Exmark Z 4500-872 User Manual

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Page 1

LAZERZ®E-SERIES

ForSerialNos. 920,000&Higher LazerZ(LZE)Units

PartNo.4500-872Rev.A

Page 2

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

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

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

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

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

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

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

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Page 3

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Figure1

1.Modelandserialnumberlocation

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

Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm

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

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready .

ModelNo.

SerialNo.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Page 4

Contents

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

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

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

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

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

Specications.......................................................15

ModelNumbers............................................15

Systems.........................................................15

Dimensions...................................................17

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

ProductOverview................................................19

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

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

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

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

Transporting.................................................27

Maintenance.........................................................29

RecommendedMaintenanceSchedule(s)...........29

PeriodicMaintenance.......................................30

CheckEngineOilLevel.................................30

CheckBatteryCharge....................................30

CheckMowerBlades.....................................32

CheckSafetyInterlockSystem.......................32

CheckRolloverProtectionsSystems(Roll

Bar)Knobs................................................33

CheckSeatBelt..............................................33

CheckforLooseHardware............................33

ServiceAirCleaner........................................33

ChangeEngineOil........................................33

CheckHydraulicOilLevel.............................34

CheckTirePressures.....................................34

CheckConditionOfBelts..............................34

LubricateGreaseFittings...............................35

LubricateBrakeHandlePivot........................36

LubricateDeckLiftPivot...............................36

CheckSparkPlugs.........................................36

ChangeHydraulicSystemFilterand

Fluid.........................................................36

WheelHub-SlottedNutTorque

Specication..............................................37

CheckSparkArrester(ifequipped).................37

ThreadLockingAdhesives.............................37

Copper-BasedAnti-seize..............................37

DielectricGrease...........................................37

Adjustments.....................................................38

DeckLeveling...............................................38

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

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

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

ElectricClutchAdjustment............................41

MotionControlLinkageAdjustment.............42

MotionControlDamperAdjustment.............43

MotionControlNeutralLockPivot

Adjustment...............................................44

MotionControlHandleAdjustment..............44

MotionControlFullForwardTracking

Adjustment...............................................44

CasterPivotBearingsPre-Load

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

Cleaning...........................................................45

CleanEngineandExhaustSystem

Area..........................................................45

RemoveEngineShroudsandCleanCooling

Fins...........................................................45

CleanHydroCoolingFins.............................45

CleanDebrisFromMachine..........................46

CleanGrassBuild-UpUnderDeck................46

WasteDisposal..............................................46

Troubleshooting...................................................47

Schematics...........................................................50

Page 5

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

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

CAUTION:Blacklettering/Yellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

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

Page 6

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

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

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Page 7

Safety

Operation

WARNING

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

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

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

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

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

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

Page 8

Safety

DANGER

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer neardrop-offs,ditches,steepbanksorwater.

Figure3).

(

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

WARNING

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

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

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

3.Water

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbaris down.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect

Page 9

Safety

sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

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

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagement ofcomponents.Sparkscouldcausean explosionormovingpartscouldaccidentally engagecausingpersonalinjury.

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

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

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts, orusingnon-Exmarkreplacementpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.

Replaceallpartsincluding,butnotlimitedto, tires,belts,andbladeswithoriginalExmark parts.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

Page 10

Safety

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

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

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.

Page 11

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-633922

1-403005

98-5954

103-2076

Page 12

Safety

109-7232

1.Fast3.Neutral

2.Slow

4.Reverse

109-7330

107-2102

109-7929

109-3148

Page 13

1.Throttle–fast3.Choke–on

2.Throttle–slow

Safety

116-0211

109-8483

4.Choke–off

1.SeeOperator’sManual

116-1654

116-0157

116-2630

116-2643

116-0205

Page 14

Safety

117–2718

116-2927

1.Latch

2.Unlatch

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

MessageDisplay

7.PTO

8.Parkingbrake

10.Operatorpresence switch

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

116-3303

109-7069

Page 15

Specications

ModelNumbers

SerialNos:920,000andHigher

LZE20KA484;LZE22KA484;LZE24KA524;LZE27KC604

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3750±50RPM(PTOnot engaged)Idle:1500±100RPM

FuelSystem

•Capacity:8.0gal.(30.3L)

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

•FuelFilter:

–Kawasaki

KawasakiP/N49019-7005

–Kohler

KohlerP/N2405013

•FuelShut-OffValve:

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

SafetyInterlockSystem

•LCDindicatorsappearforthePTO ,parkbrake, drivelevers,andoperatorpresenceinthemessage displayontheRHcontrolpanel.

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

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

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

•Fuelleveleightsegmentdisplay—righthand controlpanel.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

Allunits:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•ParkingBrakeReleaseButton:Releasesparking brake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

Page 16

Specications

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

–Unlatchingposition:Deckdoesnotlatchat

thetransportposition.

Seat

•Type:Standardseatwithfoampaddedseat cushionwitharmrestsandintegralsafetyswitch.

Optionalseat:Seatwithhighback,extra widefoampaddedseatcushionwithinternal suspension,thickbolstering,two-tonecover, armrests,integralsafetyswitch,andseatvibration isolationsystem.

Optionalseataccessoriesforunitswithstandard seats:

–Customridesuspensionsystemtoenhance

StandardSeat.Addsapproximately3inches (7.6cm)toseatheight.

–Deluxesuspensionseatwithhighback,

(dampened,adjustablespringsuspension), armrests,andintegralsafetyswitch.Adds approximately1/2inch(1.3cm)toseatheight.

–SeatIsolationSystemforreducedvibration,

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

•Mounting:Adjustableforeandaftonseattracks.

•Armrests:Moldedip-uparmrests.

•SeatSafetySwitch:

Integratedseatswitch.Timedelayseatswitch eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

12ccParkeraxialpistonpump

240ccParkergerolermotor

•HydraulicOilType:ExmarkPremiumHydroOil.

•HydraulicOilCapacity:52oz(1.5L)perside

•HydraulicFilter:P/N116-0164

•Speeds:

–0-8mph(12.9km/hr)forward.

–0-4.5mph(7.2km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

Drive

Pneumatic(Airlled)

DeckSize

Quantity

Tread

Size22x9.50-1223x10.50-12

PlyRating

Pressure

DeckSize

Quantity

Tread

Size12x5.00-6

PlyRating

Pressure

48&5260

TurfMasterTurfMaster

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

FrontCaster

Pneumatic(Airlled)

48,52,&60

Smooth

13psi(90kPa)

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

•Discharge:Side

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

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

•DeckDrive:“B”Sectionbeltwithself-tensioning idler.

•Electricclutch:200ft-lbMagStop

•Deck:Fulloatingdeckisattachedtoout-front supportframe.Anti-scalprollersprovide maximumturfprotection.Deckdesignallowsfor bagging,mulchingorsidedischarge.

Page 17

Specications

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

–60inchDeck:4anti-scalprollers

•DeckDepth:

–48inchDeck:5.5inches(14cm)

–52inchDeck:5.5inches(14cm)

–60inchDeck:5.5inches(14cm)

•CuttingHeightAdjustment:

Footactivatedleverisusedtoadjustthecutting heightfrom11/2inch(3.8cm)to41/2inches (11.4cm)in1/4inch(6.4mm)increments.

•MulchingKit:Optional.

Dimensions

OverallWidth:

Without Deck

Deector Up

48inch Deck

45.7inches (116.1cm)

51.8inches (131.6cm)

52inch Deck

45.7inches (116.1cm)

56.3inches (143.0cm)

60inch Deck

50.0inches (127.0cm)

62.5inches (158.8cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

Drive Wheels

Caster Wheels

48inch Deck

36.2inches (91.9cm)

32.8inches (83.3cm)

52inch Deck

36.2inches (91.9cm)

32.8inches (83.3cm)

60inch Deck

41.6inches (105.7cm)

39.5inches

(100.3cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

48inchDeck52inchDeck60inchDeck

48.0inches (121.9cm)

51.6inches (131.1cm)

CurbWeight:

Kawasaki Units

KohlerUnit

48inch Deck

1081lb (490kg)

——

52inch Deck

1115lb

(506kg)

60inch Deck

—

1098lb (498kg)

Deector Down

59.6inches (151.4cm)

64.8inches (164.6cm)

OverallLength:

RollBarUp

RollBarDown

48inch Deck

79.2inches (201.2cm)

80.9inches (205.5cm)

52inch Deck

79.2inches (201.2cm)

80.9inches (205.5cm)

OverallHeight:

RollBar-UpRollBar-Down

69.5inches(176.5cm)45.8inches(116.3cm)

72.8inches (184.9cm)

60inch Deck

83.1inches (211.1cm)

84.8inches (215.4cm)

Page 18

Specications

AccessoryWeightTableWorksheet:

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

LightKit

Michigan Seat/CRSS

Bagger

MulchKit

StriperKit

OCD02-5

HitchKit

Sunshade Kit

48inch

Deck

1112

-3-4-5

-2

52inch

Deck

003

121

TotalAccessoryScore

-7

60inch

Deck

-4

Accessory Score

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

BladeMountingBolt (lubricatewithanti-seize)

Anti-ScalpRollerNyloc NutSeeFigure19

Anti-ScalpRollerWhizlock NutSeeFigure19

EngineMountingBolts (Kawasaki)(Kohler)

WheelLugNuts

HydroMountingBolts72-77ft-lb(98-104N-m)

WheelHubSlottedNut211-260ft-lb

RolloverProtection System(RollBar)1/2 inchMountingBolts

Torque

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

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

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

17-23ft-lb(23-31N-m) 27-33ft-lb(37-45N-m)

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

(286-352N-m)

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

TotalAccessoryScoreRequiredWeightKit(s)

0–9

10–19

20andHigher*Two116-1173Undertoe

Nonerequired

*116-1173Undertoe boardmountweightkit

boardmountweightkits orone116-1173Undertoe boardmountweightkit andone116-1238Front toeboardmountweightkit

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

ClutchRetainingBolt (securedwiththreadlocker)

HydroParkBrakeCable Anchor1/2inchMounting Bolt(securedwith threadlocker)

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

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

Page 19

Operation

ProductOverview

1.RolloverProtection System(ROPS)

2.EngineControls(right console)

3.Seatbelt

4.Motioncontrollevers

Figure4

5.Fuelcap

6.Heightofcutadjustment

7.Parkingbrake

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition

Figure5).

(

Whenthemotioncontrolleversareintheneutral position,theLCDindicatorappearsinthemessage displayontheRHconsole(seeFigure9).

1.Neutrallockposition

2.Neutraloperateposition

3.FrontofUnit

Figure5

4.Forward

(handlesout)

5.Neutral(operate)

(handlesin)

6.Reverse

Page 20

Operation

ChokeControl

Locatedonrightconsole(blacklever)(seeFigure6).

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

Figure6

RightConsole

1.Fuses

2.Messagedisplay5.Throttle

3.Ignitionswitch

4.PTOengagementswitch

6.Choke

Depressthereleasebuttonandpushdownwardto disengagethebrake.

Figure7

1.Releasebutton2.Parkbrake

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

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

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe RHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Note:TheLCDindicatorappearsinthemessage displayontheRHconsolewhentheparkbrakeis engaged(see

Pulltheleverupandrearwardtoengagethebrake.

Figure9).

Figure8

1.Off3.Start

2.On

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

HourMeter

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Page 21

Operation

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Figure9

1.LCDIndicators

2.Lowfuelindicatorlight

3.Fuellevelbardisplay

4.Lowvoltageindicatorlight

5.Hour/Voltagedisplay

Thehourmeterisrecordingwhenthedecimalpoint isashinginHour/Voltagedisplay.

Hoursaredisplayedwhenthekeyisofforwhenthe machineisrunning.

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

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck,which couldresultinseriousinjuryordeath.

Stopengine,removekey ,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

WARNING

Theengineandhydraulicdriveunitscanbecome veryhot.T ouchingahotengineorhydraulic driveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrivewheel releasevalves.

Locatedonthebackoftheunitizedhydraulicdrive units,belowtheenginedeck.

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

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

FuelShut-OffValve

Locatedbehindandbelowtheseat.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

FuelGauge

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thefuellevelisshownonabardisplay.Theindicator lightappearswhenthefuellevelislow(approximately onegallonremaininginthetank).

Figure10

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure10), rotatethehandle1/4turntotheverticalposition untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2in

Figure10), rotatethehandle1/4turntothehorizontalposition untilithitsagainstthestop.

Note:Thehandlemustbehorizontalandagainst thestopforoperation.

DoNottowmachine.

Page 22

Operation

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isdisengaged(see

Figure9).

LowVoltageIndicator

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Alowvoltagecondition(lessthan12.3volts)exists whentheLCDindicatorappearsonthemessage displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

TransportLock

Locatedontheheightofcutadjustmentplatestothe rightoftheparkingbrake.

Positioninthetransportlatchingpositionto automaticallylatchthecuttingdeckwhenraisedto thetransportposition(seeitem1inFigure11).

Inthenon-latchingposition,thedeckwill automaticallyreturntothecuttingheightwhenthe pedalislowered(seeitem3inFigure11).

Figure11

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

Pre-Start

Fillfueltankonlevelground.Forbestresultsuse onlyclean,freshregulargradeunleadedgasolinewith anoctaneratingof87orhigher.

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

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

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

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Therollbarisanintegraland

effectivesafetydevice.Keeptherollbarinthe raisedandlockedpositionwhenoperatingthe mower.Lowertherollbartemporarilyonlywhen absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe tabsinterlockingasshownin therollbarintheraised,operateposition.

Figure12tolock

Page 23

Operation

2.Applyforwardpressuretotheupperhoopofthe rollbar.

3.Pulltheknobandrotate90°toholdinthe unlatchedpositiontolowertherollbar.

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

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

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

Figure12

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

5.Makesuretheknobsarefullyengagedwiththe rollbarintheraisedposition.Theupperhoopof therollbarmayneedtobepushedforwardor pulledrearwardtogetbothknobsfullyengaged

Figure13).

(see

Figure13

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

5.Onacoldengine,pushthechokeleverforward intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

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

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

Page 24

Operation

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

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

2.PullthePTOswitchoutwardtoengagethe blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

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

2.PushthePTOswitchintodisengagetheblades.

transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

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

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

Note:The“N”LCDindicatorappearswhenboth leversareintheneutrallockposition.

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Figure14).

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Movethemotioncontrolleversouttotheneutral lockposition.

3.Engagetheparkingbrake.

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

5.DisengagethePTO.

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when

Page 25

Operation

Figure15

1.FrontofUnit

2.Forward4.Reverse

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

3.Neutral

Figure14

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

Toturnright,releasepressureontheRHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheright.

Toturnleft,releasepressureontheLHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheleft.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from11/2to41/2inches(3.8cmto11.4cm)in 1/4inch(6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Positionthetransportlockinthelatching position.

4.Raiseandlockthedecktothe41/2inch(11.4 cm)transportposition(Figure16).

Thedeckisraisedbypushingthefootoperated deckliftpedalforward.Thepedalislocatedatthe frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Page 26

Operation

Figure16

1.Deckliftfootpedal3.Heightofcutdecal

2.Heightadjustmentpin4.Transportlockcontrol

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor cutheights.

6.Pushthedeckliftpedal,releasethetransportlock andallowthedecktolowertothecuttingheight.

AdjustingtheDeckLiftFootPedal— 48&52inchDecksOnly

Thedeckliftfootpedalcanbeadjustedforoperator comfort.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Positionthetransportlockinthelatching position.

6.Raiseandlockthedecktothe41/2inch(11.4 cm)transportposition(

7.Removethetwonutsfromthedeckliftfootpedal (seeFigure17).

Figure16).

Figure17

1.Deckliftfootpedal

2.Nuts5.Holesetthatmovesthe

3.Adjustmentholes6.Adjuststhepedalhigher

4.Holesetthatmoves thepedalclosertothe operator

pedalawayfromthe operator

orlower

8.Positionthedeckliftpedalforoperatorcomfort andreinstallthenuts.Tightenhardware.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

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

6.Placetherollersinoneofthepositionsshown

Figure18).Rollerswillmaintain3/4inch(19

( mm)clearancetothegroundtominimizegouging androllerwearordamage.

Page 27

Figure18

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

1.Springdiscwasher (conetowardsnut)

2.Frontrightanti-scalp bracketshown

Operation

Figure19

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

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

7.Besurethewhizlocknutsareinstalledwiththe springdiscwasherbetweentheheadofthenut andthemountingbracket.

Note:Thefootoperateddeckliftlevercanbe usedtomomentarilyliftthedecktoclearobjects. BesurethatPTOisdisengaged.

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

Figure19).

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

Transporting

TransportingaUnit

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

CAUTION

Thisunitdoesnothaveproperturnsignals, lights,reectivemarkings,oraslowmoving vehicleemblem.Drivingonastreetorroadway withoutsuchequipmentisdangerousand canleadtoaccidentscausingpersonalinjury. Drivingonastreetorroadwaywithoutsuch equipmentmayalsobeaviolationofStatelaws andtheoperatormaybesubjecttotrafctickets and/ornes.

DoNotdriveaunitonapublicstreetorroadway.

Page 28

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•DoNotexceeda15°anglebetweenrampand groundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

LoadingaUnit

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

Rampshouldbelongenoughsothattheangles betweentherampandthegroundandtherampand thetrailerortruckDoNotexceed15°.Asteeper anglemaycausemowerdeckcomponentstoget caughtastheunitmovesfromramptotraileror truck.Steeperanglesmayalsocausetheunittotip backward.Ifloadingonornearaslope,position thetrailerortrucksoitisonthedownsideofthe slopeandtherampextendsuptheslope.Thiswill minimizetherampangle.Thetrailerortruckshould beaslevelaspossible.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Page 29

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Maintenance

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Beforeeachuseordaily

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrocoolingns.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

WARNING

Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Every50hours

Every100hours

Every200hours

Every250hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

•Lubricatethebrakehandlepivot.

•Checkthesparkplugs.

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

Page 30

Maintenance

MaintenanceService

Interval

Every500hours

Monthly

Yearly

MaintenanceProcedure

•Replacethesecondaryaircleanerelement(Mayneedmoreoftenundersevereconditions. SeetheEngineOwner’sManualforadditionalinformation.)

•Changethehydrauliclteranduid.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Checkthebatterycharge.

•Greasethedeckandpumpidlerpivots.

•Greasethefrontcasterpivots.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner’smanualforanacceptablealternative.Do Notoverll.

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

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.T opreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

Important:Makesurethenegativebatterycable isdisconnectedandthebatterychargerusedfor chargingthebatteryhasanoutputof16voltsand 7ampsorlesstoavoiddamagingthebattery(see chartforrecommendedchargersettings).

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

Page 31

Maintenance

Voltage Reading

11.7–12.00–25%

11.7orless

Percent Charge

Maximum Charger Settings

14.4volts/4 amps

14.4volts/2 amps

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

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

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

Charging Interval

3Hours

6Hoursor More

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

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

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

Figure20.

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

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

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Figure20

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

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

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED

Page 32

Maintenance

VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

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

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installthebladeontothespindleshaft.

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

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

Figure21

1.Spindle

2.Blade

3.Bladedrivewasher

4.Bladeboltwasherassembly—Torqueto50-60ft-lb (68-81N-m)Applylubricanttothreadsasneededto preventseizing.Copper-basedanti-seizepreferable. Greaseacceptablesubstitute.

B.Applylubricanttothethreadsoftheblade

boltasneededtopreventseizing.Copper basedanti-seizeispreferable.Greaseisan acceptablesubstitute.

C.Installthebladedrivewasherandbladebolt

washerassemblyintothespindle.Makesure thehexinthewasherisengagedonthe spindlebeforetighteningthebolt.Install bladeboltngertight.

D.Placewrenchonthetopspindlenutthen

torquethebladeboltsto50-60ft-lb(68-81 N-m).

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

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

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

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

Page 33

Maintenance

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

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

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

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckRolloverProtections Systems(RollBar)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe knobsareingoodworkingcondition.Makesurethe knobsarefullyengagedwiththeROPSintheraised position.Theupperhoopoftherollbarmayneed tobepushedforwardorpulledrearwardtogetboth knobsfullyengaged.

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

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

Every500hours—Replace thesecondaryaircleaner element(Mayneedmore oftenundersevere conditions.Seethe EngineOwner’sManual foradditionalinformation.)

Figure22

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.SeetheEngineOwner’sManualformaintenance instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

Page 34

Maintenance

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

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

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

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

Figure23

1.Full2.Add

Note:Theoillevelonthedipstickwillbe incorrectiftheoilischeckedwhentheunitishot.

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe hydraulicoil.

3.Slidetheseatalltheforwardtoaccessthecapson theLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand removecap.

5.Wipethedipstickcleanandre-insertthecapback intothehydro.Lightlytightenthecap.

6.Removethecapagainandcheckthelevelofthe oilonthedipstick.See

Figure23foroillevels.

7.Ifthedipstickoillevelisatthe“add”markadd ExmarkPremiumHydroOil.

8.Replacehydraulicreservoircapandtightenuntil snug.DoNotovertighten.

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Semi-pneumaticcastertiresDoNotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

3.Checkundermachinetoinspectthepumpdrive belt.

Page 35

Note:Noadjustmentsarerequiredforbelt tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

Maintenance

Figure24

1.Sealguard2.Spacernutwithwrench ats

LubricationChart

Fitting

Locations

1.Deckand PumpIdler Pivots

2.Front Caster Pivots

Initial

Pumps

Numberof

Places

Service

Interval

Yearly

*Yearly

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

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

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

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

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

9.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

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

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

Page 36

Maintenance

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

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

LubricateBrakeHandlePivot

ServiceInterval:Every200hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebrakehandlepivotwithaspraytype lubricantorlightoil.

LubricateDeckLiftPivot

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype lubricantorlightoil.

Note:Itisimportanttoreinstallthefuellinehoses andsecurewithplastictiesthesameastheywere originallyinstalledatthefactorytokeepthefuelline awayfromcomponentsthatcouldcausefuelline damage.

ChangeHydraulicSystem FilterandFluid

ServiceInterval:Every500hours

Note:OnlyuseExmarkHydroFilter–PartNo.

116-0164forsummerorwinter.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’ s Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ReplacementFilters

KawasakiKawasaki

P/N49019-7005

KohlerKohler

P/N2405013

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem.

6.Usingasocket,unscrewlterstoremoveand allowoiltodrain.

7.Beforeinstallingthenewlters,applyathincoat ofExmarkPremiumHydroOilonthesurface ofthetworubberseals.

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

9.FillthehydraulicsystemasstatedinCheck HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

Page 37

Maintenance

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

10.Removethecatchpanandproperlydisposeof hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

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

13.Removethejackstands.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

ChangeInterval

500Hours

250Hours

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

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

ThreadLockingAdhesives

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

•ROPSspringpinhousing.

•Hydropumpcontrolarm,linkagebolt,and attachmentbolt.

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof enginecrankshaft.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

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

Note:DoNotuseanti-seizeonwheelhub.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresult inpersonalinjuryorpropertydamage.

Threadlockingadhesivesarerequiredforsome hardwareonengines—seetheEnginemanual.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Page 38

Maintenance

Adjustments

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

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbeenough supportormaymalfunctionallowingtheunitto fall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

DeckLeveling

1.Positionthemoweronaatsurface.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargedeector.

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

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

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

4.Positionthetransportlockinthelatching position.

5.Pushthefootpedalallthewayforwardand thedeckwilllatchatthe41/2inch(11.4cm) transportposition(

Figure25).

Figure26

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

2.Backbladetip

3.Frontbladetip

5.Levelsurface

10.Finetunethefrontdeckliftassemblybyturning theadjusterscrewuntilitreachesthe3inch (7.6mm)height(seeFigure27).Toincrease theheight,turntheadjusterscrewclockwise;to decrease,turncounterclockwise.

Figure25

1.Footlever3.Transportlock

2.Heightofcutpin

6.Inserttheheightadjustmentpinintothe3inch (7.6cm)cuttingheightlocation.

Page 39

Figure27

1.Adjusterscrew2.Jamnut

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

12.Re-measureuntilallfoursidesarethecorrect height.Tightenallthenutsonthedeckliftarm assemblies.

Maintenance

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

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

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

17.Re-tightenfrontandrearheight-of-cutplate mountingbolts.

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

18.Repeatsteps

9through13.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

13.Lowerdischargedeector.

14.Ifthefourdecklinksdonothaveenough adjustmenttoachieveaccuratecutheightwiththe desiredrake,thesinglepointadjustmentcanbe utilizedtogainmoreadjustment(see

Figure28

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

Figure28).

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.This proceduremustbefollowedaftertherst100hours orwhenabrakecomponenthasbeenremovedor replaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey .

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

Page 40

Maintenance

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

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

8.Disengagetheparkbrake.

9.Holdthethreadedrodendwithatoolandloosen thelocknutawayfromthestandardnut(see Figure29).DoNotallowthecabletoturnwhen thenutsarebeingloosened.

10.Removeallslackfromcablebypullingonthe caliperleverarmwithamediumamountofforce. Usinghandsandngersonly,pushthecaliper leverarmtoengagethebrakepadsontherotor untiltheleverstops.Whileholdingthelever atthestoppedposition,usetheotherhandor ngerstopulltheslackoutofthecablethreaded endthroughtheswivel.Spinthestandardnut againsttheswivel(see

Figure29).

Notetheorderofthestandardnutandlocknut (nonutonthecableanchorsideoftheswivel).

11.Releasethecaliperleverandcable.Turnthe wheelhubbyhandinbothdirectionsrelativeto thecaliper;slightdragofthecaliperpadonthe wheelhubisdesired.

12.Ifthereisnomovementbetweenthehubandthe caliperthenbackoffthestandardnutoneturn fromtheswivelandrepeatstep

11(driverelease valvesmustbeinthe“released”positiononthe hydros).

13.Ifthehubmovesveryfreelyrelativetothecaliper, thentightenthestandardnutoneturnagainstthe swivelandrepeatstep

11.

Figure29

LeftHandBrakeShown

1.Cableanchor

2.Threadedrod8.Holdthreadedrodhere

3.Pushleverthisdirection

4.Caliperleverarm10.Caliper

5.Standardnut(shown againstswivel)

6.Locknut

7.Pullcablethreadedrod thisdirection

9.Swivel(pivothead)

11.Hub

14.Oncestep11isachieved,holdthethreadedrod endwithatoolandtightenthelocknutagainst thestandardnut.DoNotallowthecabletoturn whenthenutsaretightened.

15.Afteradjustingthebrakesonbothsidesofthe mower,cyclethebrakehandleaminimumofsix timestoallowthecabletoseatintothesheath andmountingtabs.

16.Readjustbothbrakesfollowingtheprocedurein

10through14.

steps

17.Ifabrakecomponenthasbeenremovedor replaced,seethestepsbelow;otherwiseproceed tostep18.

BurnishingtheBrakeProcedure:

A.Cleartheareaofanyammablematerial

beforestartingtheburnishingprocess.

B.Rotatethedrivewheelreleasehandletothe

“operating”position.RefertotheDrive WheelReleaseValvessectioninOperation.

C.Applytheparkbrake.

D.Installa1/2x6inch(approx.)rodorbolt

throughthe2inchheightofcuthole(see Figure30).

Page 41

Figure30

1.2inchheightofcutlocation

E.Startthemowerwhileintheoperatorposition.

WARNING

Maintenance

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

20.Removejackstands.

ElectricClutchAdjustment

Noadjustmentnecessary.Howeveronunitswith60 inchdecks,whentheclutchbrakehasworntothe pointwheretheclutchnolongerengagesconsistently, theshimcanberemovedtoextendtheclutchlife.

Enginemustberunninganddrivewheels mustbeturningsoadjustmentscanbe performed.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

F.Releasetheparkbrakesothehandlerestson

the1/2x6inchrodorbolt.

G.Movethethrottletohighidle.

H.Movebothmotioncontrolleverstothefull

forwardpositionandholdfor15seconds.

I.Movebothmotioncontrolleverstothefull

reversepositionandholdfor15seconds.

J.Turnofftheengineandcompletelyrelease

theparkbrakebyremovingthe1/2x6inch rodorbolt.

K.Allowthehubstocooluntiltheyarecool

enoughtosafelytouch.

L.Rotatethedrivewheelreleasehandletothe

“released”position.RefertotheDriveWheel ReleaseV alvessectioninOperation.

M.Readjustbothbrakesfollowingtheprocedure

insteps

10through14.

Figure31

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

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

2.Usingapneumaticline,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers.

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

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

A.Loosenbothbrakemountingboltsone-half

toonefullturn(see

Figure32).

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

Note:DoNotremovethebrakepolefrom theeldshell/armature.Thebrakepolehas worntomatchthearmatureandneedsto

Page 42

Maintenance

G011733

continuetomatchaftertheshimisremoved toensureproperbraketorque.

Figure34

1.Feelergauge

Figure32

1.Brakemountingbolt

2.Shim

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

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

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

E.Usinga0.010inchthickfeelergauge,verify

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

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstepF.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengage

withthePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly ,referencethe Troubleshootingsection.

1.Feelergauge

MotionControlLinkage Adjustment

Locatedoneithersideofthefueltank,belowtheseat arethepumpcontrollinkages.Rotatingthepump

Figure33

linkagewitha1/2inchwrenchallowsnetuning adjustmentssothatthemachinedoesnotmovein neutral.Anyadjustmentsshouldbemadeforneutral positioningonly.

Page 43

WARNING

Enginemustberunninganddrivewheelsmust beturningsoadjustmentscanbeperformed. Contactwithmovingpartsorhotsurfacesmay causepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift pedalandremovetheheightofcutpin.Lower decktotheground.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.Theswitchisapartoftheseat assembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

Maintenance

Figure35

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure36formountingoptions.

6.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulicoil uptooperatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengths byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(

Figure35).Movethemotion controlleverstothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningor slightlycreepinreverse.

Figure36

RHMotionControlShown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

Page 44

Maintenance

MotionControlNeutralLock PivotAdjustment

Theangednutcanbeadjustedtoobtainamore desiredmotioncontrolleverresistance(Figure37).

Figure37

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

Figure38

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

MotionControlHandle Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(

Figure38).

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraft boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

Figure38.Tightenboth

MotionControlFullForward TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthecoverplates.

1.Loosenthescrewsonacoverplate(seeFigure39).

2.Slidethecoverplatebackwardorforwardto adjustthetraveloftheleverandtightenthe screws.

3.Drivethemachineandcheckthefullforward tracking.

4.Repeatsteps1through3untildesiredtracking isobtained.

Page 45

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

Figure39

RHMotionControlShown

1.Screw

2.Coverplate

3.Motioncontrollever

CasterPivotBearings Pre-LoadAdjustment

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

Figure40.

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

3.Makesurecoolingshroudsarereinstalled. Operatingtheenginewithoutcoolingshrouds willcauseenginedamageduetooverheating.

1.Springdiscwashers

Figure40

CleanHydroCoolingFins

ServiceInterval:Beforeeachuseordaily

Removingdebrisfromthehydrocoolingnswill allowthehydrosystemtoruncoolerandimprovethe lifeofthehydrosystem.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Page 46

Maintenance

2.Slideseatallthewayforward.

3.Removeaccumulateddebrisfromthehydro coolingns.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisedecktothetransport(41/2inch(11.4cm) cuttingheight)position.Liftthefrontofunit andsupportunitusingjackstandsorequivalent support.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

Page 47

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank

Enginewillnotstart,startshard,orfailsto keeprunning

1.PTOisengaged.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock position.

4.Batterydoesnothaveafullcharge.

5.Electricalconnectionsarecorroded,loose orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

8.Faultymodule.8.Replacemodule.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow.

4.Thethrottleandchokearenotinthe correctposition.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly.

9.Electricalconnectionsarecorroded,loose orfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.

13.Faultymodule.13.Replacemodule.

1.DisengagethePTO.

3.Ensurethedriveleversareintheneutral lockposition.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

11.Clean,adjustorreplacesparkplug.

12.Checkthesparkplugwireconnection.

Page 48

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Mowerpullsleftorright(withleversfully forward)

Machinedoesnotdrive

Unevencuttingheight.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.Dirt,water,orstalefuelisinthefuel system.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating” position.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

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

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

6.ContactanAuthorizedServiceDealer.

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

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration

Bladesdonotrotate.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

2.Deckbeltisoffpulley.2.Installbeltonclutchanddeckpulleys,

3.Brokenormissingidlerspring.

4.Drivebeltnotroutedcorrectly .4.Refertobeltroutingdecalondeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

idlers,andtensioningidlerperrouting decalondeck.

3.Replacethespring.

Page 49

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Clutchwillnotengage.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply .4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

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

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Replaceclutch.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Page 50

Schematics

G008587

PTO SWITCH

SEAT SWITCH

IGNITION SWITCH

FUSE BLOCK

REGULATOR

GROUND

PTO CLUTCH

START RELAY

LH NEUTRAL

SWITCH

RH NEUTRAL

SWITCH

BRAKE

SWITCH

START

RED

HOUR METER/MODULE

LT. GREEN

YELLOW

TAN

BROWN

WHITE

ORANGE

GRAY

VIOLET

BLUE

GREEN

RED

BLACK

ACCESSORY

ORANGE

MAG

PINK

FUEL SOLENOID

BROWN

VIOLET

ENGINE

FUEL SENDER

B+

BROWN

PINK

RED

BLACK

PINK

GRAY

PINK

BLUE

BLACK

TVS DIODE

BROWN

BLACK

VIOLET

PINK

2 1

1 3 2 4 5 6 7 8

A B

2 3 1 5 4

5 4 3 1 2

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

7 4 5 9 3 6 8 1 2

C A B

A B

26354

1 2

2 3

321

A B

IGNITION SWITCH

NOTE:

CONNECTORS VIEWED FROM MATING CONNECTOR

TERMINAL CONNECTIONS

TERMINAL A ACCESSORY

TERMINAL B BATTERY

TERMINAL I IGNITION

TERMINAL R RECTIFIER

TERMINAL S START

NONE

CIRCUIT "MAKE"

B + R + I + S

B + R + I + A

2. RUN

1. OFF

POSITION

. START

TERMINAL A

TERMINAL I

TERMINAL R

TERMINAL S

TERMINAL B

Schematics

ElectricalDiagram

Page 51

ElectricalLogicSchematic

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

REG

START

FUEL

SOLINIOD

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G008613

Schematics

Page 52

Schematics

HydraulicDiagram

Page 53

General Warranty Conditions and Products Covered

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

part on these

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

be defective in factory materials or workmanship.

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

Commercial Warranty Conditions

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

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

Consumer Warranty Conditions

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

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

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

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

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

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

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

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

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

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Lazer Z E-Series Turf Equipment

2 Year Limited Commercial Warranty

4 Year or 500 Hours Limited Consumer Warranty

G4500-734_B

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G011841

Figure41

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

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MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-872Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Z 4500-872 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual