Exmark ULTRA VAC Lazer Z HP User Manual

For Serial Nos.

540,000 & Higher

Part No. 103-9172

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

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

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

plug wire(s) or remove key before adjust ing, servicing, or

performing maint enance.
♦ If mower deck becomes clogg ed, stop engine and wait for all

moving parts to stop. Remove spark plug wire(s) or r em ove k ey

before cleaning blockage.

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

POTENTIAL HAZARD
♦ Gasoline is harmful or f at al if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening .
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.

WARNING

WARNING

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o t he muffler. If not, the operator is violating state law, Section 4442
Public Resource Code. To acquire a spark arrester for your unit, see your Eng ine Ser vice Dealer.

This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada

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

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

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

- i -

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995
Program

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

How the Program Works

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

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

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

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

5. The customer pays for the part

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

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

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

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

the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus

®

shipment of six (6) line items or less.

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

®

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

®

order of six (6) line items or less.

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

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

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

1. The dealer not submitting the Exmark Parts Plus

®

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

pays for the part and freight.

®

order

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

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

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

®

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

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

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

- ii -

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

OPERATOR'S MANUAL

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

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

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

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

All Exmark equipment dealers and distr ibut or s ar e kept informed of t he lat e st
methods of servicing and are equipped t o pr ovide prom pt and efficient service in the
field or at their service stations. T hey carr y ample stock of service parts or can
secure them promptly for you fr om the factory.

All Exmark parts are thoroughly tested and inspected before leaving the f act ory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol....................................................................................... 1

1.2 Training.........................................................................................................1

1.3 Preparation.................................................................................................1-3

1.4 Operation ...................................................................................................4-7

1.5 Maintenance & Storage..............................................................................7-8

1.6 Safety Signs............................................................................................. 8-11

2. SPECIFICATIONS

2.1 Model Numbers...........................................................................................12

2.2 Engine......................................................................................................... 12

2.3 Fuel System................................................................................................ 12

2.4 Electrical System......................................................................................... 12

2.5 Operator Controls...................................................................................12-13

2.6 Seat............................................................................................................. 13

2.7 Hydrostatic Ground Drive System................................................................13

2.8 Tires & Wheels............................................................................................ 13

2.9 Cutting Deck...........................................................................................13-14

2.10 Dimensions..................................................................................................14

2.11 Torque Requirements ............................................................................14-15

3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate Mower............................................................................................ 15

3.2 Install Rollover Protection System (roll bar)............................................ 15-17

3.3 Service Battery.......................................................................................17-18

3.4 Install Drive Wheels..................................................................................... 18

3.5 Check Tire Pressure....................................................................................18

3.6 Install

3.7 Install Canister Air Cleaner .................................................................... 18-19

3.8 Install Motion Control Levers....................................................................... 19

3.9 Position Discharge Chute............................................................................ 19

3.10 Service Engine............................................................................................ 19

3.11 Service Hydraulic Oil..............................................................................19-20

Seat .................................................................................................. 18

4. OPERATION INSTRUCTIONS

4.1 Controls.................................................................................................. 20-22

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

4.3 Operating Instructions............................................................................ 23-24

4.4 Transporting........................................................................................... 24-25

5. MAINTENANCE & ADJUSTMENTS

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

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

6. WASTE DISPOSAL

6.1 Motor Oil Disposal.......................................................................................43

6.2 Battery Disposal.......................................................................................... 44

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

8. ELECTRICAL DIAGRAMS

9. HYDRAULIC DIAGRAM
10

.

WARRANTY

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

.............................................................................46-47

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

44-45

- iv -

1. SAFETY

1.1 SAFETY ALERT SYMBOL

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

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

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

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

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

DANGER: White lett er ing / Red background. Indicates an imminently hazardous situation

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

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

situation which, if not avoided, COULD result in deat h or ser ious inj ury.

CAUTION: Black lettering / Yellow backgr ound. Indicates a potentially hazardous

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

1.2 TRAINING

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

1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English, it is the owner’s responsibility to explain this mater ial t o them.

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

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

1.3 PREPARATION

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

1.3.2 The use of per sonal pr ot ective equipment, such as (but not limited to) pr ot ection
for the eyes, ears, feet , and head is r ecom m ended.

CAUTION

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

dBA at the operator’s ear when in operation.

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

extended periods of time can cause hearing loss.

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

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

- 1 -

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

POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.

WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.

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

where dangerous carbon monoxide fumes can collect.

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable

and highly explosive.

WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot her s,

and cause property damage.

WARNING

DANGER

HOW TO AVOID THE HAZARD
♦ DO NOT smoke while refueling , and st ay away from

an open flame or where gasoline fumes m ay be ignited
by spark.

♦ Refuel only outdoors.
♦ Store gasoline in an approved container and keep it

out of the reach of children.

♦ Add fuel before starting the engine. Never remove the

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

♦ Never fill the fuel tank so t hat the gasoline level rises

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

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

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

♦ Do not operate without entire exhaust system in place

and in proper working condition.

- 2 -

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable

and highly explosive.

WHAT CAN HAPPEN
♦ A static charge can ignite g asoline vapors. A fire or

explosion from gasoline can burn you, others, and
cause property damage.

HOW TO AVOID THE HAZARD
♦ Purchase and store gasoline only in an approved

container.

♦ Always place gasoline containers on the ground away

from your vehicle before f illing.

♦ Do not fill gasoline containers inside a vehicle or on a

truck or trailer bed because interior car pet s or plastic
truck bed liners may insulate the container and slow
the loss of any static charge.

♦ When practical, r emove gas-powered equipment from

the truck or trailer and r efuel the equipment with its
wheels on the ground.

♦ If this is not possible, then refuel such equipment on a

truck or trailer from a portable container, rather than
from a gasoline dispenser nozzle.

♦ If a gasoline dispenser nozzle must be used, keep the

nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete.

DANGER

POTENTIAL HAZARD
♦ Gasoline vapor can collect inside enclosed trailers and

may be ignited by electrical sparks or hot
engine/exhaust components.

WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in proper t y

damage, personal injury, and/or deat h.

HOW TO AVOID THE HAZARD
♦ Provide adequate ventilation of any enclosed trailer to

prevent build up of gasoline vapors, especially at floor
level.

♦ Refuel only outdoors, never inside an enclosed trailer.
♦ Be sure all fuel tanks and gasoline st or age containers

have proper caps installed to prevent spillage and
minimize vapor escaping into the trailer.

♦ Do not place any equipment that is leaking gasoline in

an enclosed trailer.

WARNING

- 3 -

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

design and configuration of the equipment, t hese factors are also dependent upon
the awareness, concern, prudence, and proper training of t he personnel i nvol ved in
the operation, transport, maintenance, and st orage of t he equi pment . It is essential
that all Operator Safety Mechanisms be connect ed and i n operat i ng condi t ion prior
to use for mowing.

WARNING

POTENTIAL HAZARD
♦ Operating engine parts, especially the m uffler, become

extremely hot.

WHAT CAN HAPPEN

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

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

touching.

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

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

WARNING

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

entangled in rotating part s.

WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traum at ic am put ation

or severe lacerations.

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

safety devices in place and working.

♦ Keep hands, feet, hair, jewelry, or clot hing away from

rotating parts.

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

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

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

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

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

- 4 -

DANGER

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

loss of control.

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

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

HOW TO AVOID THE HAZARD

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

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

area to be mowed.

• Use a walk behind mower and/or a hand trimmer near drop- offs, ditches, steep

banks or water. This area can be dangerous, see Figure 1.

Figure 1

SAFE ZONE FOR MOWING

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. If t ires lose t raction,

disengage the blades and proceed slowly off the slope.

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

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

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

• Watch for ditches, holes, rocks, dips, and rises that change the operating

angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from t he m owing

area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachment s. These can change the

stability of the machine and cause loss of contr ol.

• Follow the manufacturer’s recommendat ions for wheel weights or

counterweights to improve stability.

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

- 5 -

WARNING

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

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

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

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

seat belt.

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

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

rolls into ponds of water.

• Check carefully for overhead clearances ( i. e. br anches, doorways, and

electrical wires) before driving under any objects and do not cont act them.

1.4.6 Use EXTREME caution when backing up. LO OK BEHIND YOU!

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

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

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

1.4.10 Disengage PTO befor e st arting engine.

1.4.11 Start

1.4.12 Keep hands, feet, and clothing away from r otating parts while the mower is being

1.4.13 Stop engine, wait for all moving part s t o stop, and remove key:

Stop the engine and wait for all moving part s t o stop:

1.4.14 Before stopping the engine, place the throt t le cont r ol midway between the “slow”

1.4.15 The fuel system is provided with a shut-off valve. Shut off the fuel:

1.4.16 This mower was designed for one operator only. Keep all others away fr om

the engine carefully with feet well away from the blades.

operated.

• Before checking, cleaning or work ing on the mower.

• After striking a foreign object (inspect the m ower for damage and make

repairs before restart ing and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

• Before refueling.

• Before dumping the gr ass cat cher.

and “fast” positions. Allow the engine to r un a m inim um of 15 seconds; then stop
the engine.

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

• During t r ansport to and from the job.

• When parked inside a building.

mower during operation.

- 6 -

1.4.17 Do Not mow with the discharge deflector raised, rem oved or alt er ed unless t her e
is a grass collection system or mulch kit in place and working properly.

1.4.18 Be aware of the mower discharge and direct discharge away from ot her s.

1.4.19 Do Not operate mower under the influence of alcohol or drugs.

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

1.4.21 If jump starting is required:

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

battery to the positive terminal post on the st ar ter solenoid switch (this post
has the positive battery cable attached to it).

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

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

c) disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

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

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

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

Note: To prevent damage due to freezing, bat t er y should be fully charged

before putting away for winter storag e.

1.5.4 Keep engine, engine area, and pump drive belt compartment free from
accumulation of grass, leaves, excessive grease or oil, and other debris which
can accumulate in these areas. These materials can become com bustible and
may result in a fire.

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

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

1.5.7 Gasoline powered eq uipm ent or fuel containers should not be stored in a basement
or any enclosed area where open pilot lights or heat appliances are present.

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

1.5.9 Check all bolts frequently to maint ain proper tightness.

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

1.5.11 Frequently check for worn or deteriorating com ponent s t hat could create a hazard.

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

- 7 -

POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrate

skin and cause injury.

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

surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene ma y result .

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

good condition an all hydraulic connections and fittings
are tight before applying pressure t o hydraulic system.

♦ Keep body and hands away from pinhole leaks or

nozzles that eject high pressure hydraulic fluid.

♦ Use cardboard or paper, not your hands, to f ind

hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic system, by

placing the motion control levers in neutra l and
shutting off t he engine, before perfor m ing any work on
the hydraulic system.

For Kohler EFI Units:

WARNING

POTENTIAL HAZARD
♦ Fuel system components are under high pressure.

WHAT CAN HAPPEN
♦ The use of improper components can r esult in system

failure, gasoline leakage and possible explosion.

HOW TO AVOID THE HAZARD
♦ Use only approved fuel lines and fuel filters for high

pressure systems.

WARNING

1.6 SAFETY SIGNS

1.6.1 Keep all saf et y sig ns legible. Remove all grease, dirt and debris from safety
signs and instructional labels.

1.6.2 Saf et y sig ns m ust be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sure that cur r ent safety signs are
affixed to the replaced components.

1.6.4 New safety signs m ay be obtained from your authorized Exmark equipment
dealer or distributor or fr om Exmar k Mfg. Co. Inc.

1.6.5 Saf et y signs may be affixed by peeling off the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They
are critical to the safe operation of your Exmark commercial mo wer.

- 8 -

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

All units except Kohler EFI
PART NO. 103-4474
LOCATION: Top Front of RH Fuel Tank

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

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

Kohler EFI units
PART NO. 103-5456
LOCATION: Top Front of RH Fuel Tank

Belt Shields, Left
and Right

Sides

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

PART NO. 107-2102
LOCATION: Inside Surface of

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

Upper Roll bar

- 9 -

PART NO. 98-5954
LOCATION: Under Mower Deck

Belt Shield(s)

PART NO. 107-2112
LOCATION: Top Center of Floorpan

PART NO. 103-7491
LOCATION: LH Side on Top Front of

Mower Deck

PART NO. 1-643339
LOCATION: Top of Right Engine Baffle

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

of Mower Deck

PART NO. 1-633702
LOCATION: Bottom Side of Floor Pan

PART NO. 103-9255
LOCATION: Top of console

Kohler EFI Units Only
PART NO. 103-2750
LOCATION: Panel behind LH Fuel Tank

PART NO. 103-0368
LOCATION: Rubber Heat Shield Flap

Seat

behind

DO NOT OPERATE
WI THOUT GUARD

IN PLACE.

1-513748

PART NO. 1-513748
LOCATIONS: Bottom Side

of Floorpan

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

Deck, Under Floor

Pan

PART NO. 1-633462
LOCATION: Rubber Heat Shield
Flap behind Seat

- 10 -

PART NO. 1-523552
LOCATION: Top of Hydraulic

Reservoir, Under

Seat

the

Kohler EFI Units Only
PART NO. 103-0261
LOCATION: RH Front of

Console

Type A Anti-scalp Rollers Only –
See Figure 11
PART NO. 1-323540
LOCATION: Left Rear Corner Top of

Mower Deck

All Units except Kohler EFI
PART NO. 103-0262
LOCATION: RH Front of Console

PART NO. 103-3270
LOCATION: RH Air Cleaner

Mount Plate

PART NO. 1-633922
LOCATION: Front Center on Top
of Mower Deck

PART NO. 1-633706
LOCATION: LH Side of Cutting
Height Adjustment Plate

All Units except Kohler EFI
PART NO. 103-4930
LOCATION: Right of Choke

Control on RH
Fuel Tank

All Units except Kohler EFI
PART NO. 103-1798
LOCATION: Right of Throttle

Control on RH
Fuel Tank

- 11 -

Kohler EFI Units Only
PART NO. 103-3679
LOCATION: Right of Throttle

Control on RH
Fuel Tank

2. SPECIFICATIONS

2.1 MODEL NUMBER:

Serial Nos. 510,000 and Higher

LZ25KC524; LZ27KC524; LZ23KC604; LZ25KC604; LZ27KC604; LZ28KC604;
LZ27KC724; LZ28KC724

2.2 ENGINE:

2.2.1 Engine Specifications: See your Engine Owner’s Manual

2.2.2 RPM: Full Speed: 3750 RPM (No Load) Idle: 1500 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity:

2.3.2 Type of Fuel: Regular unleaded g asoline, 87 oct ane or higher

2.3.3 Fuel Filter:
All units except Kohler EFI: In-line 15 Micron Kohler P/N 2405002.
Kohler EFI units: In-line 22 Micron Exmark P/N 99-9403 (low pressure).
In-line 10 Micron Kohler P/N 2405003 (high pressure).

2.3.4 Fuel Shut-Off Valve: 1/4 turn increments (left tank, “OFF”, right t ank)

2.3.5 Fuel gauge in left hand fuel tank.

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amps

2.4.3 Battery Type: BCI Group U1

2.4.4 Battery Voltage: 12 Volt

2.4.5 Polarity: Negative Ground

2.4.6 Fuses: All Units except Kohler EFI –Two 20 amp blade type

Kohler EFI units – Two 20 amp and one 10 amp blade type

2.4.7 Saf et y Int er lock System:
PTO must be disengaged, brake engaged, and motion control levers out

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

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

motion control levers are moved in or engine will stop.

Engine will stop if either the left, the right, or both levers ar e moved fr om neut ral

lock position while brake is engaged.

13.5 gal. (51 L.)

2.5 OPERATOR CONTROLS

2.5.1 Steering and Motion Control:
Separate levers, on each side of the console, contr ol speed and dir ect ion of

travel of the respective drive wheels.

Steering is controlled by varying the position of t he levers relative to each other.
Moving motion control levers outward
NOTE: Motion control levers are adjustable to two heights.

2.5.2 PTO Engagement Switch

: Engages electric clutch (t o dr ive belt) which engag es

mower blades.

2.5.3 Park ing Brake Lever

2.5.4 Deck Height Adjustment Lever

: Engages parking brake.

: Sets cutting height to desired position.

- 12 -

(in slots) locks the drive system in neutral.

2.5.5 Deck Lift Assist Lever:

Foot pedal that assists in raising the deck .

2.6 SEAT

2.6.1 Type:
All units except Kohler EFI: Standard seat with high back, foam padded (internal

suspension) and armrests.

Kohler EFI units: Standard seat with high back, foam padded ( int er nal suspension) ,

armrests and a custom ride suspension system.

Optional seat accessories:

• Custom ride suspension system to enhance Standard Seat.

• Deluxe suspension seat with high back, low profile foam- in- place cushion

(dampened, adjustable spring suspension) and arm r est s .

2.6.2 Mounting: Hing ed t o t ilt up for access to hydraulic pumps, battery and other
components. Held in tilted position with prop rod. Adjustable for e and aft seat track.

2.6.3 Armr est s: Standard seat: foam padded flip-up armrest s with height adjustment.

Optional suspension seat: molded adjustable f lip- up

armrests.

2.6.4 Seat Safety Switch: Incorporated into t he Safety Interlock System. T im e delay
seat switch eliminates rough ground cut-out s.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic Pumps: Two Hydro Gear PJ variable displacement piston pumps.

2.7.2 Wheel Motors: Two Parker T L with 1 1/4” tapered shafts.

2.7.3 Hydraulic Oil T ype: Synthet ic Mobil 1 15W-50.

2.7.4 Hydraulic Oil Capacity: 2. 1 qt.(2.0 L.)

2.7.5 Hydraulic Filter: Replaceable cartridge type.
P/N 1-513211: 10 microns, 18 psi bypass (Summer use above 32° F (0°C))

P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F (0°C))

2.7.6 Speeds: 0-9.8 mph (15.8 k m / hr) forward.
0-6.3 mph (10.1 km/hr ) r everse.

2.7.7 Drive wheel release valves allow machine to be moved when engine is not running.

2.8 TIRES

Pneumatic (Air-Filled)

Drive Front Caster

Semi-Pneumatic

Deck Size 52” 60” & 72” All Decks
Quantity 2 2 2
Tread “Multi- Trac C/S” Smooth
Size 24 x 9.50-12 24 x 12.00-12 13 x 6.50-6
Ply Rating 4 4
Pressure 13 psi (90 kPa) 13 psi (90 kPa)

2.9 CUTTING DECK

2.9.1 Cutting Width: 52 in. (132.1 cm)
60 in. (152.4 cm)
72 in. (182.9 cm)

2.9.2 Discharge: Side

2.9.3 Blade Size: (3 ea.) w/52” Deck 18.0 in. (45.7 cm)
w/60” Deck 20.5 in. (52.1 cm )
w/72” Deck 24.5 in. (62.2 cm)

2.9.4 Blade Spindles: Solid steel spindles with 1” I.D. bearings.

- 13 -

2.9.5 Deck Drive: Electric clutch mounted on horizontal engine shaft. “B” Section belt
(with self-tensioning idler) from electric clutch to transfer shaft mounted on deck .

Blades are driven by one “B” Section belt (w/self-tensioning idler) f r om transfer

shaft on deck to blade spindles.

2.9.6 Deck: Full floating deck is attached to out- front support fr am e. Six anti- scalp
rollers provide maximum turf protection. Deck design allows for bag ging, mulching
or side discharge.

Deck Depth

: 52” Deck: 5.5” (14.0 cm)
60” Deck: 5.5” (14.0 cm)
72” Deck: 5.5” (14.0 cm)

2.9.7 Cutting Height Adjustm ent : an extr a- long cushioned lever is used to adjust the

cutting height from 1 1/2” (3.8 cm) to 5” (10.2 cm. ) in 1/4”(.64 cm) increments.
The cutting height adjustment handle has a transport position and all
adjustments can be made while the operator remains seated. Unit s also have a
foot operated deck lift assist lever to aid in raising the deck.

2.9.8 Mulching Kit: O ptional.

2.10 DIMENSIONS

2.10.1 Overall Width:

w/52” Deck 49.8 in. (126.5 cm) 53.4 in. (135.6 cm) 64.2 in. (163.1 cm)
w/60” Deck 53.5 in. (135.9 cm) 61.4 in. (156.0 cm) 72.2 in. (183.4 cm)
w/72” Deck 57.3 in. (145.5 cm) 73.4 in. (186.4 cm) 84.3 in. (214.1 cm)

without deck deflector up deflector down

2.10.2 O verall Leng th:

Roll Bar - Up 78.5 in. (199.4 cm) 78.5 in. (199.4 cm) 82.9 in. (210.6 cm)
Roll Bar - Down 89.2 in. (226.6 cm) 89.2 in. (226.6 cm) 93.6 in (237.7 cm)

w/52” Deck w/60” Deck w/72” Deck

2.10.3 O verall Height:

Roll Bar - Up Roll Bar - Down

71.9 in. (182.6 cm) 53.8 in. (136.7 cm)

2.10.4 Tread W idt h: ( center to center of tires, widthwise)

Drive wheels 39.7 in. (100.1 cm) 41.9 in. (106.4 cm) 45.9 in. (116.6 cm)
Caster wheels 37.0 in. (93.9 cm) 39.0 in. (99.1 cm) 47.6 in. (120.9 cm)

w/52” Deck w/60” Deck w/72” Deck

2.10.5 Wheel Base: (c ent er of caster tire to center of drive tire)

w/52” & 60” Decks w/72” Deck

50.3 in. (127.8 cm) 54.5 in. (138.4 cm)

2.10.6 Cur b Weight:

23 & 27 HP Kohler units 1112 lbs. (504 kg) 1138 lbs. (516 kg) 1213 lbs. (550 kg)
28 HP Kohler EFI units 1163 lbs. (528 kg) 1238 lbs. (561 kg)

w/52” Deck w/60” Deck w/72” Deck

2.11 TORQUE REQUIREMENTS

Bolt Location

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

Blade Mounting Bolt...........................................................55-60 ft-lbs. (75-81 N-m)

Engine Deck/Front Frame Mount Bolts..............................30-35 ft-lbs. (41-47 N-m)

Anti-Scalp Roller (See Figure 11)

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

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

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

Engine Mounting Bolts ......................................................30-35 ft-lbs. (41-47 N-m)

- 14 -

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

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

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

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

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

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE MOWER

3.2 INSTALL ROLLOVER PROTECTION SYSTEM (ROLL BAR)

3.2.1 Disassemble roll bar from the cr at e.

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

wheel hub retaining plate to the bottom of the crate.

b) Remove the two bracket s used t o m ount t he bottom of the upper roll bar t ube

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

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

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

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

support or may malfunction allowing the unit to fall,

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

for support. Use adequate jack stands or equivalent

support.

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

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

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

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

the capscrew.

CAUTION

- 15 -

FIGURE 2

LOWER ROLL BAR INSTALLATION

a) Locate the latch pin assemblies (pin and hairpin connected with a lanyard).
b) Install a 1/2-13 x 3 1/4 capscrew in the washer on the lanyard of each pin

Note: Make sure the bent tab in the washer points toward the head of t he

b)

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

Notes:

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

e) Torque all lower roll bar hardware attached to the machine fram e to 30-35 ft-

f) Tight en the front knobs against t he upper r oll bar ends.

3.2.5 Install the upper u-shaped section of t he r oll bar . (Reference Figure 3 f or
alignment and installation instructions below):

assembly.

capscrew.
Lightly oil the inside surfaces of t he ear - shaped plates at the upper end of

the lower roll bar tubes.

section using one 1/2-13 x 3 1/4 capscrew (from step b) and one 1/ 2- 13 hex
flange lock nut on each side. Do not over t ighten. Make sure upper roll bar
can pivot freely.

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

• Make sure the tab on the lanyard washer is installed as shown and points
toward the front of t he unit .

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

lbs. (41-47 N-m).

- 16 -

FIGURE 3

UPPER ROLL BAR INSTALLATION

3.3 SERVICE BATTERY

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

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

The machine is shipped with a filled lead acid battery.

3.3.1 Unhook seat latch and tilt seat up to gain access to the battery.

POTENTIAL HAZARD
♦ Charging the battery may produce explosive gasses

WHAT CAN HAPPEN
♦ Battery gasses can explode causing serious injury.
HOW TO AVOID THE HAZARD

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

♦ Make sure venting path of battery is always open once

3.3.2 Check the voltage of the bat t e r y with a digital voltm et er. Locate the voltage reading
of the battery in the table below and charge the bat tery for the recommended time
interval to bring the charge up t o a full charge of 12.6 volts or greater.

DANGER

enclosed space.
battery is filled with acid.

hands after handling.

IMPORTANT: Make sure the negative battery cables are disconnected and the

battery charger used for charging the battery has an output of 16 volts and 7
amps or less to avoid damaging the batter y (see t he following chart for
recommended charger settings).

Voltage

Reading

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

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

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

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

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

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

Percent

Charge

Maximum

Charger Settings

- 17 -

Charging Interval

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

for sparks and engag em ent of components.
WHAT CAN HAPPEN
♦ Sparks could cause an explosion or moving parts

could accidentally engage causing personal injury.
HOW TO AVOID THE HAZARD
♦ Be sure ignition switch is in the “OFF” position before

charging the battery.

3.3.3 Connect the negative battery cables.
NOTE: If the positive cable is also disconnected, connect the positive (red)

cable and the red wire to the positive terminal on t he battery first, then connect
the negative (black) cable and white/white wire to the negat ive ter minal on the
battery (red wire and white/white wire are only on some units). Slip insulator
boot over the positive terminal.

NOTE: If time does not permit charging t he bat tery, or if charging eq uipm ent is

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

CAUTION

3.4 INSTALL DRIVE WHEELS

3.4.1 Mount drive wheels with the valve stem to the outside of the unit. Secure using
four (4) 1/2-20 wheel nuts (installed on studs in hubs) for each wheel. Torque to
95 ft-lbs (128 NxM).

3.5 CHECK TIRE PRESSURE.

3.5.1 Check tire pressure in drive tires. Proper inflation pressure for tir es is 13 psi ( 90
kPa). Adjust if necessary.

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

.

3.6 INSTALL SEAT

a) Remove seat assembly from the crate.
b) Remove the four 5/16-18 whizlock nuts from the seat t r ack studs at the bottom of

the seat. Retain for use later.

c) Align the seat track studs on the bottom of the seat with the holes in the seat

frame. Place seat on top of the frame and secure with the four 5/ 16- 18 whizlock
nuts remove in step b).

3.7 INSTALL CANISTER AIR CLEANER.

a) Remove air cleaner (with bracket attached) from crate. Keep air cleaner and

mounting bracket together.

b) Remove the top two valve cover mounting screws from both left and right side

engine valve covers. Keep screws for re-attaching air cleaner .

c) Position the air cleaner assembly over the engine, aligning air cleaner bracket

holes with top holes in the valve covers. Reinstall valve cover screws through air
cleaner bracket and torque t o 70 in. lb. (4.9 N-m).

d) Remove plastic plugs from air intake elbow on engine and air cleaner hose. Adjust

the air cleaner and hose as required and connect intake hose to air cleaner outlet.
Position and tighten the two hose clamps to secure the hose connections.

- 18 -

e) Secure air cleaner by tightening the tensioning bolt and spring assem bly until

ends of clamp are approximately ½” (12.7 mm) apar t.

3.8 INSTALL MOTION CONTROL LEVERS.

3.8.1 Loosen and remove the two (2) 3/8” x 1” bolts and spring disc washers which
attach the motion control levers to the cont rol arm shafts for shipping and the
two (2) 3/8” x 1” bolts and spr ing disc washers which are screwed into the
control arm shafts.

a) Install the left motion control lever onto the cont r ol ar m shaft (See Figure 4) on

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

NOTE: There are two lever height opt ions available. Place t he levers in t he top

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

If the levers do not align with each other, when in the neutral position, (See Fig ur e

5) loosen the hardware and make the appropriate adjustment by sliding/tilting t he
lever(s) forward or backward until proper ly aligned and tighten hardware.

MOTION

CONTROL

LEVER

MOUNT PLATE TO

THE REAR & OUTSIDE

OF ARM SHAFT

FIGURE 4 FIGURE 5

CONTROL ARM SHAFT LEVER ALIGNMENT

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

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

LEVERS IN

ALIGNMENT

3.9 POSITION DISCHARGE CHUTE.

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

3.10 SERVICE ENGINE.

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

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

3.11 SERVICE HYDRAULIC OIL

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

- 19 -

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the

temperature of the oil. The “HOT” level shows the level of oil when it is at 225°F
(107°C). The “COLD” level shows the level of t he oil when it is at 75° F ( 24° C) . Fill to
the appropriate level depending upon the temperature of the oil. For example: If the oil
is about 150° F (65°C). Fill to half way between the “HOT ” and “ COLD” levels. If the oil
is at room temperature ( about 75° F (24°C)), fill only to the “CO LD” level.

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4.1.2 Motion Control Levers

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

When levers are cent er ed in t he T-slot the drive system is in the neutral position.

FIGURE 6

4.1.1 Familiarize yourself with all controls before operating the mower.
: Located on each side of the console. The left lever

controls the flow of hydraulic oil fr om t he left hydrostatic pump to the lef t drive
wheel motor. The right lever controls the flow of hydraulic oil from the r ig h t
hydrostatic pump to the right drive wheel motor.

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

With levers moved out in t he T-slot the drive system is in the neutral lock position
(See Figure 6).

MOTION CONTROL POSITIONS

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

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

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

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

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

slow the left drive wheel.

To turn right while moving forward, move the ri ght l ever back toward neutral to

slow the right drive wheel.

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

holding the right lever slight ly ahead of neutral.

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

holding the left lever slight ly ahead of neutral.

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

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

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

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

- 20 -

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

too much ahead of the other.
WHAT CAN HAPPEN
♦ Operator may lose control of t he m achine, which may

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

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

4.1.3 Tracking Adjustment Knob : Located under the seat on the RH pump control
link. Rotating this k nob allows f ine t uning adjustments so that the machine
tracks straight with the dr ive levers in t he full forward position.

Stop machine and wait for all moving parts t o st op. Engage park brak e. Unhook

seat latch and tilt seat forward to gain access to the tracking k nob. Rot ate the knob
clockwise (as viewed from the rear of the machine) t o cause the machine to track
more to the right and counterclockwise to cause the machine to track more to t he
left. Adjust in quar t er-turn increments until the machine t r acks straight. Check t hat
the machine does not creep when in neutral with the park brakes disengaged.

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

to creep in neutral. Refer to section 5.2. 13 f or cont rol l i nkage adjust ment .

4.1.4 PTO Engagement Switch

Switch must be pulled out to the “ROTATE” position to engage the blades.

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

4.1.5 Choke Control

Choke is used to aid in starting a cold engine. Moving the chok e lever forward

will put the choke in the “ON” position and moving the choke lever t o t he rear
will put the choke in the “OFF” position. DO NO T r un a warm engine with choke
in the “ON” position.

4.1.6 Throttle Control

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

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

4.1.7 Brake Lever
brake lever engages a parking brake on the drive wheels.

Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.
The unit must be tied down and brake engaged when transporting.

4.1.8 Ignition Switch

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

positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise
to the “ON” position. Rotat e clockwise to the next position to engage the starter
(key must be held against spring pr essur e in t his position).

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

and PTO switch “OFF” to start engine. ( I t is not necessary for the operator to

be in the seat to start the engine. )

4.1.9 Hour Meter
pressure switch installed in the engine block and it records the number of hours
that the engine has run. If the ignition switch is left on without engine running,
hour meter will not run.

: (All units except Kohler EFI) Located on rig ht fuel tank.

: Located on right fuel tank.

: Located on left side of unit , j ust to the front of the console. The

: Located on right fuel tank.

: Located on the right fuel t ank. The hour meter is connected to a

CAUTION

: Located on right fuel tank.

- 21 -

NOTE: This switch is not a low oil sensor and will not alert the operator if the

engine oil is low.

4.1.10 Fuel Shut-Off Valve
The fuel shut-off valve is used to shut off the fuel when the machine will not be
used for a few days, during transport t o and from the job site, and when parked
inside a building. The valve has three positions, each position made in 1/ 4 t ur n
increments.

NOTE: The positions f or t he Kohler EFI units are diffe r ent than all other units.

Reference the following table for the correct locations.

VALVE HANDLE POSITION

FUEL FLOW Carburet or engines Kohler EFI

“OFF” DOWN RIGHT

RIGHT TANK RIGHT DOWN

LEFT TANK LEFT LEFT

4.1.11 Fuel Gauge: Located on the left fuel t ank.

The fuel gauge monit ors the amount of fuel in t he left tank only. Use the f uel

from the right fuel tank first. When the right fuel tank is empty switch to the left
fuel tank. Fuel gauge will monitor the remaining fuel.

4.1.12 Drive Wheel Release Valves
pumps. Drive wheel release valves are used to release the hydrostatic drive
system to allow the machine to be pushed without the engine running. Unhook
seat latch and tilt seat up to gain access to pum ps.

With a 7/16 wrench, t ur n both valves one turn counter-clockwise to release drive

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

4.1.13 Electronic Control Unit Malfunction Indicator:
electronic control unit (ECU) continuously monitor s oper ation of the EFI system.
If a problem or fault within the system is detected, the malfunct ion indicator light
(MIL) is illuminated. The MIL is the red light locat ed on the right fuel tank to the
right of the hour meter. Follow the troubleshooting steps outlined in the Kohler
engine operator’s manual if t he MIL is illuminat ed.

: Located directly below right side of console, next to cubby.

: Located on the top left front corner of hydrostatic

(Kohler EFI units only) The

4.2 PRE-START

4.2.1 Fill fuel tanks. For best r esults use only clean, fresh regular gr ade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded ga soline
may also be used; however, combustion chamber and cylinder head will require
more frequent service. See Engine Owner's Manual.

DO NOT add oil t o gasoline.
DO NOT overfill fuel t ank. Never fill the fuel t ank so that the fuel level rises

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

IMPORTANT: The fuel system for Kohler EFI units must be purged of all air

prior to start up if t he engine has been allowed to run out of gas or the system
has been disassembled. Turn the key to the “ start” position for approximately 30
seconds. If engine does not start, wait 1 minute to allow starter to cool down
before attempting t o start engine again.

4.2.2 Make sure you understand the controls, their locations, their functions, and their
safety requirements.

4.2.3 Refer to Maintenance, Section 5, and perform all the necessary inspection and
maintenance steps.

- 22 -

4.3 OPERATING INSTRUCTIONS

4.3.1 Operate units with the roll bar in the raised and lock ed position and use seat belt.
There is no rollover protection when the roll bar is down. If it is necessary to lower
roll bar do not wear the seat belt. Raise the roll bar as soon as clear ance per mits.

4.3.2 Open fuel shut-off valve

4.3.3 Starting Engine

:

Brake must be engaged, motion control levers out (neutr al l ock posi tion)

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

On a cold engine, place the throttle midway between the “SLOW” and “FAST”

positions and push choke lever forward (except Kohler EFI units ) int o t he “ ON”
position. Turn ignition switch to the “ st a r t ” position. Release the switch as soon as
the engine starts.

(left or right tank).

IMPORTANT:

DO NOT crank the engine continuously for more then ten (10)
seconds at a time. If the engine does not start, allow a 60 second cool­down period between starting attempts. Failure to f ol l ow these guidelines
can burn out the starter motor.

After starting a cold engine (except Kohler EFI units), gr adually ret ur n choke to

the “OFF” position as the engine warms up.

On a warm engine, place the throttle midway between the “SLOW” and “FAST”

positions and leave the choke in the “OFF” position.

4.3.4 Engaging PTO

:

DANGER

POTENTIAL HAZARD
♦ The rotating blades under the mower deck ar e

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

deck when the blades are engaged.

DANGER

POTENTIAL HAZARD
♦ An uncovered discharge opening will allow objects to

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

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

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

raised, removed, or altered unless there is a g r ass

collection system or mulch kit in place and working

properly.

The PTO push-pull switch engages the cut t ing blades. Be sure that all persons

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

- 23 -

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

position. Accelerate to full throttle to begin mowing.

4.3.5 Stopping PTO
“STOP” position stopping t he PTO.

4.3.6 Stopping Engine
control levers out to the neutral lock position and set parking brake.

Before stopping the engine, place the throttle control midway between the “slow”

and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then
stop the engine.

Rotate ignition switch to “OFF” position. Remove the key to prevent children or

other unauthorized persons from star t ing engine.

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

transporting, and when the unit is park ed inside a building.

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

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

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

4.4 TRANSPORTING

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

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

reflective markings, or a slow moving vehicle emblem.
These items are required to dr ive on a public str eet or

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

is dangerous and can lead to accidents causing

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

may also be a violation of State laws and the operator

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

CAUTION

- 24 -

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

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

injury or death.
HOW TO AVOID THE HAZARD

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

individual ramps for each side of the unit.
♦ If individual ramps must be used, use enough ram ps t o

create an unbroken ramp surf ace wider than t he unit .
♦ DO NOT exceed a 15° angle between ramp and

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

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

ramp to avoid tipping backward.

4.4.2 Loading a Unit: Use extreme caution when loading units on trailer s or trucks.
One full width ramp that is wide enough to extend beyond the rear tires is
recommended instead of individual ramps fo r each side of the unit. The lower
rear section of the tractor frame extends back between the rear wheels and
serves as a stop for tipping backward. Having a full width ramp provides a
surface for the frame members to contact if the unit starts to tip backward. I f it is
not possible to use one full width ramp, use enough individual ramps t o sim ulate
a full width continuous ramp.

Ramp should be long enough so that the angles bet ween the ram p and t he

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

DO NO T att em pt to turn the unit while on the ramp, you may lose control and

drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration when

backing down a ramp. Both maneuvers can cause the unit to tip back ward.

WARNING

5. MAINTENANCE & ADJUSTMENTS

POTENTIAL HAZARD
♦ While maintenance or adjustments are being made,

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

you or other bystanders.
HOW TO AVOID THE HAZARD
♦ Remove the key from the ig nit ion switch and pull the

wire(s) off the spark plug(s) before you do any

maintenance. Also push the wire(s) aside so it does

not accidentally contact the spark plug(s ) .

WARNING

- 25 -

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

making repairs around the eng ine area.

WARNING

5.1 PERIODIC MAINTENANCE

5.1.1 Check engine oil level:
Service Interval: Daily
a) Stop engine and wait for all moving parts to stop. Make sur e unit is on a

level surface.

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

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

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

and fill to the “FULL” mark on the dipstick. Use oil as specified in Engine
Owner’s Manual. DO NOT overfill.

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

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

5.1.2 Check batter y charge
Service Interval: Monthly

Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, r echarge batteries in storage when the open
circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, bat t er y should be fully charged

before putting away for winter storag e.

a) Check the voltage of t he bat tery with a digital voltmeter. Locate the voltage

reading of the batter y in the table below and charg e the battery for the
recommended time interval to bring t he charge up to a full charge of 12.6
volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected

and the battery charger used for char ging the battery has an output of 16
volts and 7 amps or less to avoid damaging the batter y (see chart below for
recommended charger settings).

Voltage

Reading

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

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

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

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

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

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

:

Percent

Charge

Maximum

Charger Settings

Charging Interval

IMPORTANT: For Kohler EFI units: Unplug the harness from the ECU

before performing any welding on the equipment.

- 26 -

5.1.3 Clean engine cooling system

:

Service Interval: Daily or more often in dry conditions

CAUTION

POTENTIAL HAZARD
♦ Excessive debris and damaged or missing rubber

baffles can cause the engine and hydraulic system to

overheat.
WHAT CAN HAPPEN
♦ Excessive debris around the engine cooling air intake

and inside of the pump drive belt compartment can

create a fire hazard.
HOW TO AVOID THE HAZARD
♦ Clean all debris from inside of pum p dr ive belt

compartment daily.

Information located:

• On right fuel tank decals 103-4774 (All units except
Kohler EFI) and 103-5456 (Kohler EFI units)

• On decal 1-633462 behind seat on rubber heat
shield flap

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Clean all debris from rotating engine air int a ke screen and from around

engine shrouding.
c) Clean all debris from inside of pump drive belt com par t ment.
d) Inspect rubber engine baffles for pr oper fit. Replace if necessary.

5.1.4 Clean grass build-up under deck

.

Service Interval: Daily
a) Stop engine, wait for all m oving parts to stop, and remove key.
b) Raise deck to the transport ( 5” (12.7 cm) cutting height ) position. Lift the

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

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or m aint enance

relying solely on mechanical or hydraulic jacks could be
dangerous.

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

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

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

support. Use adequate jack st ands or equivalent support.

c) Clean out any grass build-up from underside of deck and in discharg e chut e.

5.1.5 Check mower blades

.
Service Interval: Daily
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Lift deck and secure in r aised posit ion as stated in Section 5.1.4.
c) Inspect blades and sharpen or replace as required.

- 27 -

d) Re-install the blades ( if they were removed) in the following order (See

Figure 7):

1) Install bushing through blade with bushing flange on bottom ( grass)
side of blade.

2) Install bushing/blade combo into spindle.

3) Install blade bolt and spring disc washer. Be sure the spring disc
washer cone is installed towards the bolt head. Place a block of wood
between front or rear baffles and the blade then torque the blade bolts
to 55-60 ft-lbs. (75-81 N-m).

FIGURE 7

BLADE BOLT INSTALLATION

IMPORTANT: DO NOT use components other than the original blade, blade
bushing, spring disc washer, and blade bolt supplied with the unit. Failure t o use
all original components and assembled as shown will increase the risk of a blade
bolt becoming loose or weak after striking a foreign object.

POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened blade

bolts can be dangerous.
WHAT CAN HAPPEN
♦ A loose or weakened blade bolt could allow a blade

rotating at a high speed to come out from under the deck,

causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦ Always re-install original Exmark blades, blade bushings,

spring disc washers, and blade bolts in the correct

positions as shown.

5.1.6 Check safety interlock system

Service Interval: Daily
a) Check st ar t ing circuit. Starter should crank with, parking brake engaged,

PTO disengaged and motion contro l levers m oved out in t he neutral lock
position. The operator does not need to be in t he seat to start the engine.

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

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

CAUTION

.

- 28 -

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

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

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

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

starter must not crank.

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

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

Run engine at one- t hird throttle, engage PTO and raise off of seat (but do

not get off of machine) engine must stop af t er 1/ 2 second has elapsed.

Run engine at one- t hird throttle, with brake disengag ed, move levers in and

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

Again, r un engine at one-third throttle, br ake engaged, and move left

motion control lever in - engine must st op.

Repeat ag ain m oving t he ri ght l ever i n, t hen m oving bot h levers in -

engine must stop whether operator is on seat or not.

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

Contact your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that operator safety mechanisms be

connected and in proper operating condition prior to use for mowing.

5.1. 7 Check r ollover pr ot ections systems (roll bar) pins

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

condition.

5.1.8 Check for loose hardware

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

problem. Tighten hardware or correct the problem before operating .

5.1.9 Service air cleaner

.

Service Interval: 50 hrs.

More often under severe condi t i ons.
See Engine manual for additional information.

a) Stop engine, wait for all moving parts to st op, and remove key.

b) Loosen retaining clips and remove air cleaner compar tment cover.
c) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damaged.

d) Check the condition of t he inner elem ent . Replace whenever it appears

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

the engine.
e) DO NOT wash or use pressurized air to clean paper element or inner elem ent .
f) Reinstall element s. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

- 29 -

5.1.10 Check Spark Ar r est er

Kohler EFI engines only: Service Interval: 50 hours

POTENTIAL HAZARD
♦ Hot exhaust system components may ignite gasoline

vapors even after the engine is stopped.

♦ Hot particles exhausted during engine operation m ay

ignite flammable mat e r ials.
WHAT CAN HAPPEN
♦ Fire may result in personal injury or property damage.
HOW TO AVOID THE HAZARD
♦ Do NOT refuel or run eng ine unless spar k arrester is

installed.

a) Shut off engine, remove key, and wait for all m oving parts to stop.
b) Wait for muffler to cool.

c) If any breaks in the scr een or welds are observed, replace ar r est er .

d) If plugging of the screen is observed, rem ove arrest er and shake loose particles

out of the arrester and clean scr een with a wire brush (soak in solvent if
necessary). Re-install arrester on exhaust outlet.

5.1.11 Change engine oil:
Service Interval: 100 hrs.
NOTE: Change oil and filter after firs t five (5) hrs. of operation.
a) Stop engine, wait for all m oving parts to stop, and remove key.
b) Drain oil while engine is warm from operation.
c) The oil drain valve is located on right hand side of engine.
Place pan under machine t o cat c h oil and open valve with a 10 mm wrench.

Allow oil to drain, then close valve.

d) Replace the oil filter every other oil change. Clean around oil filter and

unscrew filter to remove. Bef o r e r einstalling new filter, apply a thin coating of
oil on the surface of the r ubber seal. Turn filter clock wise until rubber seal
contacts the filter adapt er t hen tighten filter an additional 2/3 t o 3/4 turn.

e) Clean around oil fill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NO T overfill.

f) Start the engine and check for leaks.

5.1.12 Check hydraulic oil level

WARNING

:

Service Interval: 40 hr.
a) Stop engine and wait for all moving par ts to stop.
b) Unhook seat latch and tilt seat up.
c) Clean area around hydraulic reservoir cap and re m ove cap. O il level should

be to the top of the baf fle inside the tank. If not, add oil. Use only Mobil 1
15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten
until snug. Do not overtighten.

NOT E: The baffle is labeled “HOT ” and “ COLD”. The oil level varies with

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

- 30 -

5.1.13 Check tire pressures

:
Service Interval: 40 hrs.
a) Stop engine, wait for all m oving parts to stop, and remove key.

b) Check t ire pressure in drive tires.
c) Inflate dr ive tires t o 13 psi ( 90 kPa).
d) Caster t ir es do not need t o be inflated.

NOTE: Do not add any type of tire liner or foam fill material to the tires.

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

5.1.14 Check condition of belts

:
Service Interval: 40 hrs.
a) Stop engine, wait for all m oving parts to stop, and remove key.
b) Unhook seat latch and tilt seat up. Lift the rubber flap on front side of the

engine to check pump drive belt.

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

deck drive belt.
d) Check under machine to inspect the m u le dr ive belt.
e) See Sections 5.2.3, throug h 5. 2. 5 for belt adjustment.

5.1.15 Lubricate grease fitting s

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

gun grease.

Refe r t o the following chart for fitting locations and lubrication schedule.

LUBRICATION CHART

FITTING

LOCATIONS

1. Front Caster wheel hubs

2. Front Caster Pivots

3. Height Adj. Shaft Bearings 1 5 40 hours

4. Deck Drive Belt Idler Arm 1 1 Yearly

5. Brake Brackets 1 2 200 hours

6. Mule Drive Belt Idler Arm 1 1 Yearly

7. Pump Drive Belt Idler Arm 1 1 Yearly

8. Deck Rear Struts 1 2 40 hours

INITIAL

PUMPS

∗0
∗0

NO. of

PLACES

2
2

SERVICE

INTERVAL

∗Yearly
∗Yearly

∗ See Section 5.1.15 c) f or special lubr icat ion instructions on the front caster pivots and

Section 5.1.16 for special lubrication inst r uct ions on the front casters wheel hubs.

No. 6 (Mule Drive Belt Idler Arm)
Located Under Engine Frame

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

- 31 -

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

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

5.1. 16 Lubricate caster wheel hubs:
Service Interval: Once Yearly
a) Stop engine, wait for all moving parts to

stop, and remove key.
b) Remove caster wheel from cast er forks.
c) Remove seal guards from the wheel hub.
d) Remove one of the spacer nuts from t he

axle assembly in the caster wheel. Note

that thread locking adhesive has been

applied to lock the spacer nuts to the

axle. Remove the axle (with the other

spacer nut still assembled to it) f rom the

wheel assembly.
e) Pry out seals, and inspect bearings for

CASTER WHEEL ASSEMBLY

FIGURE 8

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

apply a thread locking adhesive to (1) spacer nut and thr ead ont o the axle

with the wrench flats facing outward. Do not thr ead spacer nut all of the way

onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer

surface of the spacer nut to the end of the axle inside the nut.
i) Insert the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing.
h) With t he open end of the wheel facing up, fill t he ar ea inside t he wheel

around the axle full of NGLI grade #1 multi-purpose grease.
i) Insert the second bearing and new seal into the wheel.

nd

j) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

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

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

fork. Re-install cast er bolt and tighten nut fully.

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

adjustment often. Spin t he caster tire. The tire should not spin freely

(more than 1 or 2 revolutions) or have any side play. If the wheel spins

freely, adjust torq ue on spacer nut until there is a slight amount of dr ag.

Re-apply threadlocking adhesive.

5.1.17 Lubricate seat switch actuator:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s to stop, and remove key.
b) Unhook seat latch and tilt seat up.
c) Lubricat e switch actuator rod with spray type lubricant or light oil.

- 32 -

5.1.18 Lubricate brake handle pivot

Service Interval: 160 hrs.

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

or light oil.

5.1.19 Lubricate brake rod bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all m oving par ts to stop, and remove key.
b) Unhook seat latch and tilt seat up.
c) Lubricate bronze bushings on each end of brake rod shaft with a spray type

lubricant or a light oil (bushings ar e locat ed t o the inside of the flange bearings).

5.1.20 Lubricate motion control bronze bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all m oving par ts to stop, and remove key.
b) Unhook seat latch and tilt seat up.
c) Lubricate bronze bushings on flange bearings securing the motion control

arm shafts with a light oil or a spr ay type lubricant .

5.1.21 Remove engine shrouds and clean cooling fins

Service Interval: 80 hrs.
a) Stop engine, wait for all moving parts t o stop, and remove key.

b) Remove cooling shroud clean-out covers from eng ine and clean cooling fins.

Also clean dust, dirt, and oil from exter nal sur faces of engine, which can cause
improper cooling.

c) Make sure cooling shroud clean-out covers are reinstalled. Operating the

engine without cooling shroud clean-out covers will cause engine damage due
to overheating.

5.1.22 Check spark plugs

Service Interval: 160 hrs.

a) Remove spark plugs, check condition and reset gaps, or replace with new

plugs. See Engine Owners Manual.

5.1.23 Change fuel filter

Service Interval: As Requi red

a) A fuel filter is installed between the fuel tanks and the engine. Replace

when necessary.

For Kohler EFI Units:

:

:

:

:

:

:

POTENTIAL HAZARD
♦ Fuel system components are under high pressure.

WHAT CAN HAPPEN
♦ The use of improper components can r esult in system

failure, gasoline leakage and possible explosion.
HOW TO AVOID THE HAZARD
♦ Use only approved fuel lines and fuel filters for high

pressure systems.

WARNING

- 33 -

Note: For Kohler EFI units use only high pressure clam ps and SAE R7 or R9
hose available from Exmark or Kohler. Clam ps r equire special pliers P/N 1­643394 (Oetiker P/N 14100118 or Kohler P/N 2445505) for installation.

Replacement Filters
Kohler EFI
Kohler Air-cooled (except EFI)

Note: When replacing the fuel filter for the Kohler EFI units, wet t he interior

of the new filter with gasoline bef or e inst allation to prevent the high pressure
pump from tearing the filt er .

Note: It is important t o r einstall the fuel line hoses and secure with plastic ties

the same as they were originally installed at the fact or y to keep the fuel line away
from components that could cause fuel line damage.

For Kohler EFI units: Route the fuel line hoses as shown in Figure 9.

FIGURE 9

KOHLER EFI FUEL LINE ROUTING

5.1. 24 Fuel pressure relief and priming pr ocedur e

Exmark P/N 99-9403 (low pressure)
Kohler P/N 2405003 (high pressure)
Kohler P/N 2405002

: (Kohler EFI units only)

Service Interval: As required

POTENTIAL HAZARD
♦ Fuel system components remain under high pressure,

even when the engine is stopped.
WHAT CAN HAPPEN
♦ Failure to relieve pressure from the system can cause

gasoline to spray or spill. Spilled fuel or fuel vapors

could be ignited by hot parts.
HOW TO AVOID THE HAZARD

♦ Allow the engine to cool completely.
♦ Safely relieve the pressure from t he fuel system before

attempting to service the fuel system.

A Kohler pressure gauge with an integr al r elief valve (Kohler Part No. 2445504)

is recommended for relieving pressure and pur ging air in the fuel system.
To relieve the system of pressure:
a) Stop engine, wait for all moving par ts to stop, and remove key.

WARNING

- 34 -

b) Allow the engine to cool completely.
c) Connect the black tester hose from the Kohler pressure gauge to the test

valve in the fuel rail.

d) Route the clear hose into a portable gasoline cont ainer and depr ess t he

button on the tester relief valve.

5.1.25 Change hydraulic system filter

:

Service Interval: After First 250 hrs.
Then yearl y t hereaf t er

NOTE: Use only Exmark Part No. 1-513211 for summer use above 32°

or Part No. 1-523541 for winter use below 32°

F (0°C).

F (0°C)

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Raise seat.
c) Carefully clean area around filter . It is important that no dirt or

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

apply a thin coat of oil on the surface of the rubber seal.
T urn filter clockwise until rubber seal contact s t he filter adapter, then

tighten the filter an addit ional 2/ 3 t o 3/ 4 t u r n.
e) Fill reser voir as st at ed in Section 5.1.12.
f) Raise the rear of m achine up and suppor t with jack stands (or equivalent

support) just high enough t o allow drive wheels to turn freely.
g) Start engine and move throttle control ahead to full throttle position. Move

the speed control levers to the full speed and run for several minutes. Shut

down machine and recheck oil level.
Do not change hydraulic system oil (except for what can be drained when

changing filter), unless it is felt the oil has been contaminat ed or been

extremely hot.
Changing oil unnecessarily could damage hydraulic system by

introducing contaminates into the system.

5.1.26 Wheel hub

- slotted nut torque specification.

Service Interval: 500 hrs
When tig ht ening the slotted nut on the wheel motor tapered shaft:
a) Torque the slott ed nut t o 125 ft. lbs (169 N-M).
b) Check distance from bot t o m of slot in nut to inside edge of hole. Two

threads (0.1”) or less should be showing.

c) If more than two threads (0.1”) are showing remove nut and install washer

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

5.1.27 Fuel Tank

– mounting hardware specification.

When installing the nuts on the fuel tank studs, fully tig ht en t he nyloc nut and

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

5.1.28 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro- Lock Nut Type”

are used on the following fasteners:

- 35 -

a) Pump drive sheave set screws.
b) Square head setscrews on Hydro pump control arms.
c) Sheave ret aining bolt in the end of engine crank shaft.
d) Caster wheel spacer nuts
e) Fuel tank bulkhead fitt ing nuts.
f) Cutter housing spindle nut.
Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pr o

Pro-Lock Retaining I

or Retaining II” are used on the following:

a) Fuel tank studs, where studs are inserted into tank.

5.1.29 Mobil HTS grease (or food-grade antisieze) is used in the following locations:
a) Between the cutter housing spindle and bearing s .
b) Between the cutter housing spindle and sheave.
c) Under top cutter housing bearing g uar d.
d) Between jackshaft and bearings and jackshaft and sheaves.

5.1.30 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

5.2 ADJUSTMENTS

IMPO RTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,

and remove key before servicing, cleaning, or making any adjustments to the unit.

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

height position). See Figure 10.

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

the deck lift assist lever.

NOTE: When changing cutting height positions, al ways come to a

complete stop and disengage the PTO.

CUTTING HEIGHT POSITION

d) Insert height adjustm ent pin into hole corresponding to desired cutting

height and install hairpin cotter. See decal on t he side of deck lift plate.

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

down onto height

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

height) position.

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

lift the deck to clear objects. Be sure t hat PTO i s di sengaged.

.

FIGURE 10

adjustment pin to mow at selected height.

- 36 -

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

of the positions shown in Figure 11. Rollers will maintain 3/4 in. (19 mm)
clearance to the ground to minimize goug ing and roller wear or damage.

For Maximum Deck Flotation, place roller s one hole posit ion lower.

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

T wo types of anti-scalp roller assemblies are available. See Figure 11 to

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

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

FIGURE 11

ANTI-SCALP ROLLER ADJUSTMENT

5.2.2 Deck Leveling
a) Position mower on a flat surface.
b) Stop engine, wait for all moving parts to stop, and remove key.
c) Check tire pressure in drive tires. Proper inflation pressure for tires is 13 psi

(90 kPa). Adjust if necessary.
d) Set ant i- scalp r ollers to top holes or remove them completely f or this adjustment.
e) Raise the deck to the 5” (12.7 cm) height position (also transpor t position)

and take all force of f of the two large deck lift springs by loosening the nuts

at the front of each spr ing . See Figure 12.
f) For 52” and 60” units - Lower the deck to t he 1- 1/ 2” (3.81 cm) height position.
For 72” units – Lower the deck to the 1-1/2” (3. 81 cm) height position. Force

the left rear deck support arm downward about 1/4” (6.4 mm) to get the deck

to rest at the 1-1/2” heig h t posit ion. Place locking pliers between the rear

swivel and spring stop to hold the deck in this position. See Figure 12.
g) Place a 3/4” (19 mm) thick block of wood under each of the two (2) rear

anti- scalp roller brackets and place one under one of t he f r ont center

anti-scalp roller brackets.

- 37 -

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

jam nuts and back off the socket head adjusting screws on the bottom of the

arms until the chains are just loose. T ur n t he socket head adjusting screws in

until slack is taken out of each chain. Tighten the jam nuts. T ighten the chain

bolts in the deck lift ar m s m aking sure they don’t move while tightening.
i) Loosen the four (4) nuts which secure the front swivels (two per side) until

the front chains are loose and fr ont of deck is supported by the 3/4” (19 m m )

block. Do not loosen the front chain har dware.
j) On left side, adjust front swivel using the locking nut behind the swivel until

the front chain is tight and all slack is removed from linkage. Do not lift

front of deck off 3/4” (19 mm) block. Secure front swivel using locking nut

in front of swivel. Repeat for right side.
k) Recheck that the 3/4” (19 mm) blocks fit just snugly under the bracket s and

that the tension on all the chains are approximately equal. Make sur e all chain

attachment bolts are tight. Reposition anti-scalp rollers and tighten securely.

11 1/8” (28.3 cm) For 52” Deck
10 1/2” (26.7 cm) For 60” Deck
11 1/2” (29.2 cm) For 72” Deck

Front of Unit

FIGURE 12

SWIVEL ADJUSTMENT

SPRING COMPRESSION ADJUSTMENT

l) Raise deck lift lever to the 5” (12.7 cm) cut t ing height position See Figure 10.

Adjust spring compression until proper dist ance is obtained between the two

large washers (See Figure 12). Adjustm ent is made by turning the nut at the

front of each spring ( clockwise will shorten the spring, counter-clockwise will

lengthen the spring). Lock in position with jam nuts.

NO TE: When above adjustments have been made, the front of the

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

5.2.3 Pump Drive Belt Tension

.

Self-tensioning - No adjust ment necessary.

5.2.4 Mule Drive Belt Tension Adjustment

.

Self-tensioning idler, adjust as follows:

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

b) Check to make sure the center of the bolt head in the center of the spring

loaded pulley, on left side engine deck support, is positioned between the

centers of the two alignment holes in t he left support plate (See Figure 13) .

It is necessary to adjust the belt tension when the center of the bolt head is at

or below the center of the bottom alignment hole.
c) When adjust m ent is necessary, loosen the idler pulley on the right-hand

side so it can move up and down in the slot.
Place a wrench on the 3/8” nut in the center of the spring loaded pulley and

apply upward pressure to relieve tension on the spring (a 1/2” drive break er

bar and 9/16 socket works best).

- 38 -

Reposit ion t he adjusting pulley to the bottom of the slot.
NO TE: When inst alling a new belt, it is necessary to reposition the right

adjusting pulley upward in the slot in order to position the center of the

spring loaded pulley between the alignment holes.

FIGURE 13

MULE DRIVE BELT ADJUSTMENT

5.2.5 Deck Belt Tension

.

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

necessary.

5.2.6 Adjust Seat Switch
a) If necessary, adjust the seat actuator rod length to where the machine will

shut off when the operator raises off the seat (with brake disengaged or

PTO engaged) but will continue to run with operator in seat (a slight shift in

weight should not shut machine off).
For all units except Kohler EFI (seat spring mount weldment is painted

black): Normal adjustment is when length of spring is 2.09” (5.3 cm) ( with

seat up).
For Kohler EFI unit s ( seat spring mount weldment is yellow plated) : Nor mal

adjustment is when length of spring is 2. 50” (6.4 cm) (with seat up).

NOTE: To prevent the engine from cutti ng out when operating over

rought ground, the unit is equipped with a time-delayed seat swit ch.

When the operator raises off the seat w i t h ei t her t he brake

disengaged or the PTO engaged, the engine should stop after 1/2

second has elapsed.

b) To adjust seat switch actuator rod length, loosen lock nut on bottom of the

actuator rod (5/16 x 7” bolt) and adjust t he nuts to move the actuator

plate/washer up or down on the rod, then retighten.

5.2.7 Belt Guide Adjustment

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

pulley. Guide should be 1/8” ( 3. 2 mm) away from the belt, with bolt-end of
guide near end of slot (See Figur e 14) .

d) If adjustm ent is necessar y, loosen t he bolt secur ing the belt guide and

make proper adjustment. Tighten hardware.

- 39 -

)

FIGURE 14

BELT GUIDE POSITIONING

5.2.8 Brake Link Adjustment.
Check to make sure brake is adjusted properly.
a) Disengage brake lever (lever down).
b) Measure the length of the spring. Measurement should be 2.75” (7.0 cm)

between washers (see Figure 15).

c) If adjustment is necessar y, t ig ht en the nut directly below the yoke and

loosen the bottom nut (bottom one of the two tightened together) below the
spring. Turn the nut direct ly below the washer (top nut of the two tightened
together) until the corr ect m easur ement is obtained. Tighten the two nuts
together and repeat on opposite side of unit. Turn clockwise to shorten
spring length and turn counter- clockwise to lengthen the spring.

3/16” (4.8 mm) to
1/4” (6.4 mm

2.75”

(7.0 cm)

FIGURE 15

BRAKE ADJUSTMENT

5.2.9 Brake Adjustment

.
a) Check for brake link 2.75” (7.0 cm) measur ement as described in section 5.2.8.
b) Engage brake lever (lever up).
c) Measure the distance between the trunion roller and the rod collar.

Measurement should be 3/16” (4.8 mm) to 1/4” ( 6.4 mm). See Figure 15.

d) If adjustment is necessary, loosen the nut directly below the yoke. Turn the

bottom nut (below washer) until the correct measur em ent is obtained (See
Figure 14) turn nut clockwise to lengt hen t he gap (screws rod into yoke) and
turn counter-clockwise to shorten the gap ( scr ews rod out of yoke). Tighten
nut against yoke and check opposite side of unit, repeat if necessary.

5.2.10 Adjust Throttle Lever Tension

.
a) Stop engine, wait for all m oving parts to stop, and remove key.
b) Tension in throttle lever can be adjusted by adjusting t he t ightness of the

lever pivot bolt, which is located under the console (See Figure 16).

- 40 -

FIGURE 16

THROTTLE TENSION

5.2.11 Electric Clutch Adjustment

:

No adjustment necessary.

5.2.12 Reverse Indicator Adjustment

:
a) Stop engine, wait for all m oving parts to stop, and remove key.
b) Unhook seat latch and tilt seat forward.
c) Begin with either the left or right motion contro l lever. Move lever to the

neutral position and pull lever back until the clevis pin (on arm below pivot
shaft) contacts the end of the slot (just beginning t o put pr essur e on
spring), See Figure 17.

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

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

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

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

f) Repeat on opposite side of unit.

FIGURE 17

REVERSE INDICATOR ADJUSTMENT

- 41 -

5.2.13 Motion control linkage adjustment

WARNING

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

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

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

components and hot surfaces.

.

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or m aint enance

relying solely on mechanical or hydraulic jacks could be

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

support or may malfunction allowing the unit to fall,

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

support. Use adequate jack st ands or equivalent

support.

a) This adjustment must be m ade with the dr ive wheels turning. First raise the

frame and block up so that dr ive wheels can rotate freely.

b) Remove the electrical connection from t he seat safety switch, located directly

to the left of t he seat switch assembly beside the hydraulic oil reservoir.

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

wiring harness.

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

bring hydraulic system oil up to operating tem per ature.
d) Unhook seat latch and tilt seat forward.
e) Loosen lock nuts from t he ball joints at each end of the LH pump control

linkage (See Figure 18).

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

FIGURE 18

MOTION CONTROL ADJUSTMENT

- 42 -

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

A

start engine. Operator does not have to be in the seat because of t he

jumper wire being used. Run engine at f u ll t hr ottle and release brake.

g) The reverse indicator spring must be cor rect before the following

adjustments can be made. See Section 5.2.12.

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

any necessary adjustments.
The left rod assembly controls the left wheel and the right rod assembly

controls the right wheel.
h) Bring the LH motion contr ol lever int o t he neut ral position. Adjust LH pump

control rod length by rotating t he double nut s on the rod in the appropriate

direction until the wheels slightly creep in reverse. (See Fig ur e 18) Move

the motion control lever to the reverse posit ion and while applying slight

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

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

When adjust m ent is complete, tighten lock nuts ont o ball j oints.
i) Bring the RH motion control lever into t he neutral position. Adjust the RH

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

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

control lever to the reverse position and while applying slight pressur e t o the

lever allow the reverse indicator spring to bring the levers back to neutral. The

wheel must stop turning or slightly creep in reverse. See Figure 18.
j) Shut off unit. Remove jumper wire f r om wire harness connector and plug

connector into seat switch.

5.2.14 Caster pivot bearings pre-load adjustm ent
a) Remove dust cap from caster and tighten

nyloc nut until washers are flat and back

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

on the bearings. If disassem bled, make

sure the spring washers are reinstalled as

shown in Figure 19.

5.2.15 Seat armrest adjustment

a) Lift armrest on seat. Locate square

tab marked with the numbers 1

through 4. Rotate square tab 1/4 turn

to raise or lower the armrest in

approximately 1/4” (6.4 mm)

increments. See Figure 20.

.

.

FIGURE 19

CASTER ADJUSTMENT

Armrest Adjust ment
Tab Rotate ¼ Turn

6. WASTE DISPOSAL

6.1 MOTOR OIL DISPOSAL

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

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

- 43 -

FIGURE 20

RMREST ADJUSTMENT

6.2 BATTERY DISPOSAL

POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric acid, which is

WHAT CAN HAPPEN
♦ Swallowing electrolyte can be fatal or if it t ouches skin

HOW TO AVOID THE HAZARD

♦ Wear safety glasses to shield eyes, and rubber gloves
♦ Do not swallow electrolyte.

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

disposal practices must be within relevant federal, stat e, or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating and

is being scrapped, take the battery to a local certified recycling center. If no local
recycling is available return the battery to any certified battery reseller.

7. TROUBLE SHOOTING

poisonous and can cause severe burns

can cause severe burns.

to protect skin and clothing when handling elect r olyte.

DANGER

7.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).

a) Refer t o Tracking Adjustment Sect ion 4. 1. 3.
b) Check air pr essur e in drive tires; 13 psi
Semi-pneumatic casters do not require inflation.

c) Check reverse indicator and motion control link age adjustment. See

section 5.2.12 and 5.2.13.

7.2 MOWER CUTS UNEVENLY.

a) Check air pressure in drive tires; 13 psi.
Semi-pneumat ic casters do not require inflation.
A more uniform cutting height may be obtained with higher tire pressure on

rough terrain.
A lower tire pressure pr ovides mor e flotation.
b) Check deck support chains.
c) Check deck leveling (See Adjustments Section 5.2.2.)
Note: The front of the m ower deck will be approximately 1/4” lower than the

back of the mower deck. T his is t he “ rake” of the deck.
d) Check blades tip to tip for st r aightness (they should be within 3/16" or one

blade width from being in line.)

7.3 ENGINE WILL NOT START.

a) Make sure the battery has a full charge. See section 5.1.3 for charging

instructions.
b) For all units except Kohler EFI: Be sure the t hrottle control is midway

between the “SLOW” and “FAST” positions, and the choke is in t he “ ON”

position for a cold engine or the “ O FF” position for a warm engine.
c) Make sure there is fuel in the fuel tank and that t he fuel valve is open.
d) Be sure the seat switch is properly adjusted. See Section 5.2.6.
e) Make sure the parking brake is set and motion control levers ar e m oved

out (neutral lock position).
f) Check that the PTO is disengaged.

- 44 -

g) Check that the spark plug wires are properly connected.
h) Check for loose or faulty wiring connections.
i) Check for cor r osion at all wiring connect ions. Even minor corrosion may

cause a faulty connection. Clean connector terminals t hor oughly with

electrical contact cleaner, apply dielectric grease and r econnect.

NOTE: When disconnecting electrical connectors DO NOT pull on the

wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the

engine. If it does not start, cont act your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be

connected and in proper operating condition prior to mower use.

When a problem occur s , do not overlook the simple causes. For example:

starting problems could be caused by an empty fuel tank.

The following table lists some of t he com mon causes of trouble. Do not attem pt

to service or replace major items or any item s t hat call for special timing of
adjustments procedures (such as valves, governor, etc. ) . Have this work done
by your Engine Service Dealer.

ENGINE TROUBLESHOOTING TABLE

PROBLEM

Will not start
Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats*

High fuel

consumption

NO

IMPROPER

FUEL

FUEL

X
X

X

X

X
X
X
X

DIRT IN

FUEL LINE

X
X
X
X
X

X
X
X

DIRTY AIR

FILTER

X
X
X
X
X

X
X
X
X

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X X
X X X

X X X
X X X X
X X X

X
X
X X

X X
X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

SCREEN

AIR

INSUFFICIENT

BATTERY

CHARGE

X

X
X

X
X

X
X

X
X

7.4 ENGINE WARNING SYSTEMS

For Kohler EFI Units Only:

7.4.1 Electronic Control Unit Malfunction Indicator
The electronic control unit (ECU) cont inuously monit ors operation of the EFI

system. If a problem or fault within the system is detected, the malfunct ion
indicator light (MIL) is illuminated. The MIL is the red light located on the control
console between the key switch and the throttle controls. Follow the
troubleshooting steps outlined in the Kohler engine operator’s manual if the MIL is
illuminated.

- 45 -

8. ELECTRICAL DIAGRAM – KOHLER 23 & 27 HP AIR-COOLED UNITS

- 46 -

ELECTRICAL DIAGRAM – KOHLER EFI UNITS

- 47 -

9. HYDRAULIC DIAGRAM

- 48 -

10.

2-Year Limited Warranty

Exmark Turf Equipment

Conditions and Products Covered

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

This warranty applies to Exmark turf equipment purchased on
or after October 1, 2004 sold in the US or Canada. This
warranty may only be assigned or transferred to a second (or
third) owner by an authorized Exmark dealer. The warranty
period commences upon the date of the original retail
purchase.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

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

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

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

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

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

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

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

2. Bring the product and your proof of purchase (sales
receipt) to the Exmark Service Dealer.

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

Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310

402-223-6375 or

Warranty Period

Items and Conditions Not Covered

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

[e-mail]

Owner’s Responsibilities

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

As a condition to this warranty, customer shall have read
the operator's manual and shall have completed and
submitted to Exmark Warranty Company, within the
prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
as set forth herein. Neither Exmark nor Exmark Warra n t y

Company shall have any liability for any other cost, loss
or damage, including but not limited to, any incidental
or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge relating to
repairs or replacements 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.

There are no understandings, agreements, representations,
or warranties, express or implied, including but not limited to
any regarding the merchantability (that product is fit for
ordinary use) or fitness for use (that product is fit for a
particular purpose), not specified herein, respecting the
equipment which is the subject of this warranty.

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

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

- 49 -

- 50 -

M

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

© 2004 EXMARK MFG. CO. INC. PART NO. 103-9172
INDUSTRIAL PARK BOX 808 [phone]
BEATRICE, NE 68310 FAX [phone]

ALL RIGHTS RESERVED PRINTED IN U.S.A.

FG. CO. INC.

®