Exmark Z D-920, Z D-000 User Manual

Download

LAZERZ®D-SERIES

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

PartNo.4500-919Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

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

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

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

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

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

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

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

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.......................................................17

ModelNumbers............................................17

Systems.........................................................17

Dimensions...................................................19

TorqueRequirements....................................19

ProductOverview................................................20

Operation.............................................................20

Controls........................................................20

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

OperatingInstructions..................................23

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

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

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

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

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

CheckBatteryCharge....................................29

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

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

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................32

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

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

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

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

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

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

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

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

WheelHub-SlottedNutTorque

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

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

LubricateBrakeRodBushings.......................35

LubricateMotionControlBronze

Bushings...................................................36

DrainFuelFilter/WaterSeparator..................36

ChangeFuelFilter/WaterSeparator...............36

ChangeHydraulicSystemFilter.....................36

CheckEngineCoolantLevel..........................37

ChangeEngineCoolant.................................37

CheckSparkArrester(ifequipped).................38

ThreadLockingAdhesives.............................38

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................39

Copper-BasedAnti-seize..............................39

DielectricGrease...........................................39

Adjustments.....................................................39

DeckLeveling...............................................39

PumpDriveBeltTension...............................40

DeckBeltTension.........................................40

MuleDriveBeltTensionAdjustment.............40

AlternatorBeltTension.................................41

BeltGuideAdjustment..................................41

ParkingBrakeAdjustment.............................41

ElectricClutchAdjustment............................43

ReverseIndicatorAdjustment........................44

MotionControlLinkageAdjustment.............44

MotionControlDamperAdjustment.............46

CasterPivotBearingsPre-Load

Adjustment...............................................46

Cleaning...........................................................47

CleanEngineCoolingSystem........................47

CleanEngineandExhaustSystem

Area..........................................................47

CleantheRadiator.........................................47

CleanDebrisFromMachine..........................48

CleanGrassBuild-UpUnderDeck................48

WasteDisposal..............................................48

Troubleshooting...................................................49

Schematics...........................................................52

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

SafeOperatingPractices

Training

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

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.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

Safety

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

DANGER

Incertainconditionsdieselfuelisextremely ammableandvaporsareexplosive.

Areorexplosionfromdieselfuelcanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanydieselfuelthatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows dieselfueltoexpand.Overllingmay resultinfuelleakageordamagetothe engineoremissionsystem.

•Neversmokewhenhandlingdieselfuel, andstayawayfromanopenameor wheredieselfuelfumesmaybeignitedby spark.

•Storedieselfuelinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Dieselfuelisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Operation

WARNING

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

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.Useseatbelts withtherollbarintheraisedandlockedposition.

•Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields,

Safety

guards,switchesandotherdevicesinplaceandin properworkingcondition.

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

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

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

DANGER

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

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

Figure3).

(

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

Safety

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

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

3.Water

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

WARNING

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

•Keeptherollbarintheraisedandlocked positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely necessary.

•DoNotwearseatbeltwhentherollbaris down.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

•Intheeventofarollover,taketheunittoan AuthorizedServiceDealertohavetheROPS inspected.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect 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.

UsingtheRolloverProtectionSystem (ROPS)

ARolloverProtectionSystem(rollbar)isinstalled ontheunit.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe

Safety

negativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

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

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

CAUTION

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

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty,traction, andsafetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.Makingunauthorizedchangestothe engine,fuelorventingsystem,mayviolateEP A andCARBregulations.

Replaceallpartsincluding,butnotlimitedto, tires,belts,blades,andfuelsystemcomponents withoriginalExmarkparts.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

Safety

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

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

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,fuelleakageandpossible explosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

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.

1-633706

1-403005

1-513742

98-5954

1-513748

Safety

103-2076

103-0223

103-0261

103-7218

103-1798

107-2102

Safety

109-0872

109-1399

109-1214

109-2219

109-1215

109-2263

Safety

109-2264

109-2478

109-2951

109-3148

Safety

116-0127

116-3303

116-5074

116-0404

116-5185

1.PTO–engage2.PTO–disengage

116-0997

116-2643

117–2718

Safety

19426-87881

1.Fast3.Neutral

2.Slow

19426-87903

107-9866

4.Reverse

Specications

ModelNumbers

SerialNos:920,000andHigher

LZD25KD605;LZD25KD725

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3850±50RPM(PTOnot engaged)Idle:1400±100RPM

FuelSystem

•Capacity:15.5gal.(58.6L)

•TypeofFuel:Dieselfuel,40cetaneorhigheror biodieseluptoB20(20%biodiesel,80%petro diesel).

•FuelFilter:In-line113Micron ExmarkP/N112-7836.

•FuelShut-OffValve:1/4turnincrements (“OFF”,righttank,lefttank,)

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

EngineOverheatProtectionSystem

PTOwilldisengage,analarmwillsound,andthe coolanttemperaturegaugewillbeintheredarea whentheenginetemperaturereachesanoverheat condition.ThePTOwillnotre-engageuntilthe enginehascooledandthePTOswitchismanually shut-offandre-engaged.

Note:Iftheenginecoolantlevelisbelowthe indicatorlineontheoverowbottlewhenthe engineiscold,thecoolanttemperaturegaugemay notregistercorrectlyduringoperationand/or thewarningbuzzermaynotsoundiftheengine overheats.RefertoCheckEngineCoolantLevel inMaintenance.

•Fuelgaugeinlefthandfueltank.

ElectricalSystem

•ChargingSystem:ExternalAlternator

•ChargingCapacity:60amps

•BatteryType:BCIGroup26

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:One20ampbladetype;One30ampblade type

SafetyInterlockSystem

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

CoolingSystem

•Fan:Electricwithcontinuousoperationwith enginerunning.

•CoolantLiquid:50/50mixofDexCool© extendedlifeantifreezeandwater.

•CoolantCapacity:4quarts

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

Specications

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftAssistPedal:Footpedalthatassistsin raisingthedeck.

Seat

•Type:Deluxesuspensionseathighback,low prolefoam-in-placecushion(dampened, adjustablespringsuspension)andarmrests, adjustablebackangle.

•Mounting:Hingedtotiltupforaccessto hydraulicpumps,batteryandothercomponents. Heldintiltedpositionwithscissor—typelinks. Adjustableforeandaftseattrack.

•Armrests:Moldedadjustableip-uparmrests.

•SeatSafetySwitch:Integratedseatswitch. Timedelayseatswitcheliminatesroughground cut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearPW variabledisplacementpistonpumps.

•WheelMotors:TwoParker/Rosswith11/4inch taperedshafts.

•HydraulicOilType:ExmarkPremiumHydrooil.

•HydraulicOilCapacity:5.5qt.(5.2L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–0-12.0mph(19.3km/hr)forward. –0-8.0mph(12.9km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

DriveFrontCaster

DeckSize

Quantity

Pneumatic (Air-Filled)

60,66,&72

Semi-Pneumatic

AllDecks

DriveFrontCaster

TreadSize

Size26x12.00-1213x6.50-6

PlyRating

Pressure

“Multi-Trac C/S”

10psi(69kPa)

Smooth

CuttingDeck

•CuttingWidth:

–60inch(152.4cm)

–72inch(182.9cm)

•Discharge:Side

•BladeSize:(3ea.)

–60inchDeck:20.75inches(52.7cm)

–72inchDeck:24.75inches(62.9cm)

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

•DeckDrive:

–Electricclutchmountedonhorizontalengine

shaft.“B”Sectionbelt(withself-tensioning idler)fromelectricclutchtotransfershaft mountedondeck.

–Bladesaredrivenbyone“B”Sectionbelt

(w/self-tensioningidler)fromtransfershaft ondecktobladespindles.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport frame.Sixanti-scalprollersprovidemaximum turfprotection.Deckdesignallowsforbagging, mulchingorsidedischarge.

•DeckDepth:

–60inchDeck:6.0inches(15.2cm)

–72inchDeck:6.0inches(15.2cm)

•CuttingHeightAdjustment:

Anextra-longcushionedleverisusedtoadjust thecuttingheightfrom1inch(2.5cm)to5inches (12.7cm)in1/4inch(6.4mm)increments.The cuttingheightadjustmenthandlehasatransport positionandalladjustmentscanbemadewhile theoperatorremainsseated.Unitsalsohavea footoperateddeckliftassistlevertoaidinraising thedeck.

•MulchingKit:Optional.

Specications

Dimensions

OverallWidth:

60inchDeck72inchDeck

WithoutDeck53.5inches

(135.9cm)

DeectorUp61.4inches

(156.0cm)

DeectorDown72.8inches

(184.9cm)

OverallLength:

60inchDeck72inchDeck

RollBar-Up81.9inches

(208.0cm)

RollBar-Down92.5inches

(235.0cm)

OverallHeight:

RollBar-UpRollBar-Down

72.7inches(184.7cm)53.8inches(136.7cm)

61.5inches (156.2cm)

74.3inches (188.7cm)

85.8inches (217.9cm)

96.4inches (244.9cm)

TorqueRequirements

BoltLocation

BladeDriveSheave MountingNut

CutterHousingSpindle Nut

BladeMountingBolt (lubricatewithanti-seize)

EngineDeck/FrontFrame MountBolts

Anti-ScalpRollerNyloc NutSeeFigure11

Anti-ScalpRollerHex CapscrewSeeFigure11

EngineMountingBolts 1/2-13inchscrews M10screws

WheelLugNuts

WheelMotorMounting Bolts

WheelHubSlottedNut211-260ft-lb

RolloverProtectionSystem (RollBar)MountingBolts

Torque

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

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

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

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

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

67-83ft-lb(99-113N-m) 30ft-lb(41N-m)

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

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

(286-352N-m)

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

TreadWidth:(CentertoCenterof Tires,Widthwise)

60inchDeck72inchDeck

DriveWheels41.9inches

(106.4cm)

CasterWheels37.3inches(94.7

cm)

45.9inches (116.6cm)

47.3inches (120.1cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

60inchDeck72inchDeck

56.0inches(142.2cm)60.2inches(152.9cm)

CurbWeight:

60inchDeck72inchDeck

1545lb(701kg)1645lb(746kg)

DeckDriveJackshaftNut

ClutchRetainingBolt (securedwiththreadlocker)

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

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

Operation

ProductOverview

1.Motioncontrollevers

2.Parkingbrake

3.Heightofcutadjustment

4.Fuelcap(bothsides)

Figure4

5.EngineControls(right

6.Seatbelt

7.RolloverProtection

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theconsolecontroltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition intotheT-slotlocksthemintheneutralposition

Figure5).

(

console)

System(ROPS)

Figure5

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

7.Neutrallock

ThrottleControl

Locatedonrightfueltank.

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed

Operation

andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

BrakeLever

Locatedonleftsideofunit,justtothefrontofthe console.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedonrightfueltank.

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

Note:Brakemustbeengaged,motioncontrollevers out(neutrallockposition)andPTOswitch“OFF”to startengine.(Itisnotnecessaryfortheoperatorto beintheseattostarttheengine.)

Thevalvehasthreepositions,eachpositionmade in1/4turnincrements.

FuelFlowValveHandlePosition

“Off”Right

RightTank

LeftTankLeft

Down

FuelGauge

Locatedontheleftfueltank.

Thefuelgaugemonitorstheamountoffuelintheleft tankonly.Usethefuelfromtherightfueltankrst. Whentherightfueltankisempty ,switchtotheleft fueltank.Fuelgaugewillmonitortheremainingfuel.

DriveWheelReleaseValves

Locatedonthetoprightfrontcornerofhydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe pushedwithouttheenginerunning.Unhookseat latchandtiltseatuptogainaccesstopumps.

Witha5/8inchwrench,turnbothvalvesoneturn counterclockwisetoreleasedrivesystem.Turn clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

TrackingAdjustmentKnob

HourMeter

Locatedontherightfueltank.

Thehourmeterisconnectedtoapressureswitch installedintheengineblockanditrecordsthe numberofhoursthattheenginehasrun.Ifthe ignitionswitchisleftonwithoutenginerunning, hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locateddirectlybelowtherightsideofconsole,next tothecubby.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

LocatedundertheseatontheLHpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso thatthemachinetracksstraightwiththedrivelevers inthefullforwardposition.

Stopmachineandwaitforallmovingpartstostop. Engageparkbrake.Unhookseatlatchandtiltseat forwardtogainaccesstothetrackingknob.Rotate theknobclockwise(asviewedfromtherearofthe machine)tocausethemachinetotrackmoretothe rightandcounterclockwisetocausethemachine totrackmoretotheleft.Adjustinquarter-turn incrementsuntilthemachinetracksstraight.Check thatthemachinedoesnotcreepwheninneutralwith theparkbrakedisengaged.

Important:DoNotrotatetheknobtoofar,as thismaycausethemachinetocreepinneutral. RefertotheMotionControlLinkageAdjustment sectioninMaintenance.

Operation

PTOEngagementSwitch

Locatedonrightfueltank.

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

Note:Iftheengineoverheats,thePTOwill automaticallydisengage.ThePTOcannotbe engageduntiltheenginehascooleddown.To re-engagethePTO,pushPTOswitchinto thedisengagedpositionandthenpulloutto engage.RefertotheEngineoverheatsinthe Troubleshootingsection.

CoolantTemperatureGauge

Locatedatthefrontoftheleftfueltank.

Thecoolanttemperaturegaugemonitorsthe temperatureoftheenginecoolant.Anengine overheatingconditionisindicatedbytheredarea onthegauge.AnalarmwillsoundandthePTO willdisengage.RefertotheWarningBuzzerinthe Troubleshootingsection.

Note:Iftheenginecoolantlevelisbelowthe indicatorlineontheoverowbottlewhentheengine iscold,thecoolanttemperaturegaugemaynot registercorrectlyduringoperation.RefertoCheck EngineCoolantLevelinMaintenance.

WarningBuzzer

Locatedbehindtheseatundertheairdeectoron theelectricalpanel.

Thebuzzerisawarningsignalthattheengine isoverheatingortheoilpressureislow .Seethe Troubleshootingsection.

Note:Iftheenginecoolantlevelisbelowthe indicatorlineontheoverowbottlewhentheengine iscold,thewarningbuzzermaynotsoundifthe engineoverheats.RefertoCheckEngineCoolant LevelinMaintenance.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe cuttingdeck.Allowthepedaltomoverearwardto lowerthecuttingdecktothecutheightthathasbeen set.

Pre-Start

Fillfueltankonlevelground.

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

Voltmeter

LocatednexttotheCoolantTemperatureGaugeat thefrontoftheleftfueltank.

Thevoltmetermeasurethevoltageoutputofthe alternator.Bothhighandlowvoltageswillpotentially damagethebattery.

GlowPlugSwitchandLight

Locatedontherightfueltank.

Depressandholdtheswitchtoheattheglowplugs. Theglowpluglightcomesonwhentheglowplug switchisdepressed.Theglowpluglightindicatesthe glowplugsarepreheatingthecombustionchamber.

LowOilPressureLight

Locatedontherightfueltank.

Lightwillcomeonwhenengineoilpressureislow orlost.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

DeterminingFuel

Theenginerunsonclean,freshdieselfuelwith aminimumoctaneratingof40.Purchasefuelin quantitiesthatcanbeusedwithin30daystoensure fuelfreshness.

Usesummergradedieselfuel(No.2-D)at temperaturesabove20°F(-7°C)andwintergrade dieselfuel(No.1-DorNo.1-D/2-Dblend)below 20°F(-7°C).Useofwintergradedieselfuelatlower temperaturesprovideslowerashpointandpour pointcharacteristics,thereforeeasingstartabilityand lesseningchancesofchemicalseparationofthefuel duetolowertemperatures(waxappearance,which maypluglters).

Useofsummergradedieselfuelabove20°F(-7°C) willcontributetowardlongerlifeofthepump components.

Operation

Important:DoNotusekeroseneorgasoline

insteadofdieselfuel.Failuretoobservethis cautionwilldamagetheengine.

DoNotoverllfueltank.Fillthefueltanktothe

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

Ifpossible,llthefueltankaftereachuse.Thiswill minimizepossiblebuildupofcondensationinsidethe fueltank.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuel ofuptoB20(20%biodiesel,80%petrodiesel).The petrodieselportionshouldbeloworultralowsulfur.

Observethefollowingprecautions:

•Thebiodieselportionofthefuelmeets specicationASTMD6751orEN14214.

•Theblendedfuelcompositionshouldmeet ASTMD975orEN590.

•Paintedsurfacesmaybedamagedbybiodiesel blends.

•UseB5(biodieselcontentof5%)orlesserblend incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuel astheymaydegradeovertime.

•Fuellterpluggingmaybeexpectedforatime afterconvertingtobiodieselblends.

•Contactyourdistributorifyouwishformore informationonbiodiesel.

rearpartoftheseatissecuredwiththeseat latch.

Figure6

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

TurnthevalvetotheLHorRHtank.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral lockposition.

OperatingInstructions

RaisetheRolloverProtectionSystem (ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe tworollbarpins(Figure6).

2.Raisetherollbartotheuprightpositionand installthetwopinsandsecurethemwiththe hairpincotterpins(Figure6).

Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.Ensurethatthe

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage” position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

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

5.Onawarmengine,placethethrottleinthe “SLOW”position.

6.Onacoldengine,(below14°F(-10°C)),placethe throttleinthe“MIDWAY”position.

Note:DoNotusefuelleftoverfromsummer.

Operation

7.Turnignitionswitchtothe“ON”position. Depresstheglowplugswitchandtheglowplug lightwillturnon.Holdswitchasrequiredby chartbelow.Turntheignitionswitchtothe “START”position.Releasetheignitionswitchas soonastheenginestarts.

GlowPlugChart

AmbientT emperature

Above50°F(10°C)

50°F(10°C)to23°F(-5°C)

Below23°F(-5°C)

Limitofcontinuoususe

HoldGlowPlugsOn

NONEED

Approximately5seconds

Approximately10seconds

20seconds

Theglowpluglight,locatedneartheglow plugswitch,willilluminatewhentheswitchis depressed.Theglowpluglightindicatestheglow plugsarepreheatingthecombustionchamber.

Important:DoNotcranktheengine continuouslyformorethentensecondsata time.Iftheenginedoesnotstart,allowa30 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotorand/orfuel solenoid.

8.Movethethrottletothe“SLOW”(ifin “MIDWAY”)andlettheenginewarmupafew minutesbeforemovingthethrottletothe“FAST” position.

EngagingthePTO

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades. Besurethatallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

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

2.PullthePTOswitchoutwardtoengagethe blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

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

2.PushthePTOswitchintodisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

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.

Operation

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

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

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

Whenthemotioncontrolleversaremoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Figure7).

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

Figure8

1.FrontofUnit

2.Forward4.Reverse

3.Neutral

Figure7

1.Neutrallockposition (handlesout)

2.Neutraloperateposition (handlesin)

3.FrontofUnit

4.Forward

5.Neutral(operate)

6.Reverse

7.Neutrallock

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth leversrearwardwithequalpressure.

Toturnright,releasepressureontheRHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheright.

Toturnleft,releasepressureontheLHmotion controlleverandtherearofthemachinewill movetowardstherearandtotheleft.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from1to5inches(2.54cmto12.7cm)in1/4inch (6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Raisethedeckheightlevertothetransport position(alsothe5inch(12.7cm)cuttingheight position)(Figure9).

Operation

Thedeckcanberaisedbypullingthedecklever upand/orbypushingdownonthefootoperated deckliftassistleverlocatedatthefrontright corneroftheoorpan.

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

Figure9

1.Leverintransportand5inch(12.7cm)cuttingheight position

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingtheboltandspring discwasher.

6.Placetherollersinoneofthepositionsshown

Figure10).Rollerswillmaintain3/4inch(19

( mm)clearancetothegroundtominimizegouging androllerwearordamage.

Figure10

Forcuttingheightsabove4.0inches(102mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

4.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheightand installthehairpincotterpin.

Seethedecalonthesideofthedeckliftplatefor cutheights.

5.Movethedeckheightleveroutofthetransport position(or5inch(12.7cm)cuttingheight)and downontotheheightadjustmentpintomowat selectedheight.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

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

7.Besuretherollerboltsareinstalledwiththe springdiscwasherbetweentheheadofthebolt andthemountingbracket.

Note:Thefootoperateddeckliftassistlever canbeusedtomomentarilyliftthedecktoclear objects.BesurethatPTOisdisengaged.

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

Figure11).

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

1.Springdiscwasher (conetowardsbolthead)

2.Frontrightanti-scalp bracketshown

Figure11

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

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

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•DoNotexceeda15°anglebetweenrampand groundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

9.Ifthe3/8nylocnuthasbeenremoved, re-installandtorqueto30–35ft-lb(41–47N-m) (Figure11).

Transporting

TransportingaUnit

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

CAUTION

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

DoNotdriveaunitonapublicstreetorroadway.

LoadingaUnit

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

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

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Aftertherst250hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Checktheparkbrakeadjustment.

•Changethehydrauliclter.

WARNING

Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Beforeeachuseordaily

Every40hours

Every50hours

Every100hours

Every160hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkenginecoolantlevel.

•Cleantheenginecoolingsystem.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheheightadjustmentshaftbearings.

•Greasethereardeckstruts.

•Drainfuellter/waterseparator.

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

•Checksparkarrester(ifequipped).

•Cleantheenginecoolingsystem.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

Maintenance

MaintenanceService

Interval

Every200hours

Every400hours

Every500hours

Every600hours

Every4,000hours

Monthly

Yearly

PeriodicMaintenance

CheckEngineOilLevel

MaintenanceProcedure

•Greasethebrakebrackets.

•Replacethefuellter/waterseparator(moreoftenindirtyordustyconditions).

•Checkthewheelhubslottednuttorquespecications.

•Checkthewheellugnuts.

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checktheparkbrakeadjustment.

•Replacetheaircleanerelements.(Mayneedmoreoftenundersevereconditions.Seethe EngineOwner’sManualforadditionalinformation.)

•

Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)

•Checkthebatterycharge.

•Changetheengineoilifoperatedlessthan100hours.

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

•Greasethemuledrivebeltidlerarm.

•Greasethepumpdrivebeltidlerarm.

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

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Raiseradiatortogainaccesstodipstick.

CAUTION

Iftheradiatorproprodisnotsecurely positionedinthenotchtheradiatormayfall. Fallingradiatorcouldcauseseriousinjury.

Besuretheproprodisengagedsecurelyin thenotchatthefarrightsideoftheslot.

4.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.Removethedipstick andreadtheoillevel.

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

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

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

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Maintenance

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

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

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

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

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

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

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

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

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure12.

Figure12

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

Maintenance

Figure13

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

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

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

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

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated intheCleanGrassBuild-UpUnderDeck procedure.

Figure14

1.Usewrenchherefor bladeinstallation.This nuthasbeentorquedto 90–110ft-lb(122–149 N-m)

2.Torqueto55-60ft-lb (75-81N-m)Apply lubricanttothreads asneededtoprevent seizing.Copper-based anti-seizepreferable. Greaseacceptable substitute.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based anti-seizepreferable.Greaseacceptable substitute.Installbladeboltngertight.Place wrenchonthetopspindlenutthentorquethe bladeboltsto55-60ft-lb(75-81N-m).

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Maintenance

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

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

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

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

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

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckRolloverProtections Systems(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

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.

Makesurelatchpinandhairpinarefullyinstalled andlanyardisingoodcondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See

Maintenance

theEngineOwner’s Manualforadditional information.)

Every600hours—Replace theaircleanerelements. (Mayneedmoreoften undersevereconditions. SeetheEngineOwner’s Manualforadditional information.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhooktwoairltercanisterlatchestogain accesstotheaircleanerelement.

3.Removeaircleanercanistercoverandremove outerelement.

4.Checktheconditionofthepaperelement. Replaceifdirty,bentordamaged.

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

6.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

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

Yearlyifoperatedless than100hours.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Fastendeckbeltspanstogetherwithmechanics wireortiewraptopreventoilfromdrainingonto belt.

4.Placepanundermachinetocatchoil.Remove theoildrainplug.Allowoiltodrainandreplace oildrainplug.

5.Replacetheoilltereveryotheroilchange.Clean aroundoillterandunscrewltertoremove. Beforereinstallingnewlter,applyathincoating ofExmark4-CyclePremiumEngineOilonthe surfaceoftherubberseal.Turnlterclockwise untilrubbersealcontactsthelteradapterthen tightenlteranadditional1fullturn.

6.Unlatchradiatorandliftituptoaccessoilll. Cleanaroundoilllcapandremovecap.Fill tospeciedcapacityandreplacecap.Useoil recommendedintheCheckEngineOilLevel section.DoNotoverll.Starttheengineand checkforleaks.

7.Removewireortiewrapfrombeltspans

8.Starttheengineatidlefor5minutes.Stopengine andwaitthreeminutes,thenchecktheoillevel. Ifrequired,addoiltobringleveltothe“FULL” markonthedipstick.DoNotoverll.

9.Checkforleaks,includingaroundtheoillter.

10.Wipeupanyspilledoil.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.UseExmark PremiumHydrooil.Replacehydraulicreservoir capandtightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Maintenance

2.Checktirepressureindrivetires.

3.Inatedrivetiresto10psi(69kPa).

4.Semi-pneumaticcastertiresdonotneedtobe inated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.Removethe airdetectorpanelonfrontsideoftheengine compartmenttocheckpumpdrivebeltand alternatorbelt.

3.Removeleftandrightbeltshieldsondeckandlift upoorpantoinspectdeckdrivebelt.

4.Checkundermachinetoinspectthemule drivebelt.RefertoMuleDriveBeltTension

AdjustmentsectioninAdjustments.

LubricationChart

Fitting

Locations

4.Deck DriveBelt IdlerArm

5.Brake Brackets

6.Mule DriveBelt IdlerArm

7.Pump DriveBelt IdlerArm

8.Deck RearStruts

Initial

Pumps

Numberof

Places

*Seestep3forspeciallubricationinstructionson thefrontcasterpivotsandtheLubricateCaster WheelHubssectionforspeciallubrication instructionsonthefrontcasterswheelhubs.

Service

Interval

Yearly

200Hours

Yearly

40Hours

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.Front Casterwheel hubs

2.Front Caster Pivots

3.Height Adjustment Shaft Bearings

Initial

Pumps

Numberof

Places

540Hours

Service

Interval

*Yearly

Number6(MuleDriveBeltIdlerArm)Located

UnderEngineFrame

Number7(PumpDriveBeltIdlerArm)Located

UnderEngineFrame

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

Maintenance

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

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

Note:DoNotuseanti-seizeonwheelhub.

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

Figure15

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.

7.Insertonebearing,onenewsealintothewheel.

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

8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontothe axlewiththewrenchatsfacingoutward.Do

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

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandlepivot withaspraytypelubricantorlightoil.

LubricateBrakeRod Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake rodshaftwithaspraytypelubricantoralightoil

Maintenance

(bushingsarelocatedtotheinsideoftheange bearings).

LubricateMotionControl BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings securingthemotioncontrolarmshaftswitha lightoiloraspraytypelubricant.

DrainFuelFilter/Water Separator

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Placeadrainpanunderthefuellterandloosen thedrainplugapproximately1turn.

3.Watershoulddrain.

4.Whenfuelbeginstoowfromthelter,tighten thedrainplug.

ChangeInlineFuelFilter

ServiceInterval:Asrequired

Aninlinefuellterisinstalledbetweenthefueltank andthefuelpump.Replacewhennecessary.

ReplacementFilters

ExmarkP/N112-7836

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearlyif usingMobil115W50)

Note:UseonlyExmarkP/N103-2146.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raiseseat.

3.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

Important:Waterorothercontaminantsinfuel canseverelydamagefuelpumpand/ortheother enginecomponents.

ChangeFuelFilter/Water Separator

ServiceInterval:Every400hours/Yearly

(whichevercomesrst) (moreoftenindirtyor dustyconditions).

DANGER

Useofimpropercomponentscanresultinsystem failure,fuelleakageandpossibleexplosion.

•EnsurethatanAuthorizedServiceDealer replacethefuellterandanycomponentsfor thefuelsystem.

•Useonlyapprovedfuellines,hoseclamps andfuelltersforhighpressuresystems.

4.Unscrewltertoremoveandallowoiltodrain fromreservoir.

Important:Beforereinstallingnewlter,ll itwithExmarkPremiumHydrooilandapply athincoatofoilonthesurfaceoftherubber seal.

Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.

5.FillreservoirasstatedinCheckHydraulicOil Levelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

ChangeInterval

500Hours

250Hours

Maintenance

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .

7.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol leverstothefullspeedandrunforseveral minutes.Shutdownmachineandrecheckoil level.

Note:DoNotchangehydraulicsystemoil(except forwhatcanbedrainedwhenchanginglter),unless itisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

CheckEngineCoolantLevel

ServiceInterval:Beforeeachuseordaily

Note:Iftheenginecoolantlevelisbelowthe

indicatorlineontheoverowbottlewhenthe engineiscold,thecoolanttemperaturegaugemay notregistercorrectlyduringoperationand/or thewarningbuzzermaynotsoundiftheengine overheats.

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Viewcoolantlevelinoverowbottleontheleft sideoftheenginecompartment.Coolantlevel shouldbeattheindicatorlineontheoverow bottle.

CAUTION

Enginecoolantistoxic.Swallowingcoolantcan causepoisoning.

•DoNotswallow .

•Keepoutofreachofchildrenandpets.

ChangeEngineCoolant

ServiceInterval:Every4,000hours/Every4

years(whichevercomes rst)Dex-Cool© © lifecoolant(orangecolor)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.Machinemust bepositionedonlevelsurface.

2.Unhookseatlatch,tiltseatupandtilthood forwardtogainaccesstothecoolingarea.Do Notraiseradiator,asitmaynotfullydraininthat position.

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Spray orsteamfromhot,pressurizedliquidinthe enginecoolingsystemandtouchingahot radiatormaycausesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

extended

4.Ifthecoolantlevelislow ,openhoodorraise radiator,removethecaptotheoverowbottle andlltotheindicatorline.Unitsshouldonlybe lledwitha50/50mixofDex-Cool©extended lifecoolantandwater.Dex-Cool©canbe identiedbyitsorangecolor.

WARNING

Enginecoolantishotandpressurizedand radiatorandsurroundingpartsarehot.Sprayor steamfromhot,pressurizedliquidintheengine coolingsystemandtouchingahotradiatormay causesevereburns.

Allowtheenginetocoolcompletelybefore removingtheradiatorcaporservicingany componentofthecoolingsystem.

CAUTION

Enginecoolantistoxic.Swallowingcoolant cancausepoisoning.

•DoNotswallow .

•Keepoutofreachofchildrenandpets.

3.Draincoolantwhenengineiscool.Coolantmay bedrainedfromtheradiatorbyremovingthe drainplugintherightrearcorner.Theengine blockmaybedrainedbyremovingtherear radiatorhoseand/orbyopeningthedraincock ontheright-handsideoftheengineblock(see Figure16).

Maintenance

Figure16

1.Oildipstick

4.Reinstallalldrainplugsandhosesandtighten draincock.

5.Fillradiatorwitha50/50mixofwaterand Dex-Cool©coolantasspeciedintheCheck EngineCoolantLevelSection,allowingsome room(approximately1/2inch(12.7mm))for expansion.Add50/50coolantmixtooverow bottleontheleftsideoftheengineasrequired tobringtheleveluptotheindicatorlineonthe bottle.

2.Draincock

core.Asairispurgedfromtheengineblockand thecoolantleveldrops,addadditionalcoolantto theradiator.

8.Whentheradiatoriscompletelyfullandno additionalcoolantcanbeadded,continuerunning andinstalltheradiatorcap.Makesurethatthe capiscompletelyseatedbypressingdownrmly whileturninguntilthecapstops.Oncethecapis installed,theenginemaybestopped.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignitefuel vaporsevenaftertheengineisstopped.Hot particlesexhaustedduringengineoperationmay igniteammablematerials.Firemayresultin personalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

WARNING

Enginecompartmentcontainsopenbelt drives,fans,andotherrotatingcomponents thatcancauseinjury.Fingers,hands,loose clothing,orjewelrycangetcaughtbythe rotatingfananddriveshaft.

•DoNotoperatemachinewithoutthe coversinplace.

•Keepngers,hands,andclothingclearof rotatingcomponents.

•Shutoffengine,waitformovingpartsto stop,engageparkingbrakeandremove key,beforeperformingmaintenance.

6.Withthecapofftheradiator,tilthoodclosedand puttheseatdown.Starttheengineasstatedin theOperatingInstructionsSection.Returnthe seatupandhoodforwardtotheopenposition.

7.Operateengineuntiltheenginethermostatopens andcoolantiscirculatingthroughtheradiator

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

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

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol arms.

•Sheaveretainingboltintheendofengine crankshaft.

•Casterwheelspacernuts.

Maintenance

•Fueltankbulkheadttingnuts.

•Boltsretainingstubshafttoengineywheel.

Adhesivessuchas“LoctiteRC/609orRC/680”or “Fel-ProPro-LockRetainingIorRetainingII”are usedonthefollowing:

Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

•Betweenthejackshaftandbearingsandthe jackshaftandsheaves.

Adjustments

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

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbeenough supportormaymalfunctionallowingtheunitto fall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

DeckLeveling

1.Positionmoweronaatsurface.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing location:

OnthreadsofBladeBolts.SeeCheckMower Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checktirepressureindrivetires.Properination pressurefortiresis10psi(69kPa).Adjustif necessary.

4.Setanti-scalprollerstotopholesorremovethem completelyforthisadjustment.

5.Raisethedecktothe5inch(12.7cm)height position(alsotransportposition)andtakeallforce offofthetwolargedeckliftspringsbyloosening thenutsatthefrontofeachspring(

6.Lowerthedecktothe1inch(2.54cm)height position.Forcetheleftreardecksupportarm downwardabout1/4inch(6.4mm)togetthe decktorestatthe1inchheightposition.Place lockingpliersbetweentherearswivelandspring stoptoholdthedeckinthisposition(

7.Placea3/4inch(19mm)thickblockofwood undereachofthetworearanti-scalproller bracketsandplaceoneunderoneofthefront centeranti-scalprollerbrackets.

Figure17).

8.Loosenthetwotopchainboltsinslotsintherear deckliftarms.Loosenjamnutsandbackoffthe socketheadadjustingscrewsonthebottomof thearmsuntilthechainsarejustloose.Turnthe socketheadadjustingscrewsinuntilslackistaken outofeachchain.Tightenthejamnuts.Tighten

Maintenance

thechainboltsinthedeckliftarmsmakingsure theydon’tmovewhiletightening.

9.Loosenthefournutswhichsecurethefront swivels(twoperside)untilthefrontchainsare looseandfrontofdeckissupportedbythe3/4 inch(19mm)block.DoNotloosenthefront chainhardware.

10.Onleftside,adjustfrontswivelusingthelocking nutbehindtheswiveluntilthefrontchainistight andallslackisremovedfromlinkage.DoNotlift frontofdeckoff3/4inch(19mm)block.Secure frontswivelusinglockingnutinfrontofswivel. Repeatforrightside.

11.Recheckthatthe3/4inch(19mm)blockstjust snuglyunderthebracketsandthatthetensionon allthechainsisapproximatelyequal.Makesure allchainattachmentboltsaretight.Reposition anti-scalprollersandtightensecurely.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

MuleDriveBeltTension Adjustment

Self-tensioningidler,adjustasfollows:

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktomakesurethecenterofthebolthead inthecenterofthespringloadedpulley,onleft sideenginedecksupport,ispositionedbetween thecentersofthetwoalignmentholesinthe leftsupportplate( isnecessarytoadjustthebelttensionwhenthe centeroftheboltheadisatorbelowthecenter ofthebottomalignmenthole.

Figure18andFigure19).It

Figure17

1.Applydownwardpressurehere

2.Placelockingpliersheretoholdspring

3.13–1/2inches(34.3cm)forcutheightsat2inchesor aboveor14inches(35.6cm)forcutheightsbelow2 inches

4.Removeforceondeckspringsbylooseningnutshere

5.Swivel

6.Frontofunit

7.Socketheadadjustingscrew

8.Jamnut

12.Raisedeckliftlevertothe5inch(12.7cm) cuttingheightposition(Figure9).Adjustspring compressionuntilproperdistanceisobtained betweenthetwolargewashers(Figure17). Adjustmentismadebyturningthenutatthe frontofeachspring(clockwisewillshortenthe spring,counterclockwisewilllengthenthespring). Lockinpositionwithjamnuts.

3.Whenadjustmentisnecessary,loosentheidler pulleyontheright-handsidesoitcanmoveup anddownintheslot.

Placeawrenchonthe3/8inchnutinthecenter ofthespringloadedpulleyandapplyupward pressuretorelievetensiononthespring(a1/2 inchdrivebreakerbarand9/16inchsocketworks best).

Repositiontheadjustingpulleytothebottomof theslot.

Note:Wheninstallinganewbelt,itisnecessary torepositiontherightadjustingpulleyupwardin theslotinordertopositionthecenterofthespring loadedpulleybetweenthealignmentholes.

Note:Whenaboveadjustmentshavebeenmade, thefrontofthedeckwillbeslightlylowerthanthe rearofthedeck.

1.Frontofunit

Figure18

2.Alignmentholes

Maintenance

BeltGuideAdjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethebeltshieldontherightsideofmower deck.

3.Notebeltguideboltedtodeckneartheshield supportstudandright-handpulley .Guideshould be1/8inch(3.2mm)awayfromthebelt,with bolt-endofguidenearendofslot(

4.Ifadjustmentisnecessary,loosentheboltsecuring thebeltguideandmakeproperadjustment. Tightenhardware.

Figure20).

Figure19

1.Springidlerpulley

2.Frontofunit

3.Rightsideidlerpulley (adjustable)

AlternatorBeltTension

Stopengine,waitforallmovingpartstostopand removekey.Engageparkingbrake.

Tiltseatandremoveairdeectorpanel

Totightenalternatorbelt,loosenbothupperand loweralternatormountingbolts.Rotatealternator out,awayfromengineandretightenhardwareto secureinplace.

Whenproperlytensioned,thealternatorbeltwill deect1/4to3/8inch(7-9mm)whileapplying22 poundsofforcetothebeltmidwaybetweenfanand alternator.

Figure20

1.Endofslot

2.Beltguide

ParkingBrakeAdjustment

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

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Engagetheparkingbrake(leverup).

8.Loosenthejamnut(item9inFigure21)just abovethetrunnionroller2-3turns.

inch(3.2-4.8mm).Ifnecessary,adjustthenyloc nutaccordingly.

12.Ifthecorrectgapcannolongerbeachieved becausethereisnoclearancebetweenthenyloc nutbelowthespringandthejamnut,orthere arenothreadsleftinthebottomnylocnut,the lengthofthebrakerodcanbeadjusted.Remove apinfromayokeateitherendofthebrakerod andlengthen(orshorten)thebrakeroduntilthe correctgapcanbeachieved.

13.Ifabrakecomponenthasbeenremovedor replaced,seethestepsbelow;otherwiseproceed tostep

14.

BurnishingtheBrakeProcedure:

A.Cleartheareaofanyammablematerial

beforestartingtheburnishingprocess.

B.Whilesittingintheoperator’sseat,startthe

engine,andreleasetheparkbrake.

WARNING

Figure21

1.Leverdown (disengaged)

2.Leverup(engaged)

3.Nylocnutbelowtrunnion roller

4.Nylocnutbelowspring9.Jamnutabovetrunnion

5.1/8to3/16inch(3.2to

4.8mm)

6.Removepintoadjust rodlengthforadditional brakeadjustment

7.Trunnionroller

8.Springretainerbracket

roller

9.Tightenthebottomnylocnut(item3inFigure21) untilthebrakespringiscompletelycompressed, thenloosenone-halfturn.

10.Tightenthejamnutagainstthetrunnionroller

11.Checktheclearancebetweenthebottomofthe brakebracketandthenylocnutjustunderthe spring.Clearanceshouldmeasure1/8to3/16

Enginemustberunninganddrivewheels mustbeturningsoadjustmentscanbe performed.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

C.Increasethethrottletohighidle.

D.Bringbothdriveleversoutofneutraland

pushthemintofullforwardposition.

E.Pulltheparkbrakeleverupuntiltheengine

rpmstartstodrop.Holdtheparkbrakelever inthispositionfor15seconds.

F.Releasethebrakelever.

G.Movethedriveleversintothefullreverse

position.RepeatstepsEandF.

H.Movethedriveleversbacktotheneutrallock

position.

I.Returnthethrottletolowidle,andstopthe

engine.

J.Allowthebrakebandsanddrumstocool.

Repeatsteps7through11.

14.Installthetiresandtorquethelugnutsto90-95 ft-lb(122-129N-m).

15.Removethejackstands.

ElectricClutchAdjustment

G011733

Noadjustmentnecessary.Howeverwhentheclutch brakehasworntothepointwheretheclutchno longerengagesconsistently,theshimcanberemoved toextendtheclutchlife.

Figure22

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

Figure23

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

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

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

E.Usinga0.010inchthickfeelergauge,verify

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

2.Shim

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

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

A.Loosenbothbrakemountingboltsone-half

toonefullturn(see

Figure23).

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

Figure24

1.Feelergauge

Maintenance

Figure25

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstep

5.Ifadjustmentisneeded,loosenthenutagainstthe yokeandwhileapplyingslightrearwardpressure onthemotioncontrollever,turntheheadofthe adjustmentboltintheappropriatedirectionuntil leveriscentered(keepingrearwardpressureon theleverwillkeepthepinattheendoftheslot andallowtheadjustmentbolttomovethelever totheappropriateposition).Tightenlocknut.

6.Repeatonoppositesideofunit.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengage

withthePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly ,referencethe Troubleshootingsection.

ReverseIndicator Adjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatforward.

3.Beginwitheithertheleftorrightmotioncontrol lever.Movelevertotheneutralpositionandpull leverbackuntiltheclevispin(onarmbelowpivot shaft)contactstheendoftheslot(justbeginning toputpressureonspring).(Figure26).

Figure26

1.Turnbolthere4.Yoke

2.Levercenteredinnotch5.Loosenhere

3.Endofslot

6.Reverseindicator

MotionControlLinkage Adjustment

WARNING

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

4.Checkwhereleverisrelativetonotchinconsole (shouldbecenteredallowinglevertopivot outwardtotheneutrallockposition).

Maintenance

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

1.Thisadjustmentmustbemadewiththedrive wheelsturning.Firstraisetherearofmachine upandsupportwithjackstands(orequivalent support)justhighenoughtoallowthedrive wheelstorotatefreely.

2.Unhookseatlatchandtiltseatforward.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locateddirectlytotheleftoftheseat switchassemblybesidethehydraulicoilreservoir.

Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

4.Runtheunitatleast5minuteswiththedrive leversatfullforwardspeedtobringhydraulic systemoiluptooperatingtemperature.

5.Loosenlocknutsfromtheballjointsateachend ofthepumpcontrollinkage(

Figure27).

becauseofthejumperwirebeingused.Run engineatfullthrottleandreleasebrake.

7.Thereverseindicatorspringmustbecorrect beforethefollowingadjustmentscanbemade. SeetheReverseIndicatorAdjustmentsection.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

Theleftrodassemblycontrolstheleftwheeland therightrodassemblycontrolstherightwheel.

8.Bringthemotioncontrolleverintotheneutral position.AdjustRHpumpcontrolrodlength byrotatingthedoublenutsontherodinthe appropriatedirectionuntilthewheelsslightly creepinreverse(

Figure27).Movethemotion controllevertothereversepositionandwhile applyingslightpressuretotheleverallowthe reverseindicatorspringtobringtheleversbackto neutral.Thewheelmuststopturningorslightly creepinreverse.Whenadjustmentiscomplete, tightenlocknutsontoballjoints.

9.BringtheLHmotioncontrolleverintothe neutralposition.AdjusttheLHpumpcontrolrod lengthbyrotatingthetrackingadjustmentknobin theappropriatedirectionuntilthewheelsslightly creepinreverse.Movethemotioncontrollever tothereversepositionandwhileapplyingslight pressuretotheleverallowthereverseindicator springtobringtheleversbacktoneutral.The wheelmuststopturningorslightlycreepin reverse(

Figure28).

Figure27

Right-HandSideofUnit

1.Turnheretoadjust

2.Loosenhere(right-hand thread)

6.Startengine.Brakemustbeengagedand motioncontrolleversouttostartengine. Operatordoesnothavetobeintheseat

Figure28

Left-HandSideofUnit

1.TurnLHtrackingadjustmentknob.(DoNotloosenany nutsonLHside)

10.Shutoffunit.Removejumperwirefromwire harnessconnectorandplugconnectorintoseat switch.

Maintenance

MotionControlDamper Adjustment

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance.

Figure29formountingoptions.

See

Figure29

1.Motioncontrolbracket

2.Leastresistance(softestfeel)

3.Mediumresistance(mediumfeel)

4.Mostresistance(rmestfeel)

5.Torquenylocnutto200in-lb(16.7ft-lb).Boltmust protrudepastendofnylocnutaftertorque.

6.Damper

7.Dampermustmovefreelyonbolt.

Figure30

1.Springdiscwashers

CasterPivotBearings Pre-LoadAdjustment

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

Figure30.

Maintenance

Cleaning

CleanEngineCooling System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundtheenginecooling airintakeandinsideofthepumpdrivebelt compartmentanddamagedormissingrubber bafescancausetheengineandhydraulic systemtooverheatwhichcancreatearehazard.

•Cleanalldebrisfrominsideofpumpdrive beltcompartmentdaily.

•Cleandebrisfromradiatorscreenandcore daily.

CAUTION

Excessivedebrisaroundengineandexhaust systemareacancauseengine,exhaustarea,and hydraulicsystemtooverheatwhichcancreate arehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removeairdeectorpanelfrombehindseat.

3.Cleanaroundywheel,cylinderhead,injectors, andinjectorpump.

4.Cleanalldebrisfromtheexhaustsystemarea.

5.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustarea.

6.Reinstalltheairdeectorpanel.

Important:DoNotusewatertoclean engine.Uselowpressurecompressedair.See EngineOwner’sManual.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfrominsideofpumpdrivebelt compartment.

3.Wipedebrisfromscreeninenginecover.

4.Rotateenginecoverforwardandwipedebris fromradiatorcoreasrequired.

5.Cleandebrisfromradiatornswithcompressed air.

Important:Ifdebrisoraircannotbeblown throughtheradiator,seeCleaningofthe Radiatorsection.

6.Inspectsealsinenginecoverandreplaceif necessary.

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CleantheRadiator

ServiceInterval:Every50hours(Maybe

requiredmoreoftenindry ordirtyconditions.)

1.Stopengine,waitforallrotatingpartstostopand removekey.Engageparkingbrake.

2.Allowenginetocool.

3.Rotateseatandenginecoverforward.

4.Whileholdingfanup,removethefourscrews attachingthefantotheshroud.Disconnectand removethefan.

5.Usingcompressedair,blowoutdebrisstuck betweenthensoftheentireradiator,bothfrom thetopdownandfromthebottomup.

6.Ifdebrisremains,itmaybenecessarytousewater fromalowpressurehose.Iftheradiatorisclean, proceedtostep

7.Covertheenginewithapieceofcardboard,ora plasticsheet.Squirtwaterdownthroughthens. Blowthroughwithlowpressureairfromboth directions.Ifdebrisremains,repeatuntilclean.

8.Re-assemblethefantotheradiator.Reconnect thefan.

9.Starttheenginetoensurethefanisfunctioning properly.

Maintenance

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(5inch(12.7cm) cuttingheight)position.Liftthefrontofunit andsupportunitusingjackstandsorequivalent support.

CAUTION

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

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.

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.

1.DisengagethePTO .

3.Ensurethedriveleversareintheneutral lockposition.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheseatswitchindicator.Replace seatifneeded.

9.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

Enginelosespower

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.V entholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Engineoverheats.

Mowerpullsleftorright(withleversfully forward)

Machinedoesnotdrive

Unevencuttingheight.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Dirtyairlter.

4.Coolantlevelislow .

5.Debrisonoraroundradiator.

6.W aterpumporalternatorbeltisworn, loose,orbroken.

1.Trackingneedsadjustment.1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

3.Reverseindicatorandmotioncontrol linkageneedadjustment.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

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.Addoiltothecrankcase.

3.Cleanorreplacetheaircleanerelement.

4.Addcoolant.

Removedebris(seeCleantheRadiator sectioninMaintenance).

6.ContactanAuthorizedServiceDealer.

3.Adjustthereverseindicatorandthe motioncontrollinkage.

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.

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley .2.Checkbeltfordamage;replaceif

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

5.Brokenormissingidlerspring.

6.Clutchhasdisengaged.6.Enginehasoverheated;determinecause

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

necessary.Installdrivebeltandcheckbelt guideforcorrectposition.

pulley,idlerarmandspringforcorrect positionandfunction.

5.Replacethespring.

ofoverheat(seeEngineoverheats).

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Warningbuzzeremitscontinuousbeep.(See alsoEngineoverheats).

Warningbuzzeremitsintermittentbeep.

Clutchwillnotengage.

1.T emperatureisincreasingoncoolant temperaturegauge.

2.Coolantlevelislow .

3.Debrisonoraroundradiator.3.Removedebris.

4.W aterpumporalternatorbeltisworn, looseorbroken.

1.Oillevelislow .1.Checkoillevel.

2.Oilleakingfromengine.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

6.Enginehasoverheated.

1.Turnunitoffandallowengineandengine componentstocool.

2.Addcoolant.

4.ContactAuthorizedServiceDealer.

2.ContactAuthorizedServiceDealer.

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

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Replaceclutch.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

6.Determinecauseofoverheat(seeEngine overheats).

Schematics

ElectricalDiagram

Schematics

ElectricalSchematic

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 for a period of two years.

This warranty applies to Exmark commercial turf equipment sold in the U.S. or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine *

* The Engine warranty is covered by the engine manufacturer. Please refer to the engine manufacturer’s warranty statement that is included in the literature packet.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized   Exmark Service Dealer.

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-589_C

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure31

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-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-919Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Z D-920, Z D-000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual