Exmark S-N 790, Quest Bagger, LAZER Z 4500-471 User Manual

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Page 1

LAZERZ®MODELS

ForSerialNos. 790,000&Higher

PartNo.4500-471Rev.A

Page 2

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

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

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

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

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

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

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Page 3

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

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

Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor.

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

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Page 4

Contents

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

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

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

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

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

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

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

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

Dimensions...................................................16

TorqueRequirements....................................18

ProductOverview................................................18

Operation.............................................................19

Controls........................................................19

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

OperatingInstructions..................................22

Transporting.................................................26

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

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

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

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

CheckMowerBlades.....................................30

CheckSafetyInterlockSystem.......................30

CheckRolloverProtectionsSystems(Roll

Bar)Knobs................................................31

CheckSeatBelt..............................................31

CheckforLooseHardware............................31

ServiceAirCleaner........................................31

ChangeEngineOil........................................32

CheckHydraulicOilLevel.............................32

CheckTirePressures.....................................32

CheckConditionOfBelts..............................33

LubricateGreaseFittings...............................33

LubricateBrakeHandlePivot........................34

LubricateDeckLiftPivot...............................34

CheckSparkPlugs.........................................34

ChangeHydraulicSystemFilterand

Fluid.........................................................34

WheelHub-SlottedNutTorque

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

CheckSparkArrester(ifequipped).................35

ThreadLockingAdhesives.............................36

Copper-BasedAnti-seize..............................36

DielectricGrease...........................................36

Adjustments.....................................................36

DeckLeveling...............................................36

DeckRemoval...............................................38

PumpDriveBeltTension...............................39

DeckBeltTension........................................39

AdjustingtheParkingBrake...........................39

ElectricClutchAdjustment............................40

MotionControlLinkageAdjustment.............40

MotionControlDamperAdjustment.............40

MotionControlNeutralLockPivot

Adjustment...............................................41

MotionControlHandleAdjustment..............41

MotionControlFullForwardTracking

Adjustment...............................................41

CasterPivotBearingsPre-Load

Adjustment...............................................42

Cleaning...........................................................43

CleanEngineandExhaustSystem

Area..........................................................43

RemoveEngineShroudsandCleanCooling

Fins...........................................................43

CleanHydroFanCoolingGuards..................43

CleanDebrisFromMachine..........................43

CleanGrassBuild-UpUnderDeck................43

WasteDisposal..............................................44

Troubleshooting...................................................45

Schematics...........................................................47

Page 5

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER, WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

DANGER:Whitelettering/Redbackground. Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

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

CAUTION:Blacklettering/Y ellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Page 6

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

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

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Page 7

Safety

CAUTION

Fueltankventislocatedinsidetheroll bartube.Removingormodifyingtheroll barcouldresultinfuelleakageandviolate emissionsregulations.

•DoNotremoverollbar.

•DoNotweld,drill,ormodifyrollbarin anyway .

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

Operation

WARNING

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

•Allowengineparts,especiallythemufer, tocoolbeforetouching.

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

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly .

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Stopengine,waitforallmovingpartstostop, removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

Page 8

Safety

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

DANGER

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

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

3.Water

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•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

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

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbar isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

•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.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.

MaintenanceandStorage

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

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

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

Page 10

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-633922

1-403005

98-5954

103-2076

Page 11

Safety

109-3148

107-2102

107-2112

109-7232

1.Fast3.Neutral

2.Slow

109-7330

109-7929

4.Reverse

Page 12

Safety

1.Throttle–fast3.Choke–on

2.Throttle–slow

116-0090

109-8483

4.Choke–off

DeckDriveBeltRouting

116-0157

1.SeeOperator’smanual

116-0165

109-9361

109-9477

116-0205

Page 13

116-0211

MessageDisplay

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresence

Safety

switch

116-0752

1.Latch2.Unlatch

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

109-7069

Page 14

Specications

ModelNumbers

SerialNos:790,000andHigher

LZZ23KC486;LZZ23KA526;LZZ23KC526;LZZ27KC526;LZZ27KC606;LZZ29KA606;LZZ34KA606; LZZ34KA726

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3750±50RPM(PTOnot engaged)Idle:1500RPM

FuelSystem

•Capacity:12.0gal.(45.4L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.

•FuelFilter:

–Kohler:

KohlerP/N2405013

–Kawasaki:

KawasakiP/N49019-7001

•FuelShut-OffValve:

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

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.

•Fuelleveleightsegmentdisplay—righthand controlpanel.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

KohlerandKawasaki:15amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:

–34HPKawasaki:340CCA –Allotherengines:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•ParkingBrakeReleaseButton:Releasesparking brake.

Page 15

Specications

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

–Unlatchingposition:Deckdoesnotlatchat

thetransportposition.

Seat

•Type:Standardseatwithhighback,extra widefoampaddedseatcushionwithinternal suspension,thickbolstering,two-tonecover, armrests,integralsafetyswitch,andseatvibration isolationsystem.

Optionalseataccessoriesforunitswithstandard seats:

–Customridesuspensionsystemtoenhance

StandardSeat.Addsapproximately3inches (7.6cm)toseatheight.

–Deluxesuspensionseatwithhighback,low

prolefoam-in-placecushion(dampened, adjustablespringsuspension),armrests,and integralsafetyswitch.Seatheightremainsthe same.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

–48and52inchdecks:

◊12ccParkeraxialpistonpump

◊240ccParkergerolermotor

–60and72inchdecks:

◊16ccParkeraxialpistonpump

◊280ccRossgerolermotor

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:52oz(1.5L)perside

•HydraulicFilter:P/N116-0164

•Speeds:

–12cc

◊0-10mph(16.1km/hr)forward.

◊0-5.5mph(8.9km/hr)reverse.

–16cc

◊0-11.5mph(18.5km/hr)forward.

◊0-6mph(9.7km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

–SeatIsolationSystemforreducedvibration,

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

•Mounting:Hingedseatframetotiltupseat.Held intiltedpositionwithproprod.Adjustablefore andaftonseattracks.

•Armrests:

–Standardseat:foampaddedadjustableip-up

armrests.

–Suspensionseat:moldedadjustableip-up

armrests.

•SeatSafetySwitch:

Integratedseatswitch.Timedelayseatswitch eliminatesroughgroundcut-outs.

Tires&Wheels

Quantity

Tread

Size(60&72 Decks)

Size(48&52 Decks)

PlyRating

Pressure

DriveFrontCaster

Pneumatic (Air-Filled)

“Multi-Trac C/S”

24x12.00-1213x6.50-6

24x9.50-1213x5.00-6

13psi(90kPa)

Semi-Pneumatic

Smooth

Page 16

Specications

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

–72inchDeck:(182.9cm)

•Discharge:Side

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

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

•DeckDrive:

Electricclutch.Shaftdiameter1.125inches(2.86 cm)

–48and52inchDecks:“B”Sectionbeltwith

self-tensioningidler.

–60and72inchDecks:5VSectionbeltwith

self-tensioningidler.

•Deck:

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

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

Dimensions

OverallWidth:

48inchDeck52inchDeck

WithoutDeck45.7inches

(116.1cm)

DeectorUp51.8inches

(131.6cm)

DeectorDown59.6inches

(151.4cm)

60inchDeck72inchDeck

WithoutDeck53.0inches

(134.6cm)

DeectorUp62.5inches

(158.8cm)

DeectorDown72.8inches

(184.9cm)

OverallLength:

48inchDeck52inchDeck

RollBar-Up79.2inches

(201.2cm)

RollBar-Down80.9inches

(205.5cm)

60inchDeck72inchDeck

RollBar-Up83.1inches

(211.1cm)

RollBar-Down84.8inches

(215.4cm)

45.7inches (116.1cm)

56.3inches (143.0cm)

64.8inches (164.6cm)

59.1inches (150.1cm)

73.5inches (186.7cm)

84.9inches (215.6cm)

79.2inches (201.2cm)

80.9inches (205.5cm)

86.1inches (218.7cm)

87.8inches (223.0cm)

–60inchDeck:4anti-scalprollers

–72inchDeck:4anti-scalprollers

•DeckDepth:

–48inchDeck:5.5inches(14cm)

–52inchDeck:5.5inches(14cm)

–60inchDeck:5.5inches(14cm)

–72inchDeck:5.5inches(14cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

OverallHeight:

RollBar-UpRollBar-Down

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

Page 17

Specications

TreadWidth:(CentertoCenterof Tires,Widthwise)

48inchDeck52inchDeck

DriveWheels36.2inches

(91.9cm)

CasterWheels32.8inches

(83.3cm)

60inchDeck72inchDeck

DriveWheels41.6inches

(105.7cm)

CasterWheels39.5inches

(100.3cm)

36.2inches (91.9cm)

32.8inches (83.3cm)

43.6inches (110.7cm)

47.1inches (119.6cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

48inch Deck

48.0inches (121.9cm)

52inch Deck

48.0inches (121.9cm)

60inch Deck

50.6inches (128.5cm)

72inch Deck

53.6inches (136.1cm)

CurbWeight:

48inch Deck

23HP Kawasaki Units

23HP Kohler Units

27HP Kohler Units

29HP Kawasaki Units

34HP Kawasaki Units

—

1125lb (510kg)

—

——

52inch Deck

1108lb (503kg)

1116lb (506kg)

60inch Deck

——

1195lb (542kg)

1212lb (550kg)

1260lb (572kg)

72inch Deck

—

1292lb (586kg)

AccessoryWeightTableWorksheet:

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

Note:The72inchdeckdoesnotrequireaweightkit.

48inch

Deck

LightKit

Michigan Seat/CRSS

Bagger

Pneumatic Caster Tires

MulchKit

StriperKit-300

OCD02-6-6-4

HitchKit

Sunshade Kit

TotalAccessoryScoreRequiredWeightKit(s)

0–9

10–19

20andHigher*Two116-1173Undertoe

-3-3-5

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

52inch

Deck

222

103

003

111

TotalAccessoryScore

60inch

Deck

Nonerequired

*116-1173Undertoe boardmountweightkit

boardmountweightkits orone116-1173Undertoe boardmountweightkit andone116-1238Front toeboardmountweightkit

Accessory Score

Page 18

ProductOverview

*60inchunitswhichalreadyhaveanundertoeboard mountweightasstandardrequires116-1238fronttoe boardtopmountkitinsteadof116-1173.

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

CutterHousingSpindle Nut

BladeMountingBolt (lubricatewithanti-seize)

Anti-ScalpRollerNyloc NutSeeFigure18

Anti-ScalpRollerHex CapscrewSeeFigure18

EngineMountingBolts (Kawasaki23HP) (Kohler23-27HP) (Kawasaki29HP) (Kawasaki34HP)

WheelLugNuts

Torque

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

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

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

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

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

15-19ft-lb(20-26N-m) 27-33ft-lb(37-45N-m) 27-33ft-lb(37-45N-m) 17-21ft-lb(23-28N-m)

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

ProductOverview

1.RolloverProtection System(ROPS)

2.EngineControls(right console)

3.Seatbelt

4.Motioncontrollevers

Figure4

5.Fuelcap

6.Heightofcutadjustment

7.Parkingbrake

WheelMotorMounting Bolts

WheelHubSlottedNutminimum200ft-lb

RolloverProtection System(RollBar)1/2 inchMountingBolts

ClutchRetainingBolt (securedwiththreadlocker)

HydroParkBrakeCable Anchor1/2inchMounting Bolt(securedwith threadlocker)

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

(271N-m)

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

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

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

Page 19

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition (Figure5).

Whenthemotioncontrolleversareintheneutral position,theLCDindicatorappearsinthemessage displayontheRHconsole(seeFigure9).

ChokeControl

Locatedonrightconsole(blacklever)(seeFigure6).

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

Figure6

RightConsole

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

Figure5

4.Forward

5.Neutral(operate)

6.Reverse

1.Fuses

2.Messagedisplay

3.Ignitionswitch

4.PTOengagementswitch

5.Throttle

6.Choke

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe RHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Page 20

Operation

Note:TheLCDindicatorappearsinthemessage

displayontheRHconsolewhentheparkbrakeis engaged(seeFigure9).

Pulltheleverupandrearwardtoengagethebrake.

Depressthereleasebuttonandpushdownwardto disengagethebrake.

Figure7

1.Releasebutton2.Parkbrake

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

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

disengagedtostartengine.(Itisnotnecessaryforthe operatortobeintheseattostarttheengine.)

HourMeter

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Figure9

1.LCDIndicators

2.Lowfuelindicatorlight

3.Fuellevelbardisplay

4.Lowvoltageindicatorlight

5.Hour/Voltagedisplay

Hoursarerecordedwhenthekeyisonandtheengine isrunning(batteryvoltageis12.8Vorhigher)or whenthekeyisonandtheoperatorisintheseat.

Thehourmeterisrecordingwhenthedecimalpoint isashinginHour/V oltagedisplay.

Figure8

1.Off3.Start

2.On

Note:Brakemustbeengaged,motioncontrol leversout(neutrallockposition)andPTOswitch

Hoursaredisplayedwhenthekeyisoffandwhen themachineisrunning.

Note:Iftheignitionkeyisturnedtothe“ON” positionforafewsecondsbeforecrankingthe engine,thebatteryvoltagewilldisplayinthearea wherethehoursarenormallydisplayed.

Note:TheLCDindicatorsappearwheneach controlmeetsthe“safetostart”mode(e.g.the indicatorturnsonwhentheoperatorisintheseat.)

Page 21

FuelShut-OffValve

Locatedbehindandbelowtheseat.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

Operation

FuelGauge

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thefuellevelisshownonabardisplay.Theindicator lightappearswhenthefuellevelislow(approximately onegallonremaininginthetank).

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck, whichcouldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

WARNING

Theengineandhydraulicdriveunitscan becomeveryhot.Touchingahotengineor hydraulicdriveunitscancausesevereburns.

Figure10

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure10), rotatethehandle1/4turntotheverticalposition untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2inFigure10), rotatethehandle1/4turntothehorizontalposition untilithitsagainstthestop.

Note:Thehandlemustbehorizontalandagainst thestopforoperation.

DoNottowmachine.

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isdisengaged(seeFigure9).

LowVoltageIndicator

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrive wheelreleasevalves.

Locatedonthebackoftheunitizedhydraulicdrive units,belowtheenginedeck.

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

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Alowvoltagecondition(lessthan12.3volts)exists whentheLCDindicatorappearsonthemessage displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

Page 22

Operation

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

TransportLock

Locatedontheheightofcutadjustmentplatestothe rightoftheparkingbrake.

Positioninthetransportlatchingpositionto automaticallylatchthecuttingdeckwhenraisedto thetransportposition(seeitem1inFigure11).

Inthenon-latchingposition,thedeckwill automaticallyreturntothecuttingheightwhenthe pedalislowered(seeitem3inFigure11).

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

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 interlockpartially.Applyforwardpressuretothe rollbarupperhoopandobservethattheknobs returntothecompletelylatchedposition.

Figure11

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

Pre-Start

Fillfueltank.Forbestresultsuseonlyclean,fresh regulargradeunleadedgasolinewithanoctanerating of87orhigher.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch (13mm)belowthebottomofthellernecktoallow forfuelexpansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

Figure12

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

5.Makesuretheknobsarefullyengagedwiththe rollbarintheraisedposition.Theupperhoopof

Page 23

Operation

therollbarmayneedtobepushedforwardor pulledrearwardtogetbothknobsfullyengaged (seeFigure13).

Figure13

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

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

OpentheFuelShut-OffValve

Thefuelshutoffvalveislocatedbehindandbelow theseat.Rotatethevalveandalignwiththefuelline toopen.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

5.Onacoldengine,pushthechokeleverforward intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine continuouslyformorethantensecondsata

time.Iftheenginedoesnotstart,allowa60 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunless thereisagrasscollectionsystemormulch kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

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

2.PullthePTOswitchoutwardtoengagethe blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

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

2.PushthePTOswitchintodisengagetheblades.

Page 24

Operation

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral lockposition.

4.Engagetheparkingbrake.

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

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalve,locatedbehindand belowtheseat,whenthemachinewillnotbein useforafewdays,whentransporting,orwhen theunitisparkedinsideabuilding.

DrivingtheMachine

CAUTION

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

Figure14

4.Forward

5.Neutral(operate)

6.Reverse

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

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

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

Note:The“N”LCDindicatorappearswhenboth leversareintheneutrallockposition.

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Page 25

Figure15

1.FrontofUnit

2.Forward4.Reverse

3.Neutral

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

Toturnleftorright,releasepressureonthe motioncontrollevertowardthedesiredturn direction.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

Operation

Figure16

1.Deckfootpedal3.Cutofheightdecal

2.Heightadjustmentpin4.Transportlockcontrol

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor cutheights.

6.Pushthedeckliftpedal,releasethetransportlock andallowthedecktolowertothecuttingheight.

AdjustingtheAnti-ScalpRollers

AdjustingtheCuttingHeight

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

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Positionthetransportlockinthelatching position.

4.Raiseandlockthedecktothe51/2inch(14cm) transportposition(Figure16).

Thedeckisraisedbypushingthefootoperated deckliftpedalforward.Thepedalislocatedatthe frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Itisrecommendedtochangetheanti-scalproller position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Adjusttheanti-scalprollersbyremovingthe bushing,springdiscwasherandbolt.

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

Page 26

Operation

Figure17

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

Transporting

TransportingaUnit

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

CAUTION

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Besuretherollerboltsareinstalledwiththe springdiscwasherbetweentheheadofthebolt andthemountingbracket(Figure18).

8.Torquethe3/8–24x2Gr8hexcapscrewto 50–55ft-lb(68–75N-m)(Figure18).

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

DoNotdriveaunitonapublicstreetor roadway.

1.Springdiscwasher (conetowardsbolthead)

2.Frontrightanti-scalp bracketshown

Figure18

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

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

Page 27

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over. Backwardtip-overcouldcauseseriousinjury ordeath.

•Useextremecautionwhenoperatinga unitonaramp.

•Useonlyasingle,fullwidthramp;Do Notuseindividualrampsforeachside oftheunit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbroken rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp andgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledriving unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtipping backward.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

LoadingaUnit

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

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

Page 28

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

WARNING

Theenginecanbecomeveryhot.Touching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Beforeeachuseordaily

Every50hours

Every100hours

Every200hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrofancoolingguards.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

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

•Lubricatethebrakehandlepivot.

•Checkthesparkplugs.

Page 29

Maintenance

MaintenanceService

Interval

Every500hours

Yearly

MaintenanceProcedure

•Changethehydrauliclteranduid.

•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.Useoilasspeciedin EngineOwner’ sManual.DoNotoverll.

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

batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

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

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

CheckBatteryCharge

ServiceInterval:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.Topreserveoptimum

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

Page 30

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.

C.Applylubricanttothreadsofbladeboltto

preventseizing.Copper-basedanti-seize preferable.Greaseacceptablesubstitute. Installbladeboltngertight.Placewrench onthetopspindlenutthentorquetheblade boltsto55-60ft-lb(75-81N-m).

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock

Figure19

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Makesurethesplinesonthebushingare engagedinthespindlebeforetighteningthe bolt.

Figure20

1.Usewrenchhereforbladeinstallation.Thisnuthas beentorquedto140–145ft-lb(190–197N-m)

2.Torqueto55-60ft-lb(75-81N-m)Applylubricantto threadsasneededtopreventseizing.Copper-based anti-seizepreferable.Greaseacceptablesubstitute.

System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

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

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

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

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

Page 31

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.

Maintenance

Figure21

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

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.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every200hours—Service

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Loosenretainingclipsandremoveaircleaner compartmentcover.

3.Removepaperelement.Checkthecondition ofthepaperelement.Replaceifdirty,bentor damaged.

Page 32

Maintenance

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

5.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

6.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

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

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

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

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

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

3.Slidetheseatallthewayback,thenlifttheseatto accessthecapsontheLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand removecap.

5.Wipethedipstickcleanandre-insertthecapback intothehydro.Lightlytightenthecap.

6.Removethecapagainandcheckthelevelofthe oilonthedipstick.SeeFigure22foroillevels.

Figure22

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.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe hydraulicoil.

4.Semi-pneumaticcastertiresDoNotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

Page 33

Maintenance

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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.

pumpwithgreaseuntilitoozesoutaroundtop bearing.Removegreasezerkandthreadplugback in.Placecapbackon.

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure23

1.Sealguard2.Spacernutwithwrench ats

LubricationChart

Fitting

Locations

1.Deckand PumpIdler Pivots

2.Front Caster Pivots

Initial

Pumps

Numberof

Places

Service

Interval

Yearly

*Yearly

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

3.Lubricatefrontcasterpivotsonceayear.Remove hexplugandcap.Threadgreasezerkinholeand

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

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

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

Page 34

Maintenance

9.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

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

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

13.T orquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Make sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .

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

LubricateBrakeHandlePivot

ServiceInterval:Every200hours

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ReplacementFilters

Kohler

KawasakiKawasaki

Note:Itisimportanttoreinstallthefuellinehoses andsecurewithplastictiesthesameastheywere originallyinstalledatthefactorytokeepthefuelline awayfromcomponentsthatcouldcausefuelline damage.

KohlerP/N2405013

P/N49019-7001

ChangeHydraulicSystem FilterandFluid

ServiceInterval:Every500hours

Note:OnlyuseExmarkHydroFilter–PartNo.

116-0164forsummerorwinter.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebrakehandlepivotwithaspraytype lubricantorlightoil.

LubricateDeckLiftPivot

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’s Manual.

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem.

6.Usingasocket,unscrewlterstoremoveand allowoiltodrain.

Page 35

7.Beforeinstallingthenewlters,applyathincoat ofExmarkPremiumHydrooilonthesurfaceof thetworubberseals.

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

9.FillthehydraulicsystemasstatedinCheck HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

Maintenance

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

10.Removethecatchpanandproperlydisposeof hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

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

13.Removethejackstands.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

ChangeInterval

500Hours

250Hours

Figure24

1.0.1inchmax2.Nomorethantwo threads(0.1inchmax) shouldbeshowinghere.

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

5.Torquetheslottednutto200ft-lb(271N-m).

6.Thentightennutuntilthenextsetofslotslineup withthecrossholeinshaft.DoNotloosennut toaligntheslot.Ifrequired,tightentothenext setofslots.

7.Installnewcotterpin(P/N1-806800).

Note:DoNotuseanti-seizeonwheelhub.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor taperedshaft:

1.Removeanddiscardthecotterpin.

2.Torquetheslottednutto200ft-lb(271N-m).

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

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineis stopped.Hotparticlesexhaustedduring engineoperationmayigniteammable materials.Firemayresultinpersonalinjury orpropertydamage.

DoNotrefuelorrunengineunlessspark arresterisinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

Page 36

Maintenance

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

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

ThreadLockingAdhesives

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

•ROPSspringpinhousing.

•Hydropumpcontrolarm,linkagebolt,and attachmentbolt.

•Hydrocoolingfanscrew .

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof enginecrankshaft.

Threadlockingadhesivesarerequiredforsome hardwareonengines—seetheEnginemanual.

Adjustments

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

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

4.Positionthetransportlockinthelatching position.

5.Pushthefootpedalallthewayforwardandthe deckwilllatchatthe51/2inch(14cm)transport position(Figure25).

Page 37

Figure25

1.Footlever3.Transportlock

2.Cutofheightpin

6.Inserttheheightadjustmentpinintothe3inch (7.6cm)cuttingheightlocation.

Maintenance

10.Loosenthejamnutsonthetopofeachdeck link.Finetunetheadjusteronthefrontdecklift assemblybyturningittoget3inch(7.6mm) height(seeFigure27).

Toincreasetheheight,turntheadjusterclockwise; todecrease,turncounterclockwise.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargedeector.

9.Onbothsidesofthedeck,measurefromthe levelsurfacetothefronttipoftheblade.The measurementshouldread3inches(7.6mm).

Note:Inmostconditions,thebackbladetip shouldbeadjusted1/4inch(6.4mm)higherthan thefront.

Figure27

1.Adjusterlink3.Adjuster

2.Jamnut

11.Thebacktipofthebladeshouldmeasure3 1/4inches(8.3cm).Finetunerearadjustersas required.

12.Re-measureuntilallfoursidesarethecorrect height.Tightenallthejamnutsonthedecklift armassemblies.

13.Lowerdischargedeector.

14.Ifthefourdecklinksdonothaveenough adjustmenttoachieveaccuratecutheightwiththe desiredrake,thesinglepointadjustmentcanbe utilizedtogainmoreadjustment(seeFigure28).

Figure26

1.31/4inches(8.3cm)5.Levelsurface

2.Backbladetip

3.Frontbladetip

4.3inches(7.6cm)

6.Rearofmachine

7.Frontofmachine

Page 38

Maintenance

DeckRemoval

Beforeservicingorremovingthedeck,thespring loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthe storedenergycancauseseriousinjuryor death.

DoNotattempttodisassemblethedeck fromthefrontframewithoutlockingoutthe storedenergy.

Figure28

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

15.T oadjustthesinglepointsystem,rstloosenthe frontandrearheight-of-cutplatemountingbolts.

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

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

17.Re-tightenfrontandrearheight-of-cutplate mountingbolts.

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthe decktotheground.

3.Placetheheightadjustmentpininthe3inch(7.6 cm)cuttingheightlocation.Thislocksthedeck liftarmsinthelowestpositionwhenthedeckis removed.

4.Removetheoorpanandbeltshields.

5.Insert1/2inchsocketdriverintothesquarehole ontheidlerbracketandcarefullyrotatethedeck idlercounterclockwisetoremovethebelt.

6.Removeandretainthehardwareonbothsidesof thedeckasshowninFigure29.

18.Repeatsteps9through13.

Figure29

1.Panhardrod(rightsideonly)

2.Deckstrut

3.Reardeckliftattachmentshoulderboltandnut.

4.Frontdeckliftattachmentshoulderboltandnut.

Page 39

7.Raisethefrontofthemachineandslidethedeck leftorrighttoremove.

8.Lowerthefrontofthemachine.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey .

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

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

8.Disengagetheparkbrake.

9.Usinghandsandngersonly ,pushthecaliper leverarmtoengagethebrakepadsontherotor untiltheleverstops.Whileholdingtheleveratthe stoppedposition,usetheotherhandorngers topullthecablethreadedendtightthroughthe swivel.Spinthestandardnutagainsttheswivel (seeFigure30).

Maintenance

Figure30

LeftHandBrakeShown

1.Cableanchor

2.Threadedrod7.Pullcablethreadedrod

3.Pushleverthisdirection8.Holdthreadedrodhere

4.Caliperleverarm9.Swivel(pivothead)

5.Standardnut(shown againstswivel)

Notetheorderofthestandardnutandlocknut (nonutonthecableanchorsideoftheswivel).

10.Releaseholdonthecaliperleverandcable.The wheelhubshouldturnbyhandinbothdirections relativetothecaliper;somefriction/resistance isacceptable.

11.Ifthereisnomovementbetweenthehubrotor andthecaliperthenbackoffthestandardnutone turnfromtheswivelandrepeatstep10(drive releasevalvesmustbeinthe“released”position onthehydros).

12.Ifthehubrotormovesveryfreelyrelativetothe caliper,thentightenthestandardnutoneturn againsttheswivelandrepeatstep10.

13.Oncestep10isachieved,holdthethreadedrod endwithatoolandtightenthelocknutagainst thestandardnut.DoNotallowthecabletoturn whenthenutsaretightened.

6.Locknut

thisdirection

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

15.Repeatontheoppositesideofmachine.

Page 40

Maintenance

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

17.Removejackstands.

ElectricClutchAdjustment

Noadjustmentnecessary.

MotionControlLinkage Adjustment

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

WARNING

Enginemustberunninganddrive wheelsmustbeturningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengths byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(Figure31).Movethemotion controlleverstothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningor slightlycreepinreverse.

Figure31

1.Doublenuts

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.

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure32formountingoptions.

Page 41

Figure32

RHMotionControlShown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

MotionControlNeutralLock

Maintenance

MotionControlHandle Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(Figure34).

Figure34

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

PivotAdjustment

Theangednutcanbeadjustedtoobtainamore desiredmotioncontrolleverresistance(Figure33).

Figure33

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraftFigure34.Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

MotionControlFullForward TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthecoverplates.

1.Loosenthescrewsonacoverplate(seeFigure35).

Page 42

Maintenance

2.Slidethecoverplatebackwardorforwardto adjustthetraveloftheleverandtightenthe screws.

3.Drivethemachineandcheckthefullforward tracking.

4.Repeatsteps1through3untildesiredtracking isobtained.

Figure35

RHMotionControlShown

Figure36

1.Springdiscwashers

1.Screw

2.Coverplate

3.Motioncontrollever

CasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut untilwashersareatandbackoff1/4ofaturn toproperlysetthepre-loadonthebearings.If disassembled,makesurethespringdiscwashersare reinstalledasshowninFigure36.

Page 43

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancause engine,exhaustarea,andhydraulicsystem tooverheatwhichcancreatearehazard.

Cleanalldebrisfromengineandexhaust systemarea.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

CleanHydroFanCooling Guards

ServiceInterval:Beforeeachuseordaily

Removingdebrisfromthehydrofancoolingguards willallowthehydrosystemtoruncoolerandimprove thelifeofthehydrosystem.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Slideseatallthewayback,thenlifttheseatto accesstheLHandRHhydrodrivearea.

3.Removeaccumulateddebrisfromthehydrofan coolingguards.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecoolingshroudclean-outcovers(Kohler) orcoolingshrouds(Kawasaki)fromengineand cleancoolingns.Alsocleandust,dirtandoil fromexternalsurfacesofenginewhichcancause inadequatecooling.

3.Makesurecoolingshroudclean-outcoversor coolingshroudsarereinstalled.Operatingthe enginewithoutcoolingshroudclean-outcovers orcoolingshroudswillcauseenginedamagedue tooverheating.

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Page 44

Maintenance

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

Page 45

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.4.Chargethebattery .

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.

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral lockposition.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

4.Besurethethrottlecontrolismidway betweenthe“SLOW”and“F AST” 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.

Page 46

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Mowerpullsleftorright(withleversfully forward)

Machinedoesnotdrive

Unevencuttingheight.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.Dirt,water,orstalefuelisinthefuel system.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating” position.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

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

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

6.ContactanAuthorizedServiceDealer.

1.Positionhandlein“operating”position; seeDriveWheelReleaseValvessection inOperation.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration

Bladesdonotrotate.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Deckbeltisworn,looseorbroken.2.Installnewdeckbelt.

3.Deckbeltisoffpulley.3.Installbeltonclutchanddeckpulleys,

4.Brokenormissingidlerspring.

5.Drivebeltnotroutedcorrectly.5.Refertobeltroutingdecalondeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

idlers,andtensioningidlerperrouting decalondeck.

4.Replacethespring.

Page 47

Schematics

G008587

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

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

7 4 5 9 3 6 8 1 2

C A B

A B

26354

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram

Page 48

Schematics

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

REG

START

FUEL

SOLINIOD

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G008613

ElectricalLogicSchematic

Page 49

HydraulicDiagram

Schematics

Page 50

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 and Lazer Z AS 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 and Lazer Z AS 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 2 years* * The Engine warranty is covered by the engine manufacturer. Please

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

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair 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 and Lazer Z AS Turf Equipment

3 Year Limited Commercial Warranty

5 Year or 750 Hours Limited Consumer Warranty

G4500-434

Page 51

Notes:

Page 52

Notes:

Page 53

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

535455

Page 54

Page 55

Page 56

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-471Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark S-N 790, Quest Bagger, LAZER Z 4500-471 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual