross/netpowerratingstandards(J1940, J1995,J1349).

Exmarkreservestherighttomakechangesor addimprovementstoitsproductsatanytime withoutincurringanyobligationtomakesuch changestoproductsmanufacturedpreviously. Exmark,oritsdistributorsanddealers,accept

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Page 3

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

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

Important:Tomaximizesafety,performance, andproperoperationofthismachine,itis essentialthatalloperatorscarefullyreadand fullyunderstandthecontentsoftheOperator’s manualprovidedwiththeproduct.Safe operationofExmarkequipmentisessential. Failuretocomplywiththeoperatinginstructions orreceivepropertrainingmayresultininjury.

Gotohttp://www.Exmark.comforadditional safeoperationinformation,suchassafetytips, trainingmaterials,andOperator’smanuals.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Ifadditionalinformationisneeded,orshould yourequiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor.

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

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready .

Page 4

Contents

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

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

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

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

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

Specications........................................................19

Systems..........................................................19

Dimensions....................................................23

TorqueRequirements.....................................25

ProductOverview.................................................26

Operation..............................................................26

Controls.........................................................26

Pre-Start.........................................................31

OperatingInstructions...................................31

Transporting..................................................38

Maintenance..........................................................40

RecommendedMaintenanceSchedule(s)............40

PeriodicMaintenance........................................41

CheckEngineOilLevel..................................41

CheckMowerBlades......................................43

CheckSafetyInterlockSystem........................44

CheckRolloverProtectionsSystems(Roll

Bar)Knobs.................................................44

CheckSeatBelt...............................................45

CheckforLooseHardware.............................45

ServiceAirCleaner.........................................45

ChangeEngineOil.........................................45

CheckHydraulicOilLevel..............................46

CheckTirePressures......................................46

CheckConditionOfBelts...............................46

LubricateGreaseFittings................................47

LubricateDeckLiftPivot...............................48

CheckSparkPlugs..........................................48

ChangeHydraulicSystemFilterand

Fluid..........................................................48

WheelHub-SlottedNutTorque

Specication...............................................49

CheckSparkArrester(ifequipped)..................49

ThreadLockingAdhesives..............................49

MobilHTSGrease(OrFood-Grade

Anti-seize)X-SeriesOnly............................49

Copper-BasedAnti-seize...............................50

DielectricGrease............................................50

Adjustments......................................................50

DeckLeveling................................................50

PumpDriveBeltTension................................52

DeckBeltTension..........................................52

AdjustingtheParkingBrake............................52

ElectricClutchAdjustment.............................54

MotionControlLinkageAdjustment..............55

MotionControlDamperAdjustment..............56

MotionControlNeutralLockPivot

Adjustment................................................56

MotionControlHandleAdjustment...............57

MotionControlFullForwardTracking

Adjustment................................................57

CasterPivotBearingsPre-Load

Adjustment................................................57

Cleaning............................................................58

CleanEngineandExhaustSystem

Area...........................................................58

RemoveEngineShroudsandClean

CoolingFins...............................................58

CleanHydroFanCoolingGuards,Hydro

CoolingFins,andFan.................................58

CleanDebrisFromMachine...........................59

CleanGrassBuild-UpUnderDeck.................59

CleaningtheSuspensionSystem.....................59

WasteDisposal...............................................59

Troubleshooting....................................................60

Schematics............................................................63

Page 5

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER, WARNING,orCAUTION.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readthismanual,itistheowner’ sresponsibilityto explainthismaterialtothem;otherlanguagesmay beavailableonourwebsite.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

DANGER:Indicatesanimminentlyhazardous situationwhich,ifnotavoided,Willresultindeathor seriousinjury.

WARNING:Indicatesapotentiallyhazardous situationwhich,ifnotavoided,Couldresultindeath orseriousinjury.

CAUTION:Indicatesapotentiallyhazardous situationwhich,ifnotavoided,Mayresultinminor ormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses, substantialfootwear,andhearingprotection.Do Notoperatewhenbarefootorwhenwearingopen sandals.Longhair,looseclothingorjewelrymay gettangledinmovingparts.

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

Page 6

Safety

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

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

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

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.Do Notuseanozzlelockopendevice.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Page 7

Safety

XandS-SeriesModels:

CAUTION

Fueltankventislocatedinsidetheroll bartube.Removingormodifyingtheroll barcouldresultinfuelleakageandviolate emissionsregulations.

•DoNotremoverollbar.

•DoNotweld,drill,ormodifyrollbarin anyway.

•Checkthattheoperatorspresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly.DoNotoperateunlessthey arefunctioningproperly.

Operation

WARNING

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

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommuferand enginearea.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea, DoNotoperatethemachine;seekshelter.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

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

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesinplace andworkingproperly.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhen makingturns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecaution whencrossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

Page 8

Safety

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

DANGER

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

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

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

3.Water

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

Page 9

Safety

WARNING

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

•DoNotremovetheROPS.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbaris down.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

•Becertainthattheseatbeltcanbereleasedquickly intheeventofanemergency.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

•ReplaceadamagedROPS.DoNotrepairor revise.

•Anyaccessories,alterations,orattachmentsadded totheROPSmustbeapprovedbyExmark.

MaintenanceandStorage

•Disengagedrives,setparkingbrake,stopengine andremovekeyordisconnectsparkplugwire. Waitforallmovementtostopbeforeadjusting, cleaningorrepairing.

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

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

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

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

Page 10

Safety

CAUTION

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

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removalormodicationoforiginalequipment, partsand/oraccessoriesmayalterthewarranty, controllability,andsafetyofthemachine. Unauthorizedmodicationstotheoriginal equipmentorfailuretouseoriginalExmark partscouldleadtoseriousinjuryordeath. Unauthorizedchangestothemachine,engine, fuelorventingsystem,mayviolateapplicable safetystandardssuchas:ANSI,OSHAand NFPAand/orgovernmentregulationssuchas EPAandCARB.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

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

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.

ForKohlerEFI(ElectronicFuelInjection)Units:

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

Page 11

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

106-5517

1.Warning—donottouchthehotsurface.

99-8936

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

106-2655

1.Warning-donottouchorapproachmovingbelts; removetheignitionkeyandreadtheinstructionsbefore servicingorperformingmaintenance.

Page 12

Safety

109-6036

1.ReadtheOperator’smanual

2.Removetheignitionkeyandreadtheinstructionsbefore servicingorperformingmaintenance.

3.Heightofcut

107-3069

1.Warning-thereisnorolloverprotectionwhentherollbar isdown.

2.Toavoidinjuryordeathfromarolloveraccident,keep therollbarinthefullyraisedandlockedposition andweartheseatbelt.Lowertherollbaronlywhen absolutelynecessary;donotweartheseatbeltwhen therollbarisdown.

3.ReadtheOperator’smanual;driveslowlyandcarefully .

112-9028

1.Warning—stayawayfrommovingparts;keepallguards inplace.

114-4465

1.Hydraulicuidservice interval—50hours

2.Tirepressureservice interval—50hours

3.Lubricateservice interval—500hours

4.ReadtheOperator's Manualbefore servicingorperforming maintenance

Page 13

Safety

114-4466

1.Main,25A

2.PTO,10A

1.Parking brake—disengaged

115-9625

3.Charge,25A

4.Auxiliary,15A

2.Parkingbrake—engaged

116-8724

AllUnitsexceptEFI

1.Throttle-fast4.Choke-off

2.Throttle-slow

3.Choke-on

5.PTO

116-4858

116-8283

1.Warning—readtheOperator'sManualforinstructions ontorquingthebladebolt/nutto55-60ft-lb(75-81N-m).

116-8725

EFIUnitsOnly

1.Throttle-fast3.PTO

2.Throttle-slow

4.Checkengine

Page 14

Safety

116-8726

1.ReadtheOperator’sManualforrecommendedhydrooil.

116-8727

1.Fuelleakhazard—readtheOperator'sManual;donot attempttoremovetherollbar;donotweld,drillor modifytherollbarinanyway.

117-0346

117-3864

1.ReadtheOperator’s Manual.

2.Filltobottomofller neck;warning—donot overllthetank.

Page 15

126-0768

RearDischargeUnitsOnly

Safety

126-4108

EFIRedEquippedUnitsOnly

126-2055

1.Wheellugnuttorque95ft-lb(129N-m)(4x)

2.Wheelhubnuttorque235ft-lb(319N-m)

3.ReadandunderstandtheOperator’smanualbefore performinganymaintenance,checktorqueafterrst 100hoursthenevery500hoursthereafter.

1.Engineoiltemperature

2.Engineoilpressure6.Throttle-maximum

3.Engine failure/malfunction

4.Throttle-lowsetting; enginerotationalspeed lowidlespeed

5.Throttle-efcientsetting; enginerotationalspeed standardidlespeed-fuel economy

setting;enginerotational speedhighidlespeed

7.PTOwithclutchsaver; readtheOperator’s manual

Page 16

Safety

126-6599

1.ReadtheOperator’s manual

2.Lock

SideDischargeUnits

1.Thrownobjectshazard

-keepbystandersa safedistancefromthe machine

2.Thrownobjectshazard, mower-donotoperate withoutthedeector, dischargecoverorgrass collectionsystemin place.

126-4398

3.Unlock

1.Thrownobjectshazard

-keepbystandersa safedistancefromthe machine.

2.Cutting/dismemberment ofhand-stayawayfrom movingparts;keepall guardsandshieldsin place.

126-6464

3.Cutting/dismemberment ofhandorfoot-stay awayfrommovingparts; keepallguardsand shieldsinplace.

132-5063

“B1”,“B2”,and“B3”ModelsOnly

1.Camlock2.Camunlock

Page 17

MessageDisplay

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresence

Safety

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

switch

132-0871

1.Warning—readtheOperator’sManual;donotoperatethis vehicleunlessyouaretrained;wearhearingprotection.

2.Cuttingandpinchinghazard—keephandsandfeetaway frommovingparts;keepallguardsandshieldsinplace.

3.Thrownobjecthazard—keepbystandersaway.6.Tippinghazardonslopes—donotuseonslopesnear

4.Ramphazard—whenloadingontoatrailer,donotuse dualramps;onlyuseasingularrampwideenoughforthe machineandthathasaninclinelessthan15degrees; backuptheramp(inreverse)anddriveforwardoffthe ramp.

5.Bodilyharmhazard—lookbehindyouwhenmowingin reverse.

openwater;donotuseonslopesgreaterthan15degrees.

Page 18

Safety

132-5080

“B1”,“B2”,and“B3”ModelsOnly

1.Firmestposition

2.Softestposition

Page 19

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:

–AllexceptEFIREDEquippedUnits:

◊FullSpeed:3750±50RPM(PTOnot

engaged)

◊Idle:1500+100/-250RPM

–EFIREDEquippedUnits:

RPM±100

MaxSpeed

EfcientSpeed

LowSpeed

PTO Disengaged

36503650

25003400

15003250

PTOEngaged

–Kohler:KohlerP/N2405013 –KohlerEFI:KohlerP/N2505042

•FuelShut-OffValve:

AllUnits:1/4turn(“ON”,“OFF”).

•Fuelleveleightsegmentdisplay—righthand controlpanel.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

KohlerandKawasaki:15amps

KohlerEFI:20amps

•BatteryT ype:BCIGroupU1

•RecommendedMinimumBatteryCCA:

–AllKohler940and980engines:340CCA –Allotherengines:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

FuelSystem

•Capacity:

–XandS–Series:12.0gal.(45.4L)

–E–Series:8.0gal.(30.3L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher ((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol byvolume.Performanceproblemsand/or enginedamagemayresultwhichmaynotbe coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel stabilizerisused.

–DoNotaddoiltogasoline.

•FuelFilter:

–Kawasaki:KawasakiP/N49019-0014

Allunits:

–25ampmainfuse –25ampchargingsystemfuse –10ampPTOfuse –15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearforthePTO ,parkbrake, drivelevers,andoperatorpresenceinthemessage displayontheRHcontrolpanel.

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

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

Page 20

Specications

Note:Motioncontrolleversareadjustableto

twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engages/Disengages parkingbrake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

–Unlatchingposition:Deckdoesnotlatchat

thetransportposition.

Seat

•X-Series:

–AllModelsExcept“B1”:

Deluxesuspension(adjustablespring suspension)seatwithhighback,padded ip-uparmrests,andintegralsafetyswitch. Seatheightremainsthesame.SeatIsolation Systemforreducedvibration,toenhanceride ofstandardseat.

–“B1”Models:

Standardseatwithhighback,foampadded seatcushionwithinternalsuspension, bolstering,two-tonecover,armrests,and integralsafetyswitch.SeatIsolationSystem forreducedvibration,toenhancerideof standardseat.

•S-Series:

–“00”Models:

Standardseatwithhighback,extrawidefoam paddedseatcushionwithinternalsuspension, thickbolstering,two-tonecover,padded ip-uparmrests,integralsafetyswitch,and SeatIsolationSystemtoenhancerideof standardseat.

–“A1”and“ A2”Models:

Deluxesuspension(adjustablespringsuspension) seatwithhighback,paddedip-uparmrests,and integralsafetyswitch.Seatheightremainsthe same.SeatIsolationSystemforreducedvibration, toenhancerideofstandardseat.

Optionalseataccessoriesforunitswithstandard seats:

◊CustomRideSuspensionSystemtoenhance standardseat.Addsapproximately3inches(7.6 cm)toseatheight.

•E-Series:

–“00”or“03”Models:

Standardseatwithhighback,foampadded seatcushionwithinternalsuspension, bolstering,two-tonecover,moldedip-up armrests,andintegralsafetyswitch.

Optionalseataccessoriesforunitswith standardseats:

◊CustomRideSuspensionSystem

toenhancestandardseat.Adds approximately3inches(7.6cm)toseat height.

◊Deluxesuspensionseatwithhighback,

(adjustablespringsuspension),padded ip-uparmrests,andintegralsafetyswitch. Addsapproximately1/2inch(1.3cm)to seatheight.

◊SeatIsolationSystemforreduced

vibration,toenhancerideofstandard seat,standardseatwithCustomRideSeat SuspensionorDeluxeSuspensionSeat. Addsapproximately1inch(2.5cm)to seatheight.

–“B1”,“B2”,or“B3”Models:

Standardseatwithhighback,foampadded seatcushionwithinternalsuspension, bolstering,two-tonecover,paddedip-up armrests,andintegralsafetyswitch.Seat IsolationSystemforreducedvibration,to enhancerideofstandardseat.

–“A1”,“A2”,or“ A3”Models:

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

Page 21

Specications

•Mounting:

–XandS-Series:

Hingedseatframetotiltupseat.Heldintilted positionwithproprod.Adjustableforeand aftonseattracks.

–E-Series:

Adjustableforeandaftonseattracks.

•SeatSafetySwitch:Integratedseatswitch. Timedelayseatswitcheliminatesroughground cut-outs.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

–X-Series52inchdeck,AllS-Series,andAll

E-Series:

◊12ccParkeraxialpistonpump

◊240ccParkergerolermotor

–X–Series60and72inchdecks:

◊16ccParkeraxialpistonpump

◊280ccParkergerolermotor

•HydraulicOilType:ExmarkPremiumHydroOil.

TiresandWheels

X-Series:

Quantity

Tread

Size(60&72Decks)

Size(52Deck)

PlyRating

Pressure

DeckSize

Quantity

Tread

Size(60&72 Decks)

Size(52Deck)

S-Series:

Drive

Pneumatic(Air-Filled)

TurfMaster

24x12.00-12

23x9.50-12

13psi(90kPa)

FrontCaster

Semi-Pneumatic

“00”ModelsAllModels

Except“00”

SmoothSmooth

13x6.50-613x6.50-6

13x5.00-6

•HydraulicOilCapacity:52oz(1.5L)perside

•HydraulicFilter:P/N116-0164

•Speeds:

–E-Series48or52inchdecks:

◊0-8mph(12.9km/hr)forward.

◊0-4.5mph(7.2km/hr)reverse.

–AllE-Seriesexcept48or52inchdecksand

XandS–Series—12cc

◊0-10mph(16.1km/hr)forward.

◊0-5.5mph(8.9km/hr)reverse.

–XandS–Series—16cc

◊0-11.5mph(18.5km/hr)forward.

◊0-6mph(9.7km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Drive

Pneumatic(Airlled)

DeckSize

Quantity

Tread

Size24x9.50-1224x12.00-12

PlyRating

Pressure

48&5260&72

TurfMasterTurfMaster

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

Page 22

Specications

FrontCaster

Semi-Pneumatic

DeckSize

Quantity

Tread

Size(60& 72Decks)

Size(48& 52Deck)

E-Series:

DeckSize

Quantity

Tread

Size23x9.50-1224x12.00-12

PlyRating

Pressure

DeckSize

Quantity

Tread

Size13x6.50-613x5.00-613x6.50-12

PlyRating

Pressure

“00” Models

222

SmoothSmoothSmooth

13x6.50-613x6.50-6

13x5.00-613x5.00-6

Pneumatic(Airlled)

48&5260&72

SuperTurfSuperTurf

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

FrontCaster

Semi-PneumaticPneumatic

“A1”and “B1” Models

222

SmoothSmoothSmooth

“A2” Models

Drive

“A2”“B2”, and“00” Models

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

–72inchDeck:(182.9cm)

“A1” Models

(Airlled)

“A3” Models

13psi (90kPa)

•Discharge: –SideDischarge:Non“R”models –RearDischarge:“R”models

•BladeSize:(3ea.) –48inchDeck:16.25inches(41.3cm) –52inchDeck:18.00inches(45.7cm) –60inchDeck:20.50inches(52.1cm) –72inchDeck:24.50inches(62.2cm)

•BladeSpindles: –X-Series:Solidsteelspindleswith1.18inch

(30mm)I.D.bearings.

–SandE-Series:Solidsteelspindleswith.984

inch(25mm)I.D .bearings.

•DeckDrive:

Electricclutch:

–48and52inch,60R,72RDecks:“B”Section

beltwithself-tensioningidler.

–60and72inchDecks:5VSectionbeltwith

self-tensioningidler.

•Deck: –SideDischarge:Fulloatingdeckisattached

toout-frontsupportframe.Anti-scalprollers providemaximumturfprotection.Deck designallowsforbagging,mulchingorside discharge.

–RearDischarge:Fulloatingdeckisattached

toout-frontsupportframe.Anti-scalprollers andsidebumpersprovidemaximumturf protection.Deckdesignallowsforrear dischargeornishcut(reduceddischarge).

◊48inchDeck:3anti-scalprollers ◊52inchDeck:3anti-scalprollers ◊60inchDeck:4anti-scalprollers ◊72inchDeck:6anti-scalprollers ◊60inchDeck-RearDischarge:

4anti-scalprollers

◊72inchDeck-RearDischarge:

4anti-scalprollers

•DeckDepth—AllDeckSeries:5.5inches(14cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

Page 23

Specications

Dimensions

OverallWidth

SideDischargeUnits:

48inchDeck52inchDeck

WithoutDeck45.7inches

(116.1cm)

DeectorUp51.8inches

(131.6cm)

DeectorDown59.6inches

(151.4cm)

SideDischargeUnits:

60inchDeck72inchDeck

WithoutDeck53.0inches

(134.6cm)

DeectorUp62.5inches

(158.8cm)

DeectorDown72.8inches

(184.9cm)

RearDischargeUnits:

60inchDeck72inchDeck

WithoutDeck53.0inches

(134.6cm)

WithDeck66.2inches

(168.1cm)

45.7inches (116.1cm)

56.3inches (143.0cm)

64.8inches (164.6cm)

59.1inches (150.1cm)

73.5inches (186.7cm)

84.9inches (215.6cm)

59.1inches (150.1cm)

78.2inches (198.6cm)

OverallHeight:

AllModelsExcept“B1”,“B2”,and“B3”

RollBar-UpRollBar-Down

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

“B1”,“B2”,and“B3”Models

RollBar-UpRollBar-Down

70.5inches(179.1cm)50.3inches(127.8cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

SideDischargeUnits:

48and52 inchDeck

Drive Wheels

Caster Wheels

RearDischargeUnits:

DriveWheels41.6inches

CasterWheels33.0inches

36.2inches (91.9cm)

32.8inches (83.3cm)

60inchDeck72inchDeck

(105.7cm)

(83.8cm)

60inch Deck

41.6inches (105.7cm)

39.5inches (100.3cm)

43.6inches (110.7cm)

33.0inches (83.8cm)

72inch Deck

43.6inches (110.7cm)

47.1inches (119.6cm)

OverallLength:

SideDischargeUnits:

48and52 inchDeck

RollBarUp

RollBarDown

RearDischargeUnits:

RollBar-UpRollBar-Down

87.2inches(221.5cm)89.2inches(226.61cm)

79.2inches (201.2cm)

80.9inches (205.5cm)

60inch Deck

83.1inches (211.1cm)

84.8inches (215.4cm)

72inch Deck

86.1inches (218.7cm)

87.8inches (223.0cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

SideDischargeUnits:

48and52inch Deck

48.0inches (121.9cm)

RearDischargeUnits:

60and72inchDeck

54.7inches (139.0cm)

60inchDeck72inchDeck

51.6inches (131.1cm)

53.6inches (136.1cm)

Page 24

Specications

CurbWeight:

Unitswith48InchSide DischargeDecks

Unitswith52InchSide DischargeDecks

Unitswith60InchSide DischargeDecks

Unitswith72InchSide DischargeDecks

Unitswith60InchRear DischargeDecks

Unitswith72InchRear DischargeDecks

1080–1160lb (490–526kg)

1100–1220lb (499–553kg)

1130–1350lb (513–612kg)

1220–1410lb (553–640kg)

1260–1310lb (572–594kg)

1300–1350lb (590–612kg)

AccessoryWeightTableWorksheet:

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

Note:RearDischargeand72inchsidedischarge decksdonotrequireaweightkit.

SideDischargeUnitsOnly:

LightKit

Suspension Seat/CRSS

Bagger

Pneumatic Caster Tires

MulchKit

StriperKit

OCD02-5

HitchKit

Sunshade Kit

48inch

Deck

1112

003

-3-4-5

-2

121

52inch

Deck

-7

60inch

Deck

-4

Accessory Score

TotalAccessoryScore

TotalAccessoryScoreRequiredW eightKit(s)

0–9

10–19

20andHigher*Two116-1173Undertoe

Nonerequired

*116-1173Undertoe boardmountweightkit

boardmountweightkits orone116-1173Undertoe boardmountweightkit andone116-1238Front toeboardmountweight kit

*48and52inchunitsthathaveanundertoeboard weightasstandard,canaddanadditionaltoeboard weightforprimaryaccessoryweighting(scores 10-19);andfronttoeboardweightkitforsecondary accessoryweighting(scores20andhigher).Other unitsshouldinstallarstundertoeboardkitfor primaryaccessoryweighting(scores10-19);anda

Page 25

Specications

secondundertoeboardkitforsecondaryaccessory weighting(scores20andhigher).

*60inchunitsthathaveanundertoeboardmount weightasstandard,require116-1238fronttoeboard topmountkitinsteadof116-1173.

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut(Eand S-Series)

BladeDriveSheave MountingNut(X-Series)

CutterHousingSpindle Nut(X-Series)

BladeMountingBolt (lubricatewithanti-seize)

Anti-ScalpRollerNyloc Nut–SideDischargeUnits (SeeFigure19)

Torque

130-160ft-lb (176-217N-m)

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

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

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

50–55ft-lb(68-75N-m)

BoltLocation

SuspensionPlatformRear CrossShaft5/16inch RetentionBolt

SuspensionPlatform RearCrossShaft5/16in BearingRetainingnut

CamLock1/2inchNut

Torque

15-19ft-lb(20-26N-m)

215-265in-lb(24-30N-m)

75-85in-lb(8-10N-m)

Anti-ScalpRollerNyloc Nut–RearDischargeUnits (SeeFigure20)

EngineMountingBolts

WheelLugNuts

WheelMotorMounting Bolts

WheelHubSlottedNut211-260ft-lb

RolloverProtection System(RollBar)1/2 inchMountingBolts

ClutchRetaining Bolt(securedwith threadlocker)

RearDischargeSide Bumpers

SuspensionPlatformSide pivot1/2inchMounting Nut

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

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

85-105ft-lb (115-142N-m)

67-83ft-lb (50-113N-m)

(286-352N-m)

100-110ft-lb (136-149N-m)

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

10-12ft-lb(14-16N-m)

70-80ft-lb(95-108N-m)

RearShockLower mounting1/2inch MountingNut

80-90ft-lb(108-122N-m)

Page 26

Operation

ProductOverview

1.RolloverProtection System(ROPS)

2.Rear,shockassembly (“B1”,“B2”,&“B3” Modelsonly)

3.EngineControls(right console)

4.Seatbelt

5.Motioncontrollevers

Figure4

6.Fuelcap

7.Front,shockassembly (“B1”,“B2”,&“B3” Modelsonly)

8.Heightofcutdecklift pedal

9.Parkingbrakelever

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (Figure5).

Whenthemotioncontrolleversareintheneutral position,theLCDindicatorappearsinthemessage displayontheRHconsole(seeFigure9).

Page 27

RightConsole

Operation

Figure6

Figure5

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

ChokeControl(AllUnitsExcept KohlerEFI)

Locatedonrightconsole(blacklever)(seeFigure6).

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

1.Fuses

2.Messagedisplay5.Throttle

3.Ignitionswitch

4.PTOengagementswitch

6.Choke

ThrottleControl (AllUnitsExceptEFIREDEquipped Units)

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

ThrottleControlwithClutchSaver (EFIREDEquippedUnits)

Locatedonrightconsole.

Thethreepositionthrottleswitchisusedtocontrol enginespeed(Figure7).

Whentheswitchisinthemiddleposition(Efcient mode):

•Pressingdownonthefrontoftheswitchwill placeitinMaxmode.

•Pressingdownontherearoftheswitchwillplace itinLowmode.

Page 28

Operation

Figure7

1.PTOengagementswitch

2.Frontposition4.Rearposition

3.Middleposition

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Note:TheLCDindicatorappearsinthemessage displayontheRHconsolewhentheparkbrakeis engaged(seeFigure9).

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

PositioningthethrottleswitchtoMax,Efcient,or Lowallowsforsixdifferentoperationalmodes:three modeswiththePTOdisengaged(transport)and threemodeswithPTOengaged(mow).Seethetable belowtodeterminetheappropriateenginespeed.

ThrottleSwitch Position

1.FrontPositionMaximum

2.Middle Position

3.RearPosition

Transport Mode(PTO Disengaged)

transport speed/Highidle

Medium transport speed/Clutch engagement

Lowtransport speed/Lowidle

MowMode (PTO Engaged)

MaxThrottle Setting: Maximum powerfor extrememowing conditions

Efcient ThrottleSetting: Standard powerfor normalmowing conditions. LoweredEngine RPMandmost fuelefcient modefor mowing.

LowThrottle Setting:Reduces deckpacking inwetmowing conditions

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

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

Figure8

1.Off3.Start

2.On

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

HourMeter

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe RHmotioncontrollever.

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Page 29

Figure9

1.LCDIndicators

2.Lowfuelindicatorlight

3.Fuellevelbardisplay

4.Lowvoltageindicatorlight

5.Hour/Voltagedisplay

Thehourmeterisrecordingwhenthedecimalpoint isashinginHour/Voltagedisplay.

Hoursaredisplayedwhenthekeyisofforwhenthe machineisrunning.

Note:Iftheignitionkeyisturnedtothe“ON” positionforafewsecondsbeforecrankingtheengine, thebatteryvoltagewilldisplayintheareawherethe hoursarenormallydisplayed.

Operation

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck,which couldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

WARNING

Theengineandhydraulicdriveunitscanbecome veryhot.Touchingahotengineorhydraulic driveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrivewheel releasevalves.

Locatedonthebackoftheunitizedhydraulicdrive units,belowtheenginedeck.

Duringnormaloperatingconditions,thedrivewheel releasevalvesarepositionedhorizontally .Ifthe machinehastobepushedbyhand,thevalvesmust beinthe“released”position(seeFigure10).

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

FuelShut-OffValve

Locatedbehindandbelowtheseat.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

FuelGauge

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thefuellevelisshownonabardisplay.Theindicator lightappearswhenthefuellevelislow(approximately onegallonremaininginthetank).

Figure10

CoolingFanCongurationShown

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure10), rotatethehandle1/4turntotheverticalposition untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2inFigure10), rotatethehandle1/4turntothehorizontalposition untilithitsagainstthestop.

Page 30

Operation

Note:Thehandlemustbehorizontalandagainst

thestopforoperation.

DoNottowmachine.

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6orFigure7).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isdisengaged(seeFigure9).

Note:TheEFIREDEquippedUnitshaveaclutch saver,whichallowsthethrottletoautomatically reduceengineRPMwhenthePTOswitchis disengaged.EngaginganddisengagingthePTO switch,changestheenginethrottlebetweenmowand transportmode(referencethetableintheThrottle

ControlwithClutchSaver(EFIREDEquipped Units)section).

Positioninthetransportlatchingpositionto automaticallylatchthecuttingdeckwhenraisedto thetransportposition(seeitem1inFigure11).

Inthenon-latchingposition,thedeckwill automaticallyreturntothecuttingheightwhenthe pedalislowered(seeitem3inFigure11).

Figure11

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

LowVoltageIndicator

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Alowvoltagecondition(lessthan12.3volts)exists whentheLCDindicatorappearsonthemessage displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

TransportLock

Locatedontheheightofcutadjustmentplatestothe rightoftheparkingbrake.

ElectronicControlUnitMalfunction Indicator (EFIUnitsOnly)

Themalfunctionindicatorlight(MIL)isthelight locatedintherightconsolepanel–therightlight belowthethrottlecontrol.

Theelectroniccontrolunit(ECU)continuously monitorsoperationoftheEFIsystem.Ifaproblem orfaultwithinthesystemisdetected,theMIL isilluminated.Followthetroubleshootingsteps outlinedintheKohlerengineoperator’ smanualifthe MILisilluminated.

LowOilPressureWarningLight (EFIREDEquippedUnitsOnly)

Locatedintherightconsolepanel–themiddlelight belowthethrottlecontrol.

Iftheengineoilpressuredropsbelowasafelevel, thislightwillbeilluminatedandtheenginewill automaticallyreduceRPMandremaininasafe modeuntilthecorrectiveactionistaken(seethe Troubleshootingsection).

Page 31

Operation

HighOilTemperatureWarningLight (EFIREDEquippedUnitsOnly)

Locatedintherightconsolepanel–theleftlightbelow thethrottlecontrol.

Iftheengineoiltemperaturerisesaboveasafe level,thislightwillbeilluminatedandtheengine willautomaticallyreduceRPMandremaininasafe modeuntilthecorrectiveactionistaken(seethe Troubleshootingsection).

Pre-Start

Fillfueltankonlevelground.SeeFuel RecommendationsintheSpecicationssectionfor

additionalgasolineinformation.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

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

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

interlockpartially.Applyforwardpressuretothe rollbarupperhoopandobservethattheknobs returntothecompletelylatchedposition.

Figure12

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

5.Makesuretheknobsarefullyengagedwiththe rollbarintheraisedposition.Theupperhoopof therollbarmayneedtobepushedforwardor pulledrearwardtogetbothknobsfullyengaged (seeFigure13).

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Therollbarisanintegraland

effectivesafetydevice.Keeptherollbarinthe raisedandlockedpositionwhenoperatingthe mower.Lowertherollbartemporarilyonlywhen absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe tabsinterlockingasshowninFigure12tolock therollbarintheraised,operateposition.

2.Applyforwardpressuretotheupperhoopofthe rollbar.

3.Pulltheknobandrotate90°toholdinthe unlatchedpositiontolowertherollbar.

4.Toreturntotheoperateposition,raisetheroll bar,andthenrotateknobs90°sothatthetabs

Figure13

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

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

Page 32

Operation

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

4.Placethethrottle:

•ForAllUnitsExceptEFIREDEquipped Units:midwaybetweenthe“SLOW”and “FAST”positions.

•ForEFIREDEquippedUnits:rockerswitch inthe“LOW”position.

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

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

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

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

EngagingthePTO

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanoperate.

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

Note:ThisisnotnecessaryonEFIRED Equippedunits.Theclutchsaverfeatureallows thePTOtobeengagedatanyspeed.

2.PullthePTOswitchoutwardtoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin mowing(exceptEFIREDEquippedunits).

ForEFIREDEquippedunits:Placethethrottle intheEfcientmodetoobtainmaximumfuel economy(referencethetableintheThrottle

ControlwithClutchSaver(EFIRED EquippedUnits)sectionforothermowing

conditions).

DisengagingthePTO

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

Note:ThisisnotnecessaryonEFIRED Equippedunits.Theclutchsaverfeatureallows thePTOtobedisengagedatanyspeed.

2.PushthePTOswitchintodisengagetheblades.

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Movethemotioncontrolleversouttotheneutral lockposition.

3.Engagetheparkingbrake.

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

Page 33

5.DisengagethePTO.

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

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

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

Operation

Figure14

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

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

Whenthemotioncontrolleversarepositionedfully outward(apart)intheT-slot,thedrivesystemisin theneutrallockposition(Figure14).

Note:The“N”LCDindicatorappearswhenboth leversareintheneutrallockposition.

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Page 34

Operation

Toturnright,releasepressureontheRHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheright.

Toturnleft,releasepressureontheLHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheleft.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheCuttingHeight

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

1.Stopthemachineandmovethemotioncontrol

Figure15

leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

3.Positionthetransportlockinthelatching position.

4.Raiseandlockthedecktothe51/2inch(14cm) transportposition(Figure17).

Thedeckisraisedbypushingthefootoperated deckliftpedalforward.Thepedalislocatedatthe frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure16

Figure17

1.Deckfootpedal3.Heightofcutdecal

2.Heightadjustmentpin4.Transportlockcontrol

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Page 35

Operation

Seethedecalonthesideofthedeckliftplatefor cutheights.

6.Pushthedeckliftpedal,releasethetransportlock andallowthedecktolowertothecuttingheight.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingthemounting hardware.

6.Placetherollersinoneofthepositionsshown (Figure18).Rollerswillmaintain3/4inch(19 mm)clearancetothegroundtominimizegouging androllerwearordamage.

oftheboltandthemountingbracket(see Figure19).

B.Torquethe3/8nylocnutto50–55ft-lb

(68-75N-m).

Figure19

1.3/8-16X33/4Grade8 bolt

2.Springdiscwasher (conetowardsbolthead)

3.Frontrightanti-scalp

4.3/8nyloc-torqueto50-55

bracketshown

ft-lb(68-75N-m)

Figure18

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Reinstallthemountinghardware.

•SideDischargeUnits:

A.Besuretherollerboltsareinstalledwith

thespringdiscwasherbetweenthehead

•RearDischargeUnits:

Torquethe3/8nylocnutto30-35ft-lb(41-47 N-m)(seeFigure20).

Figure20

Note:Thefootoperateddeckliftassistlevercanbe

usedtomomentarilyliftthedecktoclearobjects.Be surethatPTOisdisengaged.

Page 36

Operation

g030021

AdjustingtheSideBumpers (RearDischargeUnitsOnly)

Mountthesidebumpersinthetopholeswhen operatinginheightofcutshigherthan21/2inches (64mm)andinthecenterholeswhenoperatingin heightofcutslowerthan21/2inches(64mm).

Note:Whenbumpersbecomeworn,switchthe bumperstotheoppositesidesofthemower,ipping themover.Thisallowsthebumperstobeusedlonger beforereplacingthem.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Positionthetransportlockinthelatching position.

AdjustingtheSuspensionSeatFor “B1”,“B2”,and“B3”ModelsOnly

Thesuspensionsystemadjuststoprovideasmooth andcomfortableride.Adjustingthereartwoshock assembliesistheeasiestandquickestadjustment forchangingthesuspensionsystem.Positionthe suspensionsystemwhereyouaremostcomfortable.

•UnlatchingtheSeat

6.Removetheboltsandnutsfromeachbumper.

Figure21

1.Bolt3.Nut

2.Bumper

7.Moveeachbumpertothedesiredpositionand securethemwiththeboltsandnuts.Torquenut to10-12ft-lb(14-16N-m).

Figure22

•AdjustingtheRear,ShockAssemblies

Theslotsfortherear,shockassemblieshave detentpositionsforreference.Therear,shock assembliescanbepositionedanywhereintheslot, notjustthedetentpositions.

Thefollowinggraphicshowsthepositionfora softorrmrideandthedifferentdetentpositions (Figure23).

Note:Onlyusethetoporcentersetsofholesto adjustthebumpers.Thebottomholesareused whenswitchingsides,atwhichtimetheybecome thetopholesontheothersideofthemower.

Page 37

g030019

Operation

Figure23

1.Firmestposition3.Detentsintheslots

2.Softestposition

Note:Ensuretheleftandrightrear,shock assembliesarealwaysadjustedtothesame positions.

Adjusttherear,shockassemblies(Figure24).

Figure24

•AdjustingtheFront,ShockAssembly

Thefront,shockassemblyissetatthemiddle positionandisnormallynotadjusted.

Page 38

Operation

g029989

g028043

Toadjustthefront,shockassembly,opentheoor panandadjustitbyusingaspannerwrench(Part No.132–5069)oraslip-jointpliers(Figure25).

Figure25

1.Middleposition3.Firmride

2.Softride

Transporting

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarylightingandmarkingasrequiredbylaw . Thoroughlyreadallofthesafetyinstructions. Knowingthisinformationcouldhelpyou,your family,pets,orbystandersavoidinjury.

LoadingtheMachine

Useextremecautionwhenloadingorunloading machinesontoatraileroratruck.Useafull-width rampthatiswiderthanthemachineforthis procedure.Backuprampsanddriveforwarddown ramps(Figure26).

Figure26

1.Backupramps

Important:Donotusenarrowindividualramps foreachsideofthemachine.

Ensuretherampislongenoughsothattheanglewith thegrounddoesnotexceed15degrees(Figure27). Onatground,thisrequiresaramptobeatleastfour times(4X)aslongastheheightofthetrailerortruck bedtotheground.Asteeperanglemaycausemower componentstogetcaughtastheunitmovesfromthe ramptothetrailerortruck.Steeperanglesmayalso causethemachinetotiporlosecontrol.Ifloadingon ornearaslope,positionthetrailerortrucksothatit isonthedownsideoftheslopeandtherampextends uptheslope.Thiswillminimizetherampangle.

2.Driveforwarddown ramps

Totransportthemachine:

•Lockthebrakeandblockthewheels.

•Besurethefuelshut-offvalveisclosed.

•Securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes.

•Secureatrailertothetowingvehiclewithsafety chains.

WARNING

Drivingonthestreetorroadwaywithoutturn signals,lights,reectivemarkings,oraslow movingvehicleemblemisdangerousandcan leadtoaccidentscausingpersonalinjury.

Donotdrivemachineonapublicstreetor roadway.

Page 39

WARNING

g027996

Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga machineonaramp.

•EnsurethattheROPSisintheupposition andusetheseatbeltwhenloadingor unloadingthemachine.Ensurethatthe ROPSwillclearthetopofanenclosedtrailer.

•Useonlyafull-widthramp;donotuse individualrampsforeachsideofthemachine.

•Donotexceeda15-degreeanglebetweenthe rampandthegroundorbetweentheramp andthetrailerortruck.

•Ensurethelengthoframpisatleastfour times(4X)aslongastheheightofthetrailer ortruckbedtotheground.Thiswillensure thatrampangledoesnotexceed15degrees onatground.

Operation

•Backuprampsanddriveforwarddown ramps.

•Avoidsuddenaccelerationordeceleration whiledrivingthemachineonarampasthis couldcausealossofcontroloratip-over situation.

1.Full-widthrampin stowedposition

2.Sideviewoffull-width rampinloadingposition

3.Notgreaterthan 15degrees

Figure27

4.Rampisatleastfour times(4X)aslongasthe heightofthetraileror truckbedtotheground

5.H=heightofthetraileror truckbedtotheground

6.Trailer

Page 40

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Aftertherst250hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Changethehydrauliclteranduid.

WARNING

Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Beforeeachuseordaily

Every50hours

Every100hours

Every200hours

Every250hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrofancoolingguards,hydrocoolingns,andfan.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

•Checkthesparkplugs.

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

Page 41

Maintenance

MaintenanceService

Interval

Every500hours

Yearly

MaintenanceProcedure

•Replacethesecondaryaircleanerelement(Mayneedmoreoftenundersevereconditions. SeetheEngineOwner'sManualforadditionalinformation.)

•Changethehydrauliclteranduid(Every250hours/YearlyifusingMobil115W50)

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Greasethedeckandpumpidlerpivots.

•Greasethefrontcasterpivots.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner'smanualforanappropriateAPIrating andviscosity.DoNotoverll.

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

CheckBatteryCharge

ServiceInterval:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

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

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

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

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

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

Charging Interval

No Charging Required

30Minutes

1Hour

Page 42

Maintenance

Voltage Reading

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

Maximum Charger Settings

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

2Hours

3Hours

6Hoursor More

Important:ForKohlerEFIunits:Unplugthe harnessfromtheECUbeforeperformingany weldingontheequipment.

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

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

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricaland/orEFIsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

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

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe engineorEFImayoccur.

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

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

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure28.

Page 43

Figure28

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

Maintenance

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

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

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK (seeFigure29).

Figure30

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Makesurethesplinesonthebushingare engagedinthespindlebeforetighteningthe bolt.

Figure29

1.Engineblock

2.Negative(–)cable

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

Figure31

1.Usewrenchhereforbladeinstallation.Thisnuthas beentorquedto90ft-lb(122N-m)minimum

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

Page 44

Maintenance

C.Applylubricanttothreadsofbladeboltto

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

Important:Onreardischargedecks,theRH bladerotatescounterclockwise.Besureto reinstallthatbladeontotheRHspindleonly .

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

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

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

ofseat(butdonotgetoffofmachine)engine mustinitiateshutdownafterapproximately1/2 secondhaselapsed(seathastimedelaykillswitch topreventcut-outsonroughterrain).

Runengineatone-thirdthrottle,engagePTO andraiseoffofseat(butdonotgetoffof machine)enginemustinitiateshutdownafter onesecondhaselapsedifthehandlesarein.The delaywillbe1/2secondifthehandlesareout.

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

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

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

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing .

CheckRolloverProtections Systems(RollBar)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe knobsareingoodworkingcondition.Makesurethe knobsarefullyengagedwiththeROPSintheraised position.Theupperhoopoftherollbarmayneed tobepushedforwardorpulledrearwardtogetboth knobsfullyengaged.

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

2.Checkthekillcircuits.Runengineatone-third throttle,disengageparkingbrakeandraiseoff

Page 45

Maintenance

G016165

EngineOwner'sManual foradditionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.SeetheEngineOwner'sManualformaintenance instructions.

CheckAirFilterAssembly(if

Figure32

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

equipped)

ServiceInterval:Asrequired

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandcover installed.

1.Whencheckingorreplacingtheairlterelement, makesuretheairlterassemblyisinstalledinthe brackets.

2.Positiontheaircleanercoversothatthe breathervalvedoesnotinterferewiththethrottle mechanism.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

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

Every500hours—Replace thesecondaryaircleaner element(Mayneedmore oftenundersevere conditions.Seethe

Figure33

1.Aircleanercover3.Breathervalve

2.Throttlemechanism

3.Securethecoverwithlatches.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours/Yearly (whichevercomesrst)

Page 46

Maintenance

(Mayneedmoreoften undersevereconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

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

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

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

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

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe hydraulicoil.

3.Slidetheseatalltheforwardtoaccessthecapson theLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand removecap.

5.Wipethedipstickcleanandre-insertthecapback intothehydro.Lightlytightenthecap.

Figure34

1.Full2.Add

Note:Theoillevelonthedipstickwillbe incorrectiftheoilischeckedwhentheunitishot.

7.Ifthedipstickoillevelisatthe“add”markadd ExmarkPremiumHydroOil.

8.Replacehydraulicreservoircapandtightenuntil snug.DoNotovertighten.

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetiresandpneumatic casters.

3.Inatedrivetiresandpneumaticcastersto13psi (90kPa).

4.Semi-pneumaticcastertiresDoNotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

6.Removethecapagainandcheckthelevelofthe oilonthedipstick.SeeFigure34foroillevels.

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Page 47

Maintenance

2.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

3.Checkundermachinetoinspectthepumpdrive belt.

Note:Noadjustmentsarerequiredforbelt tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.Deckand PumpIdler Pivots

2.Front Caster Pivots

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

Initial

Pumps

Numberof

Places

Service

Interval

Yearly

*Yearly

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure35

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

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

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

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

9.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

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

Page 48

Maintenance

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

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

LubricateDeckLiftPivot

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner's Manual.

ReplacementFilters

KawasakiKawasaki

P/N49019-0014

Kohler

KohlerEFI

Note:Itisimportanttoreinstallthefuellinehoses andsecurewithplastictiesthesameastheywere originallyinstalledatthefactorytokeepthefuelline awayfromcomponentsthatcouldcausefuelline damage.

KohlerP/N2405013

KohlerP/N2505042

ChangeHydraulicSystem FilterandFluid

ServiceInterval:Aftertherst250hours

Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearly ifusingMobil115W50 thereafter)

Note:OnlyuseExmarkHydroFilter–PartNo.

116-0164forsummerorwinter.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

CAUTION

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ForKohlerEFIUnits:

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem.

Page 49

Maintenance

6.Usingasocket,unscrewlterstoremoveand allowoiltodrain.

7.Beforeinstallingthenewlters,applyathincoat ofExmarkPremiumHydroOilonthesurface ofthetworubberseals.

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

9.FillthehydraulicsystemasstatedinCheck HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50Afterrst250hours

*Mayneedmoreoftenundersevereconditions.

10.Removethecatchpanandproperlydisposeof hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

ServiceInterval

Afterrst250hours *Every500hours/Y early thereafter

*Every250hours/Y early thereafter

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresult inpersonalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

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

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

13.Removethejackstands.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

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

ThreadLockingAdhesives

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

•ROPSspringpinhousing.

•Hydropumpcontrolarm,linkagebolt,and attachmentbolt.

•Hydrocoolingfanscrew .

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof enginecrankshaft.

Threadlockingadhesivesarerequiredforsome hardwareonengines—seetheEnginemanual.

MobilHTSGrease(Or Food-GradeAnti-seize) X-SeriesOnly

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocation:

Note:DoNotuseanti-seizeonwheelhub.

Betweenthespindlesandbearings.

Page 50

Maintenance

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact. Dielectricgreaseshouldnotbeappliedtosealed connectors.

Adjustments

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

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbeenough supportormaymalfunctionallowingtheunitto fall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checkthetirepressureindrivetiresand pneumaticfrontcastertires(ifequipped).Proper inationpressurefortiresis13psi(90kPa). Adjustifnecessary.

4.Positionthetransportlockinthelatching position.

5.Pushthefootpedalallthewayforwardandthe deckwilllatchatthe51/2inch(14cm)transport position(Figure36).

Figure36

1.Footpedal3.Transportlock

2.Heightofcutpin

6.Inserttheheightadjustmentpinintothe3inch (7.6cm)cuttingheightlocation.

Page 51

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargedeector(sidedischargeunits only).

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

Note:Inmostconditions,thebacktipsonthe sidebladesshouldbeadjusted:

SideDischargeUnits:1/4inch(6.4mm)higher thanthefront.

RearDischargeUnits:tobelevelwiththefront.

Maintenance

Figure38

1.Adjusterlink3.Adjuster

2.Jamnut

Figure37

1.SideDischarge:31/4inches(8.3cm) RearDischarge:3inches(7.6cm)

2.Backbladetip

3.Frontbladetip

4.3inches(7.6cm)

5.Levelsurface

10.Adjusttheheight—toincrease,turnthe adjusterscrewclockwise;todecrease,turn counterclockwise.

•SandE-Series:

Finetunethefrontdeckliftassemblyby turningtheadjusterscrewuntilitreachesthe 3inch(7.6cm)height(seeFigure39).

Figure39

1.Adjusterscrew2.Jamnut

•X-Series:

Loosenthejamnutsonthetopofeachdeck adjuster.Finetunetheadjusteronthefront deckliftassemblybyturningittoget3inch (7.6cm)height(seeFigure38).

11.Measurethebacktipheight.Finetunerear adjustersasrequired;thesinglepointadjustment canbeutilizedtogainmoreadjustment.

Page 52

Maintenance

•SideDischargeUnits:Thebacktipsofthe sidebladesshouldmeasure31/4inches(8.3 cm).

•RearDischargeUnits:Thebacktipsofthe sidebladesshouldmeasure3inches(7.6cm).

12.Re-measureuntilallfoursidesarethecorrect height.Tightenallthenutsonthedeckliftarm assemblies.

13.Lowerdischargedeector(sidedischargeunits only).

14.Ifthefourdeckadjustersdonothaveenough adjustmenttoachieveaccuratecutheightwiththe desiredrake,thesinglepointadjustmentcanbe utilizedtogainmoreadjustment(seeFigure40).

Figure41

1.Mowerdeck3.Backhole

2.Fronthole

Figure40

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

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

Note:OnRearDischargeUnits:Themower deckisattachedinthefrontholesatthefactory (seeFigure41).Ifneeded,usethebackholesfor furtheradjustmentwhenlevelingthemowerdeck.

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

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

17.Re-tightenfrontandrearheight-of-cutplate mountingbolts.

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

18.Repeatsteps9through13.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Page 53

Checktomakesurebrakeisadjustedproperly.This proceduremustbefollowedaftertherst100hours orwhenabrakecomponenthasbeenremovedor replaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandengagetheparkingbrake(leverisin the“up”position).

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey .

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

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

8.Checktoseeifthereisavisiblegapbetweenthe L-bracketandthelinkagestop(seeFigure42).

Maintenance

Figure42

LeftSideShown

1.L-bracket4.Rearlinkageassembly

2.Linkagestop

3.Gap

9.Disengagetheparkbrake,thelevershouldbein thedownposition.Turnthewheelhubbyhand inbothdirectionsrelativetothecaliper;thewheel hubshouldmovefreelybetweenthecaliper.

10.Ifagapisneededorthewheelhubdoesnot movefreely:

A.Disengagetheparkbrake.

B.Disconnectandne-tunetherearlinkage

assembly:

•Shortenthelinktocreateagap.

•Lengthenthelinktoallowwheelhub movement.

C.Reconnecttherearlinkageassembly.

5.Caliper

6.Wheelhub

11.Engagetheparkingbrakeandcheckthegap.

12.Repeatsteps9through12untilavisiblegapis achievedandthewheelhubrotatesfreely.Repeat forthebrakeontherightside.

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

14.Installthereartiresandtorquelugnutsto85-105 ft-lb(115-142N-m).

15.Removejackstands.

Page 54

Maintenance

G011733

ElectricClutchAdjustment

Noadjustmentnecessary.Howeveronunitswith60 inchdecks,whentheclutchbrakehasworntothe pointwheretheclutchnolongerengagesconsistently, theshimcanberemovedtoextendtheclutchlife.

Figure44

Figure43

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

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

2.Usingapneumaticline,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers.

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

1.Brakemountingbolt

2.Shim

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

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

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

E.Usinga0.010inchthickfeelergauge,verify

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

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

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

A.Loosenbothbrakemountingboltsone-half

toonefullturn(seeFigure44).

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

Figure45

1.Feelergauge

Page 55

Figure46

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstepF.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewith

thePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly ,referencethe Troubleshootingsection.

Maintenance

WARNING

Enginemustberunninganddrivewheelsmust beturningsoadjustmentscanbeperformed. Contactwithmovingpartsorhotsurfacesmay causepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift pedalandremovetheheightofcutpin.Lower decktotheground.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.Theswitchisapartoftheseat assembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

6.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulicoil uptooperatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

MotionControlLinkage Adjustment

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

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengths byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(Figure47).Movethemotion controlleverstothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningor slightlycreepinreverse.

Page 56

Maintenance

Figure47

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

Figure48

RHMotionControlShown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure48formountingoptions.

MotionControlNeutralLock PivotAdjustment

Theangednutcanbeadjustedtoobtainamore desiredmotioncontrolleverresistance(Figure49).

Figure49

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

Page 57

Maintenance

MotionControlHandle Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(Figure50).

Figure50

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

1.Loosenthescrewsonacoverplate(seeFigure51).

2.Slidethecoverplatebackwardorforwardto adjustthetraveloftheleverandtightenthe screws.

3.Drivethemachineandcheckthefullforward tracking.

4.Repeatsteps1through3untildesiredtracking isobtained.

Figure51

RHMotionControlShown

1.Screw

2.Coverplate

3.Motioncontrollever

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraftFigure50.Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

MotionControlFullForward TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthecoverplates.

CasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut untilwashersareatandbackoff1/4ofaturn toproperlysetthepre-loadonthebearings.If disassembled,makesurethespringdiscwashersare reinstalledasshowninFigure52.

Page 58

Maintenance

1.Springdiscwashers

Figure52

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea.

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

3.Makesurecoolingshroudsarereinstalled. Operatingtheenginewithoutcoolingshroudswill causeenginedamageduetooverheating.

CleanHydroFanCooling Guards,HydroCoolingFins, andFan

ServiceInterval:Beforeeachuseordaily

Removingdebrisfromthehydrofancoolingguards, hydrocoolingns,andfanwillallowthehydro

Page 59

Maintenance

g030538

systemtoruncoolerandimprovethelifeofthe hydrosystem.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Slideseatallthewayback,thenlifttheseatto accesstheLHandRHhydrodrivearea.

3.Removeaccumulateddebrisfromthehydrofan coolingguards,hydrocoolingns,andfan.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CleanGrassBuild-UpUnder Deck

CleaningtheSuspension System

Note:Donotcleantheshockassemblieswith

pressurizedwater.

Figure53

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

Page 60

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank

Enginewillnotstart,startshard,orfailsto keeprunning

1.PTOisengaged.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

4.Batterydoesnothaveafullcharge.

5.Electricalconnectionsarecorroded,loose orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

8.Faultymodule.8.Replacemodule.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow .

4.Thethrottleandchokearenotinthe correctposition.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly.

9.Electricalconnectionsarecorroded,loose orfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.

13.Faultymodule.13.Replacemodule.

14.MILilluminatesandblinks14.ContactanAuthorizedServiceDealer

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral lockposition.

Chargethebattery.SeeCheckBattery

ChargeandRecommendedJump StartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

11.Clean,adjustorreplacesparkplug.

12.Checkthesparkplugwireconnection.

OiltemperaturelightisonandengineRPM islow

1.EngineControlUnithaslimitedengine RPMs,knownas“limp”mode.

1.Checkoillevel.Iflevelisabove“add”, contactanAuthorizedServiceDealer.

Page 61

Troubleshooting

ProblemPossibleCauseCorrectiveAction

OilpressurelightisonandengineRPMislow

Enginelosespower

Mowerpullsleftorright(withleversfully forward)

Machinedoesnotdrive

1.EngineControlUnithaslimitedengine RPMs,knownas“limp”mode.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Lowoilpressure

8.Highoiltemperature

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating” position.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

1.Letenginecoolandcheckoillevel.Iflevel isabove“add”,contactanAuthorized ServiceDealer.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthe coolingnsandairpassages.

6.ContactanAuthorizedServiceDealer.

7.Checkoillevel.Iflevelisabove“add”, contactanAuthorizedServiceDealer.

8.Letenginecoolandcheckoillevel.Iflevel isabove“add”,contactanAuthorized ServiceDealer.

1.Positionhandlein“operating”position; seeDriveWheelReleaseV alvessection inOperation.

2.Changethebelt.

4.Replacethespring.

cooldown.

Unevencuttingheight.

Abnormalvibration

Bladesdonotrotate.

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

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

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

2.Deckbeltisoffpulley .2.Installbeltonclutchanddeckpulleys,

3.Brokenormissingidlerspring.

4.Drivebeltnotroutedcorrectly.4.Refertobeltroutingdecalondeck.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

idlers,andtensioningidlerperrouting decalondeck.

3.Replacethespring.

Page 62

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Clutchwillnotengage.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply .4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

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

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary .

3.Replaceclutch.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Page 63

Schematics

G032375

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REG OR ECU POWER

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

GND-S/D

GND OR NC

PINK

FUEL OR MIL POWER

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

EAFBC

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

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

7 4 5 9 3 6 8 1 2

C A B

A B

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—AllunitsexceptKohlerEFI

Page 64

G031228

STARTER

ENGINE

INDICATOR

LED

RED

MIL PWR ECU PWR NC GND-S/D START

MIL GND ECU PWR NC

GND-S/D START

B+

WHITE

BLUE

RED

BLACK

1 6 2 5 4 3

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

ECU PWR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

GND-S/D

PINK

MIL PWR

BROWN

VIOLET

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

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

7 4 5 9 3 6 8 1 2

C A B

A B

EAFBC

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram—KohlerEFI

Page 65

ElectricalDiagram—KohlerEFIRedEquippedUnits

Schematics

Page 66

Schematics

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

(BRAKE

OFF)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

(PTO OFF)

SW2

25A

(SEAT)

(OPERATOR

NOT IN SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

GND-S/D

REG

START

SOLENOID

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

(LH HYDRO

IN DRIVE)

(RH HYDRO

IN DRIVE)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G032372

FUEL

STARTER

ElectricalLogicSchematic—Kawasaki

Page 67

ElectricalLogicSchematic—KohlerCarburated

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

25A

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

GND-S/D

REG

START

FUEL

SOLENOID

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KOHLER CARB

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

FNCA

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G032373

(BRAKE

OFF)

(PTO SWITCH)

(PTO OFF)

SW2

(OPERATOR

NOT IN SEAT)

(LH HYDRO

IN DRIVE)

(RH HYDRO

IN DRIVE)

Schematics

Page 68

Schematics

S R

PK PK

LTGR

BN V

R BK

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

PTO

CLUTCH

(PTO SWITCH)

SW2

LAMP

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

GND-S/D

MIL GND

ECU PWR

START

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

352

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G032376

R/W R/BK

KOHLER EFI

STARTER

FUEL

PUMP

ECU

10A

GND

10A

30A

SENSOR

INJECTORS

IGNITION

COILS

25A

(BRAKE

OFF)

(PTO OFF)

(OPERATOR

NOT IN SEAT)

(LH HYDRO

IN DRIVE)

(RH HYDRO

IN DRIVE)

ElectricalLogicSchematic—KohlerEFI

Page 69

S R

V PK

LTGR

PK V

BK/OR

BK/W

R/W R/BK

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

LAMP

(SEAT)

SW7

235

(START RELAY)

(NEUT_R)

SW5

KILL

MIL

GND

OIL

PRESS

KEY SWPWR

START

KOHLER EFI

(NEUT_L)

SW4

1 2

START_RELAY

MAGNETO

FUEL_SOLENOID

5 3 2 11 4 9 10 12

GROUND

FUEL

PTO

NEUTRAL

BRAKE

SEAT

KEY A

KEY S

B+

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

235

KEY SW

OPTIONAL

ACCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

R/W = RED/WHITE

R/Y = RED/YELLOW

BK/OR = BLACK/ORANGE

BK/W = BLACK/WHITE

G032374

STARTER

R/Y R/Y

FUEL

PUMP

ECU

OIL

TEMP

E-GOV GCU

CLUTCH

VIGN

ENG SEL

PTO SW

SPD SEL

510116

ENABLE GND

GND

E-GOV

OIL PRESS

OIL TEMP

ENABLE

RED MODULE

ENABLE

MODULE

(OPTIONAL)

643

ROCKER

SWITCH

GND

OIL PRESS

LIGHT

BK/W

BK/OR

OIL TEMP

LIGHT

10A

GND

10A

30A

SENSOR

INJECTORS

IGNITION

COILS

(BRAKE

OFF)

(PTO OFF)

(OPERATOR

NOT IN SEAT)

(LH HYDRO

IN DRIVE)

(RH HYDRO

IN DRIVE)

ElectricalLogicSchematic—KohlerEFIRedEquippedUnits

Schematics

Page 70

Schematics

HydraulicDiagram

Page 71

General Warranty Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any

part on these

products and found by us (in the exercise of our reasonable discretion) to

be defective in factory materials or workmanship.

This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

Commercial Warranty Conditions

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

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

Consumer Warranty Conditions

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

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

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

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine  * * The Engine warranty is covered by the engine manufacturer. Please

refer to the engine manufacturer’s warranty statement that is included in the literature packet.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

• Any product or part which has been altered or misused or required   replacement or repair due to normal wear, accidents, or lack of proper  maintenance as set forth in the maintenance section of the operator’s   manual.

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein. Neither Exmark nor Exmark Warranty Company

shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Lazer Z X-Series, Lazer Z S-Series, and Vantage Turf Equipment

3 Year Limited Commercial Warranty

5 Year or 750 Hours Limited Consumer Warranty

G4500-733_C

Page 72

General Warranty Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any

part on these

products and found by us (in the exercise of our reasonable discretion) to

be defective in factory materials or workmanship.

This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

Commercial Warranty Conditions

This warranty applies to Exmark Lazer Z E-Series turf equipment sold in the U.S. or Canada for a period of two years for commercial usage.

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

Consumer Warranty Conditions

This warranty applies to Exmark Lazer Z E-Series turf equipment sold in the U.S. or Canada for a period of four years or 500 hours (whichever occurs first) for residential usage.

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

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine * * The Engine warranty is covered by the engine manufacturer. Please

refer to the engine manufacturer’s warranty statement that is included in the literature packet.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

Owner’s Responsibilities

General Conditions

shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

Lazer Z E-Series Turf Equipment

2 Year Limited Commercial Warranty

4 Year or 500 Hours Limited Consumer Warranty

G4500-734_C

Page 73

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

Page 74

Page 75

G011841

Figure54

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

Page 76

MI D -MOUNT RIDIN G AC CESSORIES AN D OPTIONS

EXMARK ACCESSORIES AND OPTIONS*

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRO N T RIDING ACCESSO RIES AND OPT I ONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

*Some accessories and options not available for some models.

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

ModelNo.EngineSerialNo.(E/No)

SerialNo.

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

www.exmark.com

PartNo.4502-754Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

*4502-754*A

Exmark LAZER Z X Series, LAZER Z S Series, LAZER Z E Series Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual