Exmark Z Advantage, Z 850 User Manual

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LAZERZ®

ADV ANTAGESERIES

MODELS

ForSerialNos. 850,000&Higher LazerZ(LZA)Units

PartNo.4500-566Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

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

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

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

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

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

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

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

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

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

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

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

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Contents

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

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

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

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

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

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

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

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

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

TorqueRequirements....................................17

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

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

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

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

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

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

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

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

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

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

CheckMowerBlades.....................................31

CheckSafetyInterlockSystem.......................31

CheckRolloverProtectionsSystems(Roll

Bar)Knobs................................................32

CheckSeatBelt..............................................32

CheckforLooseHardware............................32

ServiceAirCleaner........................................32

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

CheckHydraulicOilLevel.............................33

CheckTirePressures.....................................33

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

LubricateGreaseFittings...............................34

LubricateBrakeHandlePivot........................35

LubricateDeckLiftPivot...............................35

CheckSparkPlugs.........................................35

ChangeHydraulicSystemFilterand

Fluid.........................................................35

WheelHub-SlottedNutTorque

Specication..............................................36

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

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

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

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

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

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

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

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

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

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

MotionControlLinkageAdjustment.............43

MotionControlDamperAdjustment.............44

MotionControlNeutralLockPivot

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

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

MotionControlFullForwardTracking

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

CasterPivotBearingsPre-Load

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

Cleaning...........................................................46

CleanEngineandExhaustSystem

Area..........................................................46

RemoveEngineShroudsandCleanCooling

Fins...........................................................46

CleanHydroCoolingFins.............................46

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

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

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

Troubleshooting...................................................48

Schematics...........................................................51

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

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.

•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.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

SafeOperatingPractices

Training

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Wearhearingprotectionwhenoperatingthis machine.

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

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevel ground,inanopenarea,whentheengine iscold.Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

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

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Safety

Operation

WARNING

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

•Allowengineparts,especiallythemufer, tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

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

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly .

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Stopengine,waitforallmovingpartstostop, removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

Safety

DANGER

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandlossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

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

3.Water

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

WARNING

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

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbar isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

Safety

drivingunderanyobjectsandDoNotcontact them.

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

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

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

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

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

Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugcharger beforeconnectingordisconnectingfrombattery. Wearprotectiveclothinganduseinsulatedtools.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately .

CAUTION

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

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

Safety

WARNING

Removingstandardoriginalequipment parts,orusingnon-Exmarkreplacement partsandaccessoriesmayalterthewarranty, traction,andsafetyofthemachine.Failure touseoriginalExmarkpartscouldcause seriousinjuryordeath.

Replaceallpartsincluding,butnotlimitedto tires,belts,andbladeswithoriginalExmark parts.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Ifequipped,makesureallhydraulicuid hosesandlinesareingoodcondition andallhydraulicconnectionsandttings aretightbeforeapplyingpressureto hydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

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

Safety

109-3148

107-2102

107-2112

109-7232

1.Fast3.Neutral

2.Slow

109-7330

109-7929

4.Reverse

1.Throttle–fast3.Choke–on

2.Throttle–slow

Safety

116-0211

109-8483

4.Choke–off

116-1654

116-0165

ForStyleBSlottedNuts—See“WheelHub–Slotted

NutTorqueSpecication”intheMaintenancesection

116-0205

116-2630

116-2643

ForStyleASlottedNuts—See“WheelHub–Slotted

NutTorqueSpecication”intheMaintenancesection

Safety

MessageDisplay

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

116-2927

1.Latch

2.Unlatch

7.PTO

8.Parkingbrake

10.Operatorpresence switch

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

117-2718

109-7069

Specications

ModelNumbers

SerialNos:850,000andHigher

LZA20KAS484;LZA20KAX484;LZA20KAX524

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•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

•FuelShut-OffValve:

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

•Fuelleveleightsegmentdisplay—righthand controlpanel.

•Lowfuelindicatorlight.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:Kawasaki:15amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:260CCA

•BatteryVoltage:12Volt

•LowVoltageLight—RHcontrolpanel

•Polarity:NegativeGround

•Fuses:

Allunits:

–25ampmainfuse

–25ampchargingsystemfuse

–10ampPTOfuse

–15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearforthePTO,parkbrake, drivelevers,andoperatorpresenceinthemessage displayontheRHcontrolpanel.

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

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

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.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:

–Latchingposition:Automaticallylatchesat

thetransportposition.

Specications

–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,low

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

Tires&Wheels

DeckSize

Quantity

Tread

Size22x9.50-12

PlyRating

Pressure

DeckSize

Quantity

Tread

Size12x5.00-6

PlyRating

Pressure

Drive

Pneumatic(Airlled)

48&52

TurfMaster

13psi(90kPa)

FrontCaster

Pneumatic(Airlled)

48&52

Smooth

13psi(90kPa)

–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.

CuttingDeck

•CuttingWidth:

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

•Discharge:Side

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

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

•DeckDrive:“B”Sectionbeltwithself-tensioning idler.

•Electricclutch:175ft-lbMagStop

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

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

•DeckDepth:

–48inchDeck:5.5inches(14cm)

–52inchDeck:5.5inches(14cm)

Specications

•CuttingHeightAdjustment:

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

•MulchingKit:Optional.

Dimensions

OverallWidth:

48inchDeck52inchDeck

WithoutDeck45.7inches

(116.1cm)

DeectorUp51.8inches

(131.6cm)

DeectorDown59.6inches

(151.4cm)

OverallLength:

48inchDeck52inchDeck

RollBar-Up79.2inches

(201.2cm)

RollBar-Down80.9inches

(205.5cm)

45.7inches (116.1cm)

56.3inches (143.0cm)

64.8inches (164.6cm)

79.2inches (201.2cm)

80.9inches (205.5cm)

CurbWeight:

48inchDeck52inchDeck

20HPKawasaki Units

1081lb(490kg)1115lb(506kg)

AccessoryWeightTableWorksheet:

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

48inch

Deck

LightKit

Michigan Seat/CRSS

Bagger

MulchKit

StriperKit-30

OCD02-6-6

HitchKit

SunshadeKit

-3-3

TotalAccessoryScore

52inch

Deck

Accessory Score

OverallHeight:

RollBar-UpRollBar-Down

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

TreadWidth:(CentertoCenterof Tires,Widthwise)

48inchDeck52inchDeck

DriveWheels36.2inches

(91.9cm)

CasterWheels32.8inches

(83.3cm)

36.2inches (91.9cm)

32.8inches (83.3cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

48inchDeck52inchDeck

48.0inches(121.9cm)48.0inches(121.9cm)

TotalAccessoryScoreRequiredWeightKit(s)

0–9

10–19

20andHigherTwo116-1173Undertoe

Nonerequired

116-1173Undertoeboard mountweightkit

boardmountweightkits orone116-1173Undertoe boardmountweightkit andone116-1238Front toeboardmountweightkit

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

BladeMountingBolt (lubricatewithanti-seize)

Torque

140-145ft-lb(190-197 N-m)

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

ProductOverview

BoltLocation

Anti-ScalpRollerNyloc

Torque

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

NutSeeFigure19

Anti-ScalpRollerWhizlock

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

NutSeeFigure19

EngineMountingBolts (Kawasaki20HP)

WheelLugNuts

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

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

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

WheelHubSlottedNut (StyleA)

WheelHubSlottedNut (StyleB)

RolloverProtection

211-260ft-lb (286-352N-m)

minimum200ft-lb (271N-m)

75-80ft-lb(102-108N-m) System(RollBar)1/2 inchMountingBolts

ClutchRetainingBolt

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

HydroParkBrakeCable

67-89ft-lb(91-121N-m) Anchor1/2inchMounting Bolt(securedwith threadlocker)

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).

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

Figure5

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

ChokeControl

Locatedonrightconsole(blacklever)(seeFigure6).

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonrightsideofunit,justtothefrontofthe RHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Note:TheLCDindicatorappearsinthemessage displayontheRHconsolewhentheparkbrakeis engaged(seeFigure9).

Pulltheleverupandrearwardtoengagethebrake.

Depressthereleasebuttonandpushdownwardto disengagethebrake.

Operation

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.

Figure8

1.Off3.Start

2.On

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.

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

FuelShut-OffValve

Locatedbehindandbelowtheseat.

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

HourMeter

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

FuelGauge

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Thefuellevelisshownonabardisplay.Theindicator lightappearswhenthefuellevelislow(approximately onegallonremaininginthetank).

Operation

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck, whichcouldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

WARNING

Theengineandhydraulicdriveunitscan becomeveryhot.T ouchingahotengineor hydraulicdriveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrive wheelreleasevalves.

Locatedonthebackoftheunitizedhydraulicdrive units,belowtheenginedeck.

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

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isdisengaged(seeFigure9).

LowVoltageIndicator

Locatedontherightconsoleinthemessagedisplay (seeFigure6andFigure9).

Alowvoltagecondition(lessthan12.3volts)exists whentheLCDindicatorappearsonthemessage displaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Figure10

1.Handlein“released”position

2.Handlein“operating”position

Toreleasethedrivesystem(seeitem1inFigure10), rotatethehandle1/4turntotheverticalposition untilithitsagainstthestop.

Toresetthedrivesystem(seeitem2inFigure10), rotatethehandle1/4turntothehorizontalposition untilithitsagainstthestop.

Note:Thehandlemustbehorizontalandagainst thestopforoperation.

DoNottowmachine.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

TransportLock

Locatedontheheightofcutadjustmentplatestothe rightoftheparkingbrake.

Positioninthetransportlatchingpositionto automaticallylatchthecuttingdeckwhenraisedto thetransportposition(seeitem1inFigure11).

Inthenon-latchingposition,thedeckwill automaticallyreturntothecuttingheightwhenthe pedalislowered(seeitem3inFigure11).

Operation

Figure11

1.Latchingposition3.Non-latchingposition

2.Transportlockcontrol

Pre-Start

Fillfueltankonlevelground.Forbestresultsuse onlyclean,freshregulargradeunleadedgasolinewith anoctaneratingof87orhigher.

2.Applyforwardpressuretotheupperhoopofthe rollbar.

3.Pulltheknobandrotate90°toholdinthe unlatchedpositiontolowertherollbar.

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

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

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system(ifequipped).

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Figure12

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

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

Important:Therollbarisanintegraland effectivesafetydevice.Keeptherollbarinthe raisedandlockedpositionwhenoperatingthe mower.Lowertherollbartemporarilyonlywhen absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe tabsinterlockingasshowninFigure12tolock therollbarintheraised,operateposition.

Figure13

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

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

Operation

attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

DANGER

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

5.Onacoldengine,pushthechokeleverforward intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

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

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunless thereisagrasscollectionsystemormulch kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

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

2.PullthePTOswitchoutwardtoengagethe blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

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

2.PushthePTOswitchintodisengagetheblades.

Operation

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 transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

Figure14

4.Forward

5.Neutral(operate)

6.Reverse

CAUTION

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

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

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

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

Note:The“N”LCDindicatorappearswhenboth leversareintheneutrallockposition.

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

1.FrontofUnit

2.Forward4.Reverse

Figure15

3.Neutral

Operation

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

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.

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor cutheights.

6.Pushthedeckliftpedal,releasethetransportlock andallowthedecktolowertothecuttingheight.

AdjustingtheDeckLiftFootPedal

Thedeckliftfootpedalcanbeadjustedforoperator comfort.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Positionthetransportlockinthelatching position.

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

7.Removethetwonutsfromthedeckliftfootpedal (seeFigure17).

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

Thedeckisraisedbypushingthefootoperated deckliftpedalforward.Thepedalislocatedatthe frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure16

1.Deckliftfootpedal3.Heightofcutdecal

2.Heightadjustmentpin4.Transportlockcontrol

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.

Operation

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.

1.Springdiscwasher (conetowardsnut)

2.Frontrightanti-scalp bracketshown

Figure19

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

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

Figure18

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

7.Besurethewhizlocknutsareinstalledwiththe springdiscwasherbetweentheheadofthenut andthemountingbracket.

Note:Thefootoperateddeckliftlevercanbe usedtomomentarilyliftthedecktoclearobjects. BesurethatPTOisdisengaged.

Transporting

TransportingaUnit

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

CAUTION

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

8.Torquethe3/8–16whizlocknutto30-35ft-lb (41-47N-m)(Figure19).

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

DoNotdriveaunitonapublicstreetor roadway.

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over. Backwardtip-overcouldcauseseriousinjury ordeath.

•Useextremecautionwhenoperatinga unitonaramp.

•Useonlyasingle,fullwidthramp;Do Notuseindividualrampsforeachside oftheunit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbroken rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp andgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledriving unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtipping backward.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

LoadingaUnit

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

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

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

WARNING

Theenginecanbecomeveryhot.T ouching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Beforeeachuseordaily

Every50hours

Every100hours

Every200hours

Every250hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrocoolingns.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Checksparkarrester(ifequipped).

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethedeckliftpivots.

•Removetheengineshroudsandcleanthecoolingns.

•Lubricatethebrakehandlepivot.

•Checkthesparkplugs.

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

Maintenance

MaintenanceService

Interval

Every500hours

Yearly

MaintenanceProcedure

•Replacethesecondaryaircleanerelement(Mayneedmoreoftenundersevereconditions. SeetheEngineOwner’sManualforadditionalinformation.)

•Changethehydrauliclteranduid.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Greasethedeckandpumpidlerpivots.

•Greasethefrontcasterpivots.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Useoilasspeciedin EngineOwner’ sManual.DoNotoverll.

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

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

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

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

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

CheckBatteryCharge

ServiceInterval:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced

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

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.

Charging Interval

3Hours

6Hoursor More

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamage theelectricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

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

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

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure20.

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 VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

Maintenance

Figure21

1.Spindle

2.Blade

3.Bladedrivewasher

4.Bladeboltwasherassembly—T orqueto55-60ft-lb (75-81N-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

torquethebladeboltsto55-60ft-lb(75-81 N-m).

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

Maintenance

motioncontrolleversmovedoutintheneutral lockposition.Theoperatordoesnotneedtobe

intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

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

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

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

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

CheckRolloverProtections Systems(RollBar)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe knobsareingoodworkingcondition.Makesurethe knobsarefullyengagedwiththeROPSintheraised position.Theupperhoopoftherollbarmayneed tobepushedforwardorpulledrearwardtogetboth knobsfullyengaged.

Figure22

1.Engaged2.Partiallyengaged—Do NotoperatewithROPS inthiscondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

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.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

theprimaryaircleaner element—check secondaryaircleaner element;replaceifdirty.

Maintenance

(Mayneedmoreoften undersevereconditions. SeetheEngineOwner’s Manualforadditional information.)

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.SeetheEngineOwner’sManualformaintenance instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe hydraulicoil.

3.Slidetheseatallthewayforwardtoaccessthe capsontheLHandRHhydrodrives.

4.Cleantheareaaroundhydraulicreservoircapand removecap.

5.Wipethedipstickcleanandre-insertthecapback intothehydro.Lightlytightenthecap.

6.Removethecapagainandcheckthelevelofthe oilonthedipstick.SeeFigure23foroillevels.

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

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

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

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

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

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

Figure23

1.Full2.Add

Note:Theoillevelonthedipstickwillbe incorrectiftheoilischeckedwhentheunitishot.

7.Ifthedipstickoillevelisatthe“add”markadd ExmarkPremiumHydrooil.

8.Replacehydraulicreservoircapandtightenuntil snug.DoNotovertighten.

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Checktirepressureincastertires.

5.Inatecastertiresto13psi(90kPa).

Maintenance

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.

Note:Noadjustmentsarerequiredforbelt tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.Deckand PumpIdler Pivots

2.Front Caster Pivots

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

Initial

Pumps

Numberof

Places

Service

Interval

Yearly

*Yearly

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

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure24

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

Maintenance

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.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .

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

LubricateBrakeHandlePivot

ServiceInterval:Every200hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatedeckliftpivotwithaspraytype lubricantorlightoil.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’s Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ReplacementFilters

KawasakiKawasaki

P/N49019-7005

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.

2.Lubricatebrakehandlepivotwithaspraytype lubricantorlightoil.

LubricateDeckLiftPivot

ServiceInterval:Every100hours

Maintenance

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Removethepumpdrivebelt.

4.Placeacatchpanunderthehydro.

5.Carefullycleanareaaroundthelters.Itis importantthatnodirtorcontaminationenterthe hydraulicsystem.

6.Usingasocket,unscrewlterstoremoveand allowoiltodrain.

7.Beforeinstallingthenewlters,applyathincoat ofExmarkPremiumHydrooilonthesurfaceof thetworubberseals.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

SeeFigure25todeterminewhichslottednuthas beeninstalledontheunit.

Figure25

1.StyleA(blacknish)3.StyleB(yellowzinc)

2..03inch(.76mm)4..24inch(6mm)

•StyleA(blacknish):

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

9.FillthehydraulicsystemasstatedinCheck HydraulicOilLevelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

ChangeInterval

500Hours

250Hours

10.Removethecatchpanandproperlydisposeof hydrooilandlteraccordingtolocalcodes.

11.Re-installthepumpdrivebelt.

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

13.Removethejackstands.

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

Note:DoNotuseanti-seizeonwheelhub.

•StyleB(yellowzinc):

1.Removeanddiscardthecotterpin.

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

3.Checkdistancefrombottomofslotinnutto insideedgeofhole.Twothreads(0.1inch)or lessshouldbeshowing.

Figure26

1.0.1inchmax2.Nomorethantwo threads(0.1inchmax) shouldbeshowinghere.

Maintenance

4.Ifmorethantwothreads(0.1inch)are showingremovenutandinstallwasher(P/N 1-523157)betweenhubandnut.

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

6.Thentightennutuntilthenextsetofslotsline upwiththecrossholeinshaft.DoNotloosen nuttoaligntheslot.Ifrequired,tightento thenextsetofslots.

7.Installnewcotterpin(P/N1-806800).

Note:DoNotuseanti-seizeonwheelhub.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

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

•Hydroparkbrakecableanchormountingbolt

•Sheaveandclutchretainingboltintheendof enginecrankshaft.

Threadlockingadhesivesarerequiredforsome hardwareonengines—seetheEnginemanual.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

DoNotrefuelorrunengineunlessspark arresterisinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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.

Maintenance

Adjustments

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

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

DeckLeveling

6.Inserttheheightadjustmentpinintothe3inch (7.6cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargedeector.

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

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

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

4.Positionthetransportlockinthelatching position.

5.Pushthefootpedalallthewayforwardand thedeckwilllatchatthe41/2inch(11.4cm) transportposition(Figure27).

Figure28

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

2.Backbladetip

3.Frontbladetip

10.Finetunethefrontdeckliftassemblybyturning theadjusterscrewuntilitreachesthe3inch (7.6mm)height(seeFigure29).Toincrease theheight,turntheadjusterscrewclockwise;to decrease,turncounterclockwise.

5.Levelsurface

Figure27

1.Footlever3.Transportlock

2.Heightofcutpin

Figure29

1.Adjusterscrew2.Jamnut

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

12.Re-measureuntilallfoursidesarethecorrect height.Tightenallthenutsonthedeckliftarm assemblies.

Maintenance

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

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

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

17.Re-tightenfrontandrearheight-of-cutplate mountingbolts.

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

18.Repeatsteps9through13.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

13.Lowerdischargedeector.

14.Ifthefourdecklinksdonothaveenough adjustmenttoachieveaccuratecutheightwiththe desiredrake,thesinglepointadjustmentcanbe utilizedtogainmoreadjustment(seeFigure30).

Figure30

1.Singlepointheightadjustmentbolt

2.Frontheight-of-cutplatemountingbolt

3.Rearheight-of-cutplatemountingbolt

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.

Maintenance

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

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

8.Disengagetheparkbrake.

9.Holdthethreadedrodendwithatoolandloosen thelocknutawayfromthestandardnut(see Figure31).DoNotallowthecabletoturnwhen thenutsarebeingloosened.

10.Removeallslackfromcablebypullingonthe caliperleverarmwithamediumamountofforce. Usinghandsandngersonly,pushthecaliper leverarmtoengagethebrakepadsontherotor untiltheleverstops.Whileholdingthelever atthestoppedposition,usetheotherhandor ngerstopulltheslackoutofthecablethreaded endthroughtheswivel.Spinthestandardnut againsttheswivel(seeFigure31).

Notetheorderofthestandardnutandlocknut (nonutonthecableanchorsideoftheswivel).

11.Releasethecaliperleverandcable.Turnthe wheelhubbyhandinbothdirectionsrelativeto thecaliper;slightdragofthecaliperpadonthe wheelhubisdesired.

12.Ifthereisnomovementbetweenthehubandthe caliperthenbackoffthestandardnutoneturn fromtheswivelandrepeatstep11(driverelease valvesmustbeinthe“released”positiononthe hydros).

13.Ifthehubmovesveryfreelyrelativetothecaliper, thentightenthestandardnutoneturnagainstthe swivelandrepeatstep11.

Figure31

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 steps10through14.

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 Figure32).

Figure32

1.2inchheightofcutlocation

E.Startthemowerwhileintheoperatorposition.

WARNING

Maintenance

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

20.Removejackstands.

ElectricClutchAdjustment

Noadjustmentnecessary;howeverwhentheclutch brakehasworntothepointwheretheclutchno longerengagesconsistently,theshimcanberemoved toextendtheclutchlife.

Enginemustberunninganddrivewheels mustbeturningsoparkbrakeadjustment canbeperformed.Contactwithmoving partsorhotsurfacesmaycausepersonal injury.

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

ReleaseValvessectioninOperation. M.Readjustbothbrakesfollowingtheprocedure

insteps10through14.

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

Figure33

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.

Maintenance

Figure36

Figure34

1.Shim

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

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

A.Loosenbothbrakemountingboltsone-half

toonefullturnasshownbelow .

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

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.)

Figure37

1.Feelergauge

Figure35

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

Figure38

1.Feelergauge

Maintenance

•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.

MotionControlLinkage Adjustment

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

oftheseat.Theswitchisapartoftheseat assembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat becauseofthejumperwirebeingused.Run

engineatfullthrottleandreleasebrake.

6.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulicoil uptooperatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengths byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(Figure39).Movethemotion controlleverstothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningor slightlycreepinreverse.

WARNING

Enginemustberunninganddrive wheelsmustbeturningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift pedalandremovetheheightofcutpin.Lower decktotheground.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion

Figure39

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

Maintenance

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure40formountingoptions.

Figure40

RHMotionControlShown

2.Tightenorloosentheangednuttothedesired feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

MotionControlHandle Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(Figure42).

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

MotionControlNeutralLock PivotAdjustment

Theangednutcanbeadjustedtoobtainamore desiredmotioncontrolleverresistance(Figure41).

Figure42

1.Bolts4.Nuts

2.Controllever5.Slottedholes

3.Controlarmshaft

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

Figure41

1.Flangednut2.Jamnut

1.Loosenthejamnut.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraftFigure42.Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

MotionControlFullForward TrackingAdjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthecoverplates.

1.Loosenthescrewsonacoverplate(seeFigure43).

2.Slidethecoverplatebackwardorforwardto adjustthetraveloftheleverandtightenthe screws.

3.Drivethemachineandcheckthefullforward tracking.

4.Repeatsteps1through3untildesiredtracking isobtained.

Maintenance

Figure44

1.Springdiscwashers

Figure43

RHMotionControlShown

1.Screw

2.Coverplate

3.Motioncontrollever

CasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut untilwashersareatandbackoff1/4ofaturn toproperlysetthepre-loadonthebearings.If disassembled,makesurethespringdiscwashersare reinstalledasshowninFigure44.

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancause engine,exhaustarea,andhydraulicsystem tooverheatwhichcancreatearehazard.

Cleanalldebrisfromengineandexhaust systemarea.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

3.Makesurecoolingshroudsarereinstalled. Operatingtheenginewithoutcoolingshrouds willcauseenginedamageduetooverheating.

CleanHydroCoolingFins

ServiceInterval:Beforeeachuseordaily

Removingdebrisfromthehydrocoolingnswill allowthehydrosystemtoruncoolerandimprovethe lifeofthehydrosystem.

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied

recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately .

Maintenance

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

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“FAST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

11.Clean,adjustorreplacesparkplug.

12.Checkthesparkplugwireconnection.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Mowerpullsleftorright(withleversfully forward)

Machinedoesnotdrive

Unevencuttingheight.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.Dirt,water,orstalefuelisinthefuel system.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating” position.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

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

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

6.ContactanAuthorizedServiceDealer.

1.Positionhandlein“operating”position; seeDriveWheelReleaseValvessection inOperation.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration

Bladesdonotrotate.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley ,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

2.Deckbeltisoffpulley.2.Installbeltonclutchanddeckpulleys,

3.Brokenormissingidlerspring.

4.Deckbeltnotroutedcorrectly.4.Refertobeltroutingdecalondeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

idlers,andtensioningidlerperrouting decalondeck.

3.Replacethespring.

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.

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

Schematics

S R

PK PK

LTGR

BN V

GND

BK PK

GND

15A

IBA

FUEL SENDER

10A

(BRAKE)

SW6

PKOR R

25A

PTO

CLUTCH

(PTO SWITCH)

SW2

25A

(SEAT)

SW7

(START RELAY)

TVS DIODE

(NEUT_R)

SW5

B+

MAG

REG

START

FUEL

SOLINIOD

STARTER

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KAW TWIN-

(NEUT_L)

SW4

B+

KEY_S

KEY_A

SEAT

BRAKE

NEUTRAL

PTO

FUEL

START_RELAY

MAGNETO

FUEL_SOLENOID

GROUND

HOUR METER

R A

1 3

SW1

24 5

(IGNITION)

KEY SW

OPTIONAL

CCESSORIES

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

G008613

ElectricalLogicSchematic

HydraulicDiagram

Schematics

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 Advantage Series (AS) 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 AS 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 2 years* * The Engine warranty is covered by the engine manufacturer. Please

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

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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 Advantage Series Turf Equipment

2 Year Limited Commercial Warranty

4 Year or 500 Hours Limited Consumer Warranty

G4500-591_B

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure45

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

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-FRONT RIDING ACCESSORIES AND OP TIONS

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.4500-566Rev.B (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Z Advantage, Z 850 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual