Exmark Z XS User Manual

For Serial Nos.

600,000 & Higher

Part No. 109-4569 Rev. A

WARNING

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

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

discharge system) in place and in proper working condit ion. ♦ Stop engine, wait for all moving part s t o st op, and engage

parking brake. Remove spark plug wire(s) or remove key before

adjusting, servicing, or performing maintenance. ♦ If mower deck becomes clogged, stop engine, wait for all moving

parts to stop, and engage par king brake. Remove spark plug

wire(s) or remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts . ♦ Keep off mower unless seat platf o r m is pr ovided. ♦ Keep others off mower.

WARNING

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

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

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

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442 Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.

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

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

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

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

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EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995 Program

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

How the Program Works

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

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

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

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

5. The customer pays for the part

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

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

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

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

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

shipment of six (6) line items or less.

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

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

central time, with an Exmark Parts Plus

order of six (6) line items or less.

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

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

accordance to the program.

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

1. The dealer not submitting the Exmark Parts Plus

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

pays for the part and freight.

order

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

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

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

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

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

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

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

OPERATOR'S MANUAL

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

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, m aint enance, and safety instructions, you will prolong the life of your mower, mainta in it s m aximum efficiency, and promote safe oper ation.

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

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

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

iii

TABLE OF CONTENTS

1. SAFETY PAGE

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

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

1.3 Preparation.................................................................................................1-4

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

1.5 Maintenance & Storage.............................................................................. 8-9

1.6 Safety Signs............................................................................................. 9-11

2. SPECIFICATIONS

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

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

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

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

2.5 Operator Controls........................................................................................ 12

2.6 Seat........................................................................................................12-13

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

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

2.9 Cutting Deck................................................................................................ 13

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

2.11 Torque Requirements ................................................................................. 14

3. OPERATION INSTRUCTIONS

3.1 Controls.................................................................................................. 14-17

3.2 Pre-Start...................................................................................................... 17

3.3 Operating Instructions ............................................................................17-19

3.4 Transporting...........................................................................................19-21

4. MAINTENANCE & ADJUSTMENTS

4.1 Periodic Maintenance.............................................................................21-30

4.2 Adjustments ...........................................................................................30-37

5. WASTE DISPOSAL

5.1 Motor Oil Disposal....................................................................................... 37

5.2 Battery Disposal..........................................................................................37

6. TROUBLE SHOOTING................................................................................... 37-39

7. ELECTRICAL DIAGRAM .................................................................................... 40

8. HYDRAULIC DIAGRAM...................................................................................... 41

9. WARRANTY.......................................................................................................... 42

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1. SAFETY

1.1 SAFETY ALERT SYMBOL

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

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

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an im m inent ly hazardous situat ion which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / Or ange background. Indicates a potent ially hazardous situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

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

1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and t he proper use of the equipment. If the operator(s) or m echanic(s) can not read English, it is the owner’s responsibility to explain this mater ial t o t hem .

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

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

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachment s ar e needed t o properly and safely perform the job. Only use accessories and attachments approved by Exmark.

1.3.2 The use of personal protective equipment , such as (but not limited to) protect ion for the eyes, ears, feet , and head is r ecom m ended.

CAUTION

POTENTIAL HAZARD ♦ This machine produces sound levels in

excess of 85 dBA at the operator’s ear

when in operation. WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or

above for extended periods of time can

cause hearing loss. HOW TO AVOID THE HAZARD ♦ Wear hearing protection when operating

this machine.

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

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

WARNING

POTENTIAL HAZARD ♦ Engine exhaust contains carbon

monoxide, which is an odorless deadly

poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you. HOW TO AVOID THE HAZARD ♦ Do not run engine indoors or in a small

confined area where dangerous carbon

monoxide fumes can collect.

DANGER

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely

flammable and highly explosive. WHAT CAN HAPPEN ♦ A fire or explosion from gasoline can burn

you, others, and cause property damage. HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling , and stay

away from an open flame or where gasoline fumes may be ignited by spark .

♦ Refuel only outdoors. ♦ Store gasoline in an approved container

and keep it out of the reach of children.

♦ Add fuel before start ing the engine.

Never remove the cap of the fuel t ank or

add fuel when engine is running or when the engine is hot.

♦ Never fill the fuel tank so that the gasoline

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

♦ If fuel is spilled, DO NOT attempt to start

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

♦ Do not operate without entire exhaust

system in place and in proper working

condition.

DANGER

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely

flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite g asoline

vapors. A fire or explosion from g asoline

can burn you, others, and cause property

damage. HOW TO AVOID THE HAZARD

♦ Purchase and store gasoline only in an

approved container.

♦ Always place gasoline containers on the

ground away from your vehicle before filling.

♦ Do not fill gasoline containers inside a

vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

♦ When practical, r em ove g as- powered

equipment from t he t r uck or trailer and refuel the equipment with its wheels on the ground.

♦ If this is not possible, then refuel such

equipment on a truck or t r ailer from a portable container, rather than from a gasoline dispenser nozzle.

♦ If a gasoline dispenser nozzle must be

used, keep the nozzle in contact with the

rim of the fuel tank or container opening

at all times until fueling is com p let e.

WARNING

POTENTIAL HAZARD ♦ Gasoline vapor can collect inside

enclosed trailers and may be ignited by

electrical sparks or hot engine/ exhaust

components. WHAT CAN HAPPEN ♦ Explosion and fire may occur, resulting in

property damage, personal injury, and/or

death. HOW TO AVOID THE HAZARD

♦ Provide adequate ventilation of any

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

♦ Refuel only outdoors, never inside an

enclosed trailer.

♦ Be sure all fuel tanks and gasoline

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

♦ Do not place any equipment that is

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

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

leaking gasoline in an enclosed trailer.

WARNING

POTENTIAL HAZARD ♦ Operating engine parts, especially the

muffler, become extremely hot. WHAT CAN HAPPEN

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

can catch fire. HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muff ler ,

to cool before touching.

♦ Remove accumulated debris from muffler

and engine area.

♦ Install and maintain in working order a

spark arrester before using equipment on

forest-covered, grass-covered, or br ush-

covered unimproved land.

WARNING

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

can become entangled in rotating part s . WHAT CAN HAPPEN ♦ Contact with rotating parts can cause

traumatic amputation or severe

lacerations. HOW TO AVOID THE HAZARD

♦ Do not operate the machine without

guards, shields, and safety devices in place and working properly.

♦ Keep hands, feet, hair, j ewelry, or clot hing

away from rotating parts.

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

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

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

1.4.3 When f easible, avoid operating the equipment in wet grass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction and/or tip-over could occur. The oper at or is responsible for safe operation on slopes.

DANGER

POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can

cause sliding and loss of control. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning. HOW TO AVOID THE HAZARD

♦ Do not mow slopes when grass is wet. ♦ Do not mow near drop-offs or near water. ♦ Do not mow slopes greater than 15

degrees.

♦ Reduce speed and use extreme caution

on slopes.

♦ Avoid sudden turns or rapid speed

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

area to be mowed.

• Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water. This area can be dangerous, see Figure 1.

changes.

FIGURE 1

• Progr essively great er care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. I f tires lose traction,

disengage the blades and proceed slowly off the slope.

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

• Be aware that loss of traction may occur going downhill. Weight transf e r t o

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

• Watch for ditches, holes, rocks, dips, and rises that chang e t he oper ating angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing area. Tall grass can hide obstacles.

• Use extreme care with grass cat chers or attachments. These can change t he stability of the machine and cause loss of control.

• Follow the manufact urer’s recommendations for wheel weights or counterweights to improve stability.

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

WARNING

POTENTIAL HAZARD ♦ There is no rollover protection when the

roll bar is down. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning. HOW TO AVOID THE HAZARD

♦ Keep the roll bar in the raised and locked

position and use seat belt.

♦ Lower the roll bar only when absolutely

necessary.

♦ Do not wear seat belt when the roll bar is

down.

♦ Drive slowly and carefully. ♦ Raise the roll bar as soon as clearance

• Be certain t hat the seat belt can be released quickly if the m achine is dr iven or

rolls into ponds of water.

permits.

• Check carefully for overhead clearances (i.e. branches, door ways, and electrical wires) before driving under any objects and do not contact them.

1.4.6 Use EXTREME caution when backing up. LOOK BEHI ND YO U!

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

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

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

1.4.10 Disengage PTO before starting engine.

1.4.11 Start

the engine carefully with feet well away from the blades.

1.4.12 Keep hands, feet, and clothing away from rotating part s while the mower is being operated.

1.4.13 Stop engine, wait for all moving parts t o stop, and remove key. Engage park ing brake:

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

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

repairs before restart ing and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

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

• Before refueling.

• Before dumping the gr ass cat c her .

1.4.14 Before stopping the engine, place the throt t le cont r ol midway between the “slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.

1.4.15 The f uel system is pr ovided with a shut-off valve. Shut off the fuel:

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

• During t r anspor t to and from the job.

• When parked inside a building.

1.4.16 This mower was designed fo r one oper at or only. Keep all others away from mower during operation.

1.4.17 Do Not mow with the discharge deflector raised, removed or altered unless ther e is a grass collection system or mulch kit in place and work ing properly.

1.4.18 Be aware of the mower discharg e and dir ect discharge away from others.

1.4.19 Do Not operat e m ower under t he influence of alcohol or drugs.

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

1.4.21 If jump starting is required:

a) connect the positive (+) power cable fr om t he positive post on the booster

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

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

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

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

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine m anufacturer’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable from t he negative battery post when the unit will be

allowed to sit for more than 30 days without use.

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

will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storag e.

1.5.4 Keep engine, engine area, and pump drive belt compar tment free fr om

accumulation of grass, leaves, excessive grease or oil, and ot her debris which can accumulate in these areas. These materials can become com bustible and may result in a fire.

1.5.5 Store fuel in a container specif ically desig ned for this purpose in a cool, dry

place.

1.5.6 Keep the mower and fuel container in locked storage to prevent children from

playing or tampering with them.

1.5.7 Gasoline powered equipment or fuel containers should not be stored in a

basement or any enclosed area where open pilot lights or heat appliances are present.

1.5.8 Maximum mowing results and safety can only be achieved if the mower is

properly maintained and operated correctly.

1.5.9 Check all bolts frequently to maintain proper tightness.

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

condition.

1.5.11 Frequently check for worn or deteriorating com ponent s that could create a

hazard.

1.5.12 All replacement parts must be the same as or equivalent t o the parts supplied as

original equipment.

WARNING

POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure

can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin

must be surgically removed within a few

hours by a doctor familiar with this for m of

injury or gangrene may result. HOW TO AVOID THE HAZARD

♦ Make sure all hydraulic fluid hoses and

lines are in good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

♦ Keep body and hands away from pinhole

leaks or nozzles that eject high pressure hydraulic fluid.

♦ Use cardboard or paper, not your hands,

to find hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic

system by placing the motion control

levers in neutral and shutting off the

engine before perfor m ing any work on the

hydraulic system.

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sur e that current safety signs are affixed to the replaced components.

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

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

1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They

are critical to the safe operation of your Exmark commercial mower.

PART NO. 1-513746 LOCATIONS: Rear RH

PART NO. 98-5954 LOCATION: Under Mower Deck

Frame

Belt Shield(s)

PART NO. 103-6700 LOCATION: Panel behind

LH Fuel Tank

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

of Mower Deck

DO NOT OPERATE WITHOUT GUARD

IN PLACE.

1-513748

PART NO. 1-513748 LOCATIONS: Bottom Side

of Floor

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

Belt Shields, Left and Right

Sides

PART NO. 109-1214 LOCATION: LH Side of Console

LOCATION: Left of Center on Mower

Deck, Under Floor

Pan

PART NO. 103-1798 LOCATION: Right of Throttle

PART NO. 107-2102 LOCATION: Inside Surface of

Upper Roll bar

PART NO. 103-4930 LOCATION: Right of Choke

Control on RH Fuel Tank

PART NO. 109-0872 LOCATION: LH Side on Top Front

of Mower Deck

PART NO. 109-1215 LOCATION: RH Side of Console

Control on RH Fuel Tank

PART NO. 103-6936 LOCATION: Rubber Heat Shield

Flap Behind Seat

PART NO. 1-523552 LOCATION: Top of Hydraulic

Reservoir,

PART NO. 109-3148 LOCATION: LH Side on Top Front

of Mower Deck

PART NO. 103-0262 LOCATION: RH Front of

Console

PART NO. 109-2219

PART NO. 103-5881 LOCATION: Rubber Heat Shield Flap

behind

Seat

PART NO. 103-7218 LOCATION: Under Seat, Between

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

Height Adjustment Plate

PART NO. 103-7616 LOCATION: Top Front of RH

Fuel Tank

PART NO. 109-1921 LOCATION: Back of Seat

PART NO. 1-403005 LOCATION: Left and Right

Corners of Mower Deck

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

PART NO. 109-1399 LOCATION: Front Center on Top of Mower Deck

PART NO. 107-9866 LOCATION: Top of Console

Pumps on Frame

2. SPECIFICATIONS

2.1 MODEL NUMBER

Serial Nos. 600,000 and Higher: LXS31BV605; LX S31BV665, LXS35BV725

2.2 ENGINE

2.2.1 Engine Specifications: See your Engine Owner’s Manual

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

2.3 FUEL SYSTEM

2.3.1 Capacity: 15.5 gal. (56.8 L.)

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

2.3.3 Fuel Filter: In-line 30 Micron Briggs P/N 695327.

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

2.3.5 Fuel gauge in left hand fuel tank.

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 20 amps

2.4.3 Battery Type: BCI Group U1

2.4.4 Battery Voltage: 12 Volt

2.4.5 Polarity: Negative Ground

2.4.6 Fuses: Two 20 amp blade type

2.4.7 Safety Interlock System:

PTO must be disengaged, brake engaged, and motion control l evers out

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

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

motion control levers are moved in or engine will stop.

Engine will stop if either the left, the right, or both levers are moved from neutral

lock position while brake is engaged.

2.5 OPERATOR CONTROLS

2.5.1 Steering and Motion Control:

Separate levers, on each side of the console, contr ol speed and dir ect ion of travel of the respective drive wheels.

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

2.5.2 PTO Engagement Switch mower blades.

2.5.3 Parking Brake Lever

2.5.4 Deck Height Adjustment Lever

2.5.5 Deck Lift Assist Lever:

2.6 SEAT

2.6.1 Type: Deluxe suspension seat high back, low profile f oam - in- place cushion ( dam pened,

adjustable spring suspension) and armrests, adjustable back angle.

(in slots) locks the drive system in neutral.

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

: Engages parking brake.

: Sets cutting height to desired position.

Foot pedal that assists in raising the deck .

2.6.2 Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other

components. Held in tilted position with scissor-type links. Adjustable fore and aft seat track.

2.6.3 Armrests: Molded adjustable flip-up

armrests.

2.6.4 Seat Safety Switch: Incorporated into t he Safety Interlock System. T ime delay seat

switch eliminates rough ground cut-outs.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

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

2.7.2 Wheel Motors: T wo Park er / Ross with 1 1/4” t aper ed shafts.

2.7.3 Hydraulic Oil Type: Use Mobile 1 15W-50 Synthet ic m o t or oil.

2.7.4 Hydraulic Oil Capacity: 5.5 qt. (5. 2 L.)

2.7.5 Hydraulic Filter: Replaceable cartridge type.

P/N 103-2146: 25 microns, No bypass

2.7.6 Speeds: 0-12. 0 mph (19.3 km/hr) f orward

0-8.0 mph (12.9 km/hr ) r everse

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

2.8 TIRES

Drive Front Caster

Pneumatic (Air-Filled) Semi-Pneumatic

Quantity 2 2 Tread “Multi-Trac C/S” Smooth Size 26 x 12.00-12 13 x 6.50-6 Ply Rating 4 Pressure 10 psi (69 kPa)

2.9 CUTTING DECK

2.9.1 Cutting Width: 60 in. (152.4 cm)

66 in. (167.6 cm) 72 in. (182.9 cm)

2.9.2 Discharge: Side

2.9.3 Blade Size: (3 ea.) 60” Deck: 20.75 in. (52.7 cm)

66” Deck: 22. 75 in. (57.8 cm) 72” Deck: 24. 75 in. (62.9 cm)

2.9.4 Blade Spindles: Solid steel spindles with 1.18 in (3.00 cm) I.D. bear ings.

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

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

shaft on deck to blade spindles.

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

Deck Depth 66” Deck: 6.0” (15.2 cm) 72” Deck: 6.0” (15.2 cm)

2.9.7 Cutting Height Adjustm ent : an extr a- long cushioned lever is used to adjust the cutting heig ht from 1” (2.5 cm) to 5” ( 10. 2 cm .) in 1/4”(.64 cm) increments. The cutting height adjustm ent handle has a t ransport position and all adjustments can be made while the operator rem ains seat ed. Units also have a foot operated deck lift assist lever t o aid in r aising the deck.

2.9.8 Mulching Kit: Optional.

: 60” Deck: 6.0” (15.2 cm )

2.10 DIMENSIONS

2.10.1 Overall Width:

60” Deck 66” Deck 72” Deck

without deck deflector up deflector down

53.5 in. (135.9 cm) 61.4 in. (155.8 cm) 72.8 in. (184.9 cm)

57.3 in. (145.5 cm) 68.0 in. (172.7 cm) 79.4 in. (201.7 cm)

61.5 in. (156.2 cm) 74.3 in. (188.7 cm) 85.8 in. (217.9 cm)

2.10.2 Overall Length:

60” Deck 81.9 in. (208.0 cm) 92.5 in. (235.0 cm) 66” Deck 83.4 in (211.8 cm) 94.0 in (238.8 cm) 72” Deck 85.8 in. (217.9 cm) 96.4 in. (244.9 cm)

Roll Bar – Up Roll Bar - Down

2.10.3 Overall Height:

60”, 66” & 72” Decks 72.7 in. (184.7 cm) 53.6 in. (136.1 cm)

2.10.4 Tread Width: (c ent er to center of tires, widthwise)

60” Deck 41.9 in. (106.4 cm) 37.3 in. (94.7 cm) 66” Deck 45.9 in. (116.6 cm) 42.3 in (107.4 cm) 72” Deck 45.9 in. (116.6 cm) 47.3 in. (120.1 cm)

Drive Wheels Casters

2.10.5 Wheel Base: (center of caster to center of dr ive tire)

Roll Bar - Up Roll Bar - Down

60” Deck 56.0 in. (142.2 cm) 66” Deck 57.6 in. (146.3 cm) 72” Deck 60.2 in. (152.9 cm)

2.10.6 Curb Weight:

60” Deck 1510 lbs. (685 kg) 66” Deck 1560 lbs. (708 kg) 72” Deck 1610 lbs. (730 kg)

2.11 TORQUE REQUIREMENTS

Bolt Location Torque

Blade Drive Sheave Mounting Nut...............................90-110 ft-lbs. (122-149 N-m)

Cutter Housing Spindle Nut .....................................160-185 ft-lbs. (217-251 N-m)

Blade Mounting Bolt (lubricate with anti-seize)...................55-60 ft-lbs. (75-81 N-m)

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

Anti-Scalp Roller (See Figure 6)

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

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

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

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

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

Wheel Hub Slotted Nut.............................................minimum 125 ft-lbs. (169 N-m)

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

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

3. OPERATION INSTRUCTIONS

3.1 CONTROLS

3.1.1 Familiarize yourself with all controls before operating the mower.

3.1.2 Motion Control Levers

: Located on each side of the console. The left lever controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor. The right lever controls the flow of hydraulic oil from the r ight hydrostatic pump to the right drive wheel motor.

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

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

When levers are centered in the T-slot the drive system is in the neutral posit ion.

With levers moved out in t he T-slot the drive system is in the neutral lock position (See Figure 2).

FIGURE 2

By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line.

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

To turn left while moving forward, move the left lever back toward neutral to slow the left drive wheel.

To turn right while moving forward, move the right lever back toward neutral t o slow the right drive wheel.

To make a zero turn to the left, pull the left lever back beyond neutral while holding the right lever slight ly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutral while holding the left lever slight ly ahead of neutral.

Pulling the levers back from t he neutral position will cause the respective drive wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutr al) .

To turn to the left while backing, move the left lever f o r ward toward neutral. To turn to the right while backing , m ove the right lever forward toward neutral.

CAUTION

POTENTIAL HAZARD ♦ Machine can spin very rapidly by

positioning one lever too much ahead of

the other. WHAT CAN HAPPEN ♦ Operator may lose control of the

machine, which may cause damage to

the machine or injury. HOW TO AVOID THE HAZARD

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

3.1.3 Tracking Adjustm ent Knob: Locat ed under the seat on the LH pump control link. Rotating this k nob allows f ine t uning adjustments so that the machine tracks straight with the dr ive levers in the full forward position.

Stop machine and wait for all moving parts t o stop. Engage park brake. Unhook

seat latch and tilt seat forward to gain access to the tracking k nob. Rotate the knob clockwise (as viewed from the rear of the machine) to cause the machine to track more to the right and counterclockwise to cause the machine to track more to t he left. Adjust in quar ter-turn increments until the m achine t racks straight. Check that the machine does not creep when in neutral with the park brakes disengaged.

sharp turns.

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

to creep in neutral. Refer to section 4.2. 11 f or cont rol l inkage adjustment.

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

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

3.1.5 Choke Control

: Located on right fuel tank.

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

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

3.1.6 Throttle Control

: Located on right fuel tank.

Throttle is used to control engine speed. Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed.

3.1.7 Brake Lever

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

brake lever engages a parking brake on the drive wheels.

Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage the brake.

The unit must be tied down and brake engaged when transpor ting.

3.1.8 Ignition Switch

: Located on right fuel tank.

The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise to the “ON” position. Rotat e clockwise to the next position to engage the starter (key must be held against spring pr essur e in t his position).

: Located on right fuel tank.

Brake must be engaged, motion control levers out (neutr al lock position) and PTO switch “OFF” to start engine. (It is not necessary for the operator to

be in the seat to start the engine. )

3.1.9 Hour Meter

: Located on the right fuel t ank. The hour meter is connected to a pressure switch installed in the engine block and it record s t he num ber of hours that the engine has run. If the ignition switch is left on without engine running, hour meter will not run.

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

engine oil is low.

3.1.10 Fuel Shut-Off Valve

: Located directly below right side of console, next to cubby. The fuel shut-off valve is used to shut off the fuel when the machine will not be used for a few days, during transport to and from the job site, and when parked inside a building. The valve has three positions, each position made in 1/ 4 t urn increments.

FUEL FLOW VALVE HANDLE POSITION

“OFF” DOWN

RIGHT TANK RIGHT

LEFT TANK LEFT

3.1.11 Fuel Gauge: Located on the left fuel tank. The fuel gauge monit ors the amount of fuel in t he left tank only. Use the f uel

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

3.1.12 Drive W heel Release Valves

: Located on the top right f r ont cor ner of hydrostatic pumps. Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running. Unhook seat latch and tilt seat up to gain access to pum ps.

With a 5/8 wrench, t ur n both valves one turn counter-clockwise to release drive

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

3.2 PRE-START

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

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

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

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

3.2.3 Refer to Maintenance, Section 4, and perf orm all the necessary inspection and maintenance steps.

3.3 OPERATING INSTRUCTIONS

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

3.2.2 Open fuel shut-off valve

(left or right tank).

3.2.3 Starting Engine

Brake must be engaged, motion control levers out (neutr al l ock position) and PTO switch “OFF” to start engine. (It is not necessary for the operator to be in

the seat to start the engine. ) On a cold engine, place the throttle midway between the “SLOW” and “FAST”

positions and push choke lever forward into the “O N” posit ion. Turn ignition switch to the “start” position. Release the switch as soon as the engine starts.

IMPORTANT:

DO NOT crank the engine continuously for more then ten (10) seconds at a time. If the engine does not st art , al low a 60 second cool-down period between starting at t empt s. Failure to follow these guidelines can burn out the starter motor.

After starting a cold engine, gradually return choke to the “OFF” position as the engine warms up.

On a warm engine, place the throttle midway between the “SLOW” and “FAST” positions and leave the choke in the “OFF” position.

3.2.4 Engaging PTO

DANGER

POTENTIAL HAZARD ♦ The rotating blades under the mower

deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or

kill you. HOW TO AVOID THE HAZARD ♦ DO NOT put hands or feet under t he

mower or mower deck when the blades

are engaged.

DANGER

POTENTIAL HAZARD ♦ An uncovered discharge opening will

allow objects to be thrown in an

operator’s or bystander’s direction. Also,

contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can

cause serious injury or death. HOW TO AVOID THE HAZARD ♦ Never operate the mower with the

discharge deflector raised, r emoved, or

altered unless there is a grass collection

system or mulch kit in place and working

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

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

properly.

IMPORTANT

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

position. Accelerate to full throttle to begin mowing.

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

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

Before stopping the eng ine, place t he throttle control midway between the “slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.

Rotate ignition switch to “OFF” posit ion. Rem o ve the key to prevent children or other unauthorized persons from star t ing engine.

Close fuel shut-off valve when machine will not be used for a few days, when transporting, and when the unit is park ed inside a building.

3.4 TRANSPORTING

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

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

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

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

CAUTION

POTENTIAL HAZARD ♦ This unit does not have proper turn

signals, lights, reflective markings, or a slow moving vehicle emblem. These items are required to drive on a public street or roadway.

WHAT CAN HAPPEN ♦ Driving on a street or roadway without

such equipment is dangerous and can lead to accidents causing personal injury.

♦ Driving on a street or roadway without

such equipment may also be a violation of State laws and the operator may be

subject to traff ic tickets and/or fines. HOW TO AVOID THE HAZARD ♦ Do not drive a unit on a public street or

roadway.

WARNING

POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck

increases the possibility of backward tip-

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

serious injury or death. HOW TO AVOID THE HAZARD

♦ Use extreme caution when operating a

unit on a ramp.

♦ Use only a single, full width ramp; DO

NOT use individual ramps for each side of the unit.

♦ If individual ramps must be used, use

enough ramps to create an unbroken ramp surface wider than the unit.

♦ DO NOT exceed a 15° angle between

ramp and ground or between ramp and trailer or truck.

♦ Avoid sudden acceleration while driving

unit up a ramp to avoid tipping backward.

♦ Avoid sudden deceleration while backing

unit down a ramp to avoid tipping

backward.

3.4.2 Loading a Unit full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps f or each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.

If it is not possible to use one f ull width ram p, use enough individual ramps to simulate a full width continuous ramp.

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

DO NOT attempt to tur n t he unit while on the ramp, you may lose control and drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward.

: Use extreme caution when loading units on trailers or t rucks. One

4. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD ♦ While maintenance or adjustments are

being made, someone could start the

engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could

seriously injure you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ignition switch,

engage parking brake, and pull the wire(s)

off the spark plug(s) before you do any

maintenance. Also push the wire(s) aside

so it does not accidentally contact the

spark plug(s).

WARNING

POTENTIAL HAZARD ♦ The engine can become very hot. WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe

burns. HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before

service or making repairs around the

4.1 PERIODIC MAINTENANCE

4.1.1 Check engine oil level:

Service Interval: Daily

a) Stop engine and wait for all moving parts to stop. Make sure unit is on a

level surface. b) Check with engine cold. c) Clean area around dipstick. Rem ove dipstick and wipe oil off. Reinsert the

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

read the oil level. d) If the oil level is low, wipe off the area around the oil fill cap, r e m ove cap and

fill to the “FULL” mark on the dipstick. Use oil as specified in Engine

Owner’s Manual. DO NOT overfill.

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

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

engine area.

4.1.2 Check battery charge

Service Interval: Monthly

Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and ser vice life. To preserve optimum

battery performance and lif e, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storag e.

a) Check the voltage of the battery with a digital voltmeter . Locate the voltage

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

IMPORTANT: Make sure the negative battery cables are disconnected and the battery charger used for char ging the battery has an output of 16 volts and 7 amps or less to avoid damaging the batter y (see char t below for recommended charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

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

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

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

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

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

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

4.1.3 Clean engine cooling system:

Service Interval: Dai l y or more of t en in dry conditions

CAUTION

POTENTIAL HAZARD ♦ Excessive debris and damaged or

missing rubber baffles can cause t he

engine and hydraulic system to overheat. WHAT CAN HAPPEN ♦ Excessive debris around the engine

cooling air intake and inside of t he pump

drive belt compartment can create a f ir e

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

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

parking brake.

b) Clean all debris from rotating engine air intake scr een and from around

engine shrouding.

c) Inspect rubber engine baffles for proper fit . Replace if necessary.

4.1.4 Clean grass build-up under deck

Service Interval: Daily

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.

b) Raise deck to the transpor t (5” (12.7 cm) cutting heig ht ) position. Lift the

front of unit and support unit using jack stands or eq uivalent support.

belt compartment daily.

CAUTION

POTENTIAL HAZARD ♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

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

hydraulic jacks for support. Use adequate

c) Clean out any grass build-up from underside of deck and in discharge chute.

4.1.5 Check mower blades

Service Interval: Daily

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

parking brake. b) Lift deck and secure in raised position as stated in Section 4.1. 4. c) Inspect blades and sharpen or replace as r equired. d) Re-install the blades (if they were removed) in the following order (See

Figure 3):

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

jack stands or equivalent support.

side of blade.

2) Install bushing/blade combo into spindle.

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

FIGURE 3

IMPORTANT: DO NOT use components other than the original blade, blade

bushing, spring disc washer, and blade bolt supplied with the unit. Failure t o use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or weak after striking a foreign object.

CAUTION

POTENTIAL HAZARD ♦ Operating a mower deck with loose or

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

allow a blade rotating at a high speed to

come out from under the deck , causing

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

blade bushings, spring disc washers, and

blade bolts in the correct positions as

4.1.6 Check safety interlock system.

Service Interval: Daily

a) Check starting circuit. Starter should cr ank with, parking brake engaged,

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

Try to start with operator in seat, parking brak e disengaged, PTO

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

Try to start with operator in seat, parking brak e engaged, PTO engaged and motion control levers in the neutral lock position - starter must not crank.

Try to start with operator in seat, parking brak e engaged, PTO disengaged, and the left motion control lever in, starter must not crank, repeat again with the right lever in, then with both levers i n - starter must not crank.

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

brake and raise off of seat ( but do not get off of machine) engine must stop after approx. 1/2 second has elapsed (seat switch circuit has a t ime delay switch to prevent cut-outs on rough terrain).

Run engine at one-third throttle, engage PTO and raise off of seat (but do not get off of machine) engine must stop af t er 1/2 second has elapsed.

Run engine at one-third throttle, with brake disengaged, move levers in and raise off seat (but do not get off of machine) engine must stop aft er 1/ 2 second has elapsed.

Again, run engine at one-thir d throttle, brake engaged, and move left motion control lever in - engine must st op.

Repeat again moving the right lever in, t hen m oving bot h l evers in - engine must stop whether operator is on seat or not.

shown.

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

Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that operator safety mechanisms be

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

4.1.7 Check rollover protections systems (roll bar) pins

Service Interval: Daily

a) Make sure latch pin and hair pin are fully installed and lanyard is in good

condition.

4.1.8 Check for loose hardware

Service Interval: Daily

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

4.1.9 Service air cleaner

First Service Interval: 50 hrs.

Normal Service I nt erval : 100 hrs. Replacement Interval: 600 hrs. (More of t en under severe condi t ions.) See Engine manual f or additional information.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Unhook seat latch and tilt seat up to gain access to the air cleaner. c) Loosen retaining clips and remove air cleaner compartment cover. d) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damag ed. e) Check the condition of t he inner element. Replace whenever it appears

dirty, typically every other time the paper element is replaced. Clean t he

base around the inner element before removing, so dirt does not get into

the engine. f) DO NOT wash or use pressur ized air to clean paper elem ent or inner

element. g) Reinstall elements. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

4.1.10 Change engine oil and oil filter

First Service Interval: 50 hrs. Normal Service Interval: 100 hrs. (yearly if operated less t han 100 hrs. )

(more often under heavy load or high temperat ures)

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Drain oil while engine is warm from oper ation. c) The oil drain is located on right hand side of engine.

Place pan under machine to catch oil. Remove plug from oil drain hose.

Allow oil to drain, then replace plug. Torque plug to 20-24 ft-lbs. d) Clean around oil filter and unscr ew f ilt er to remove. Before reinst alling new

filter, apply a thin coating of oil on the surface of t he rubber seal. Turn filter

clockwise until rubber seal contacts the filter adapter then tighten filter an

additional 1/2 to 3/4 turn.

e) Clean around oil fill cap and remove cap. Fill t o the specified capacity and

replace cap. Use oil recommended in engine owner’s manual. DO NOT

overfill. f) Replace oil fill cap. Start the engine and check for leaks.

4.1.11 Check hydraulic oil level

Service Interval: 40 hr.

a) Stop engine and wait for all moving parts to stop. Engage parking brake. b) Clean area around hydraulic reservoir cap and remove cap. Oil level

should be to the top of the baf fle inside the tank. If not, add oil. Use only

Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap and

tighten until snug. Do not overt i ghten.

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

the temperature of the oil. The “HOT” level shows the level of oil when it is

at 225°F (107°C). The “COLD” level shows the level of the oil when it is at

75°F (24°C). Fill to the appropriat e level depending upon the temperature

of the oil. For example: If the oil is about 150°F (65°C), fill to halfway

between the “HOT” and “COLD” levels. If the oil is at room temperatur e

(about 75°F (24°C)), fill only to the “COLD” level.

4.1.12 Check tire pr essur es

Service Interval: 40 hrs.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Check tire pressure in drive tires. c) Inflate drive tires to 10 psi (69 kPa). d) Semi-pneumatic caster tires do not need to be inflated.

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

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

4.1.13 Check condition of belts

Service Interval: 40 hrs.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Unhook seat latch and tilt seat up. Lift the rubber flap on front side of the

engine to check pump drive belt. c) Remove left and right belt shields on deck and lift up floor pan to inspect

deck drive belt. d) Check under machine to inspect t he mule drive belt. e) See Sections 4.2.3, through 4.2.5 for belt adjustm ent.

4.1.14 Lubricate gr ease fittings

Service Interval: Refer to chart.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Lubricate fittings with one to two pumps of NGLI grade #2 multi- pur pose

gun grease.

Refer to the following chart for fitting locations and lubrication schedule.

LUBRICATION CHART

FITTING

LOCATIONS

1. Front Caster wheel hubs

2. Front Caster Pivots

3. Height Adj. Shaft Bearings 1 5 40 hours

4. Deck Drive Belt Idler Arm

5. Brake Brackets 1 2 200 hours

6. Mule Drive Belt Idler Arm

7. Pump Drive Belt Idler Arm

8. Deck Rear Struts 1 2 40 hours

∗ See Section 4.1.14 c) f or special lubr ication instructions on the front cast er pivots and

Section 4.1.15 for special lubrication inst r uct ions on the front casters wheel hubs.

INITIAL PUMPS

∗0 ∗0

1 1 Yearly

1 1 Yearly 1 1 Yearly

NO. of

PLACES

2 2

SERVICE

INTERVAL

∗yearly ∗yearly

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

No. 7 (Pump Dri ve Bel t Idler Arm) Located Under Engine Frame

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

grease zerk in hole and pump with grease until it oozes out around top

bearing. Remove grease zerk and thr ead plug back in. Place cap back on.

4.1.15 Lubricate caster wheel hubs:

Service Interval: Once Yearly

a) Stop engine, wait for all moving parts to

stop, and remove key. Engage park ing

brake. b) Remove caster wheel from caster forks. c) Remove seal guards from t he wheel hub. d) Remove one of the spacer nuts from the

axle assembly in the caster wheel. Note

that thread locking adhesive has been

applied to lock the spacer nuts to the axle.

Remove the axle (with the other spacer nut

still assembled to it) fr om t he wheel

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

or damage and replace if necessary. f) Pack the bearings with a NGLI grade #1 multi-purpose grease. g) Insert (1) bearing, (1) new seal into the wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

FIGURE 4

h) If the axle assembly has had both spacer nuts removed (or broken loose),

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

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

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

surface of the spacer nut to the end of the axle inside the nut. i) Insert t he assem bled nut and axle into the wheel on the side of the wheel with

the new seal and bearing. j) With the open end of the wheel facing up, fill the area inside the wheel

around the axle full of NGLI grade #1 multi-purpose grease. k) Insert the second bearing and new seal into the wheel. l) Apply a thread locking adhesive to the 2

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

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

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

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

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

than 1 or 2 revolutions) or have any side play. If the wheel spins freely,

adjust torque on spacer nut until there is a slight amount of drag. Re-apply

threadlocking adhesive.

4.1.16 Lubricate brake handle pivot

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and r em o ve k ey. Engage

parking brake.

b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant

or light oil.

4.1.17 Lubricate brake rod bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Unhook seat latch and tilt seat up. c) Lubricate bronze bushings on each end of br ake rod shaft with a spray type

lubricant or a light oil (bushings ar e locat ed to the inside of the flange bear ings).

4.1.18 Lubricate mot ion control bronze bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Unhook seat latch and tilt seat up. c) Lubricate bronze bushings on f lange bearings securing the motion control

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

4.1.19 Remove accumulated debris from engine

Service Interval: Daily

Engine parts should be kept clean to reduce t he r isk of overheating and ignition of accumulated debris.

a) Stop engine, wait for all moving parts to stop, and r em o ve k ey. Engage

parking brake.

spacer nut and thread onto the

b) Remove front carburetor cover from engine and clean around the intake

manifold and carburetor.

c) Reinstall the carburetor cover

4.1.20 Check spark plugs

Service Interval: 160 hrs.

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

plugs. See Engine Owners Manual.

4.1.21 Change fuel filter

Service Interval: As Requi red

a) A fuel filter is installed between the fuel tank s and t he engine. Replace

when necessary.

Replacement Filters Briggs and Strattton Briggs P/N 695327

4.1.22 Change hydraulic system filter:

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

NOTE: Use only Exmark Part No. 103- 2146.

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

parking brake. b) Raise seat. c) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system. d) Unscrew filter to remove and allow oil to drain from reser voir.

IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and

apply a thin coat of oil on the surface of the rubber seal.

Turn filter clock wise until rubber seal contacts the filter adapter , t hen

tighten the filter an addit ional 2/ 3 to 3/4 turn. e) Fill reservoir as stated in Section 4.1.11 f) Raise the rear of machine up and support with jack stands (or equivalent

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

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

Shut down machine and recheck oil level.

Do not change hydraulic system oil more frequently than recommended

(except for what can be drained when changing filter), unless it is felt the oil

has been contaminated or been extremely hot.

Changing oil unnecessarily could damage hydraulic system by

introducing contaminates into the system.

4.1.23 Wheel hub

- slotted nut torque specification.

Service Interval: 500 hrs When tig ht ening the slotted nut on the wheel motor tapered shaft:

a) Torque t he slot ted nut to 125 ft. lbs (169 N-M). b) Check distance f rom bottom of slot in nut t o inside edge of hole. Two

threads (0.1”) or less should be showing.

c) If more than two threads ( 0. 1” ) are showing remove nut and install washer

(PN 1-523157) between hub and nut.

d) Torque t he slot ted nut to 125 ft. lbs (169 N-M).

e) Then tighten nut until the next set of slots line up with the cross hole in shaf t . f) Replace cotter pin.

NOTE: Do not use antiseize on wheel hub.

4.1.24 Fuel Tank

– mounting hardware specification.

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

back off 1/2 t ur n . This allows for normal fuel tank expansion and contr action with changes in temperature and fuel levels.

4.1.25 Thread lock ing adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

a) Pump dr ive sheave set screws. b) Sq uar e head setscrews on Hydro pump control arms. c) Sheave retaining bolt in the end of engine crankshaft. d) Caster wheel spacer nuts e) Fuel tank bulkhead fitting nut s.

Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro

Pro-Lock Retaining I

or Retaining II” are used on the following:

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

4.1.26 Mobil HTS grease (or food-grade antiseize) is used in the f ollowing locat ions: a) Between the cutter housing spindle and bearings. b) Between jack shaft and bearings and jackshaft and sheaves.

4.1.27 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

4.2 ADJUSTMENTS

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

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

4.2.1 Cutting Height Adjustm ent

a) Stop machine and move drive levers out to neutral lock position. b) Disengage PTO. c) Raise the deck lever to the transport position (also the 5” (12.7 cm ) cut ting

height position). See Figure 5. The deck can be raised by pulling the deck lever up and/or by pushing on

the deck lift assist lever.

NOTE: When changing cutting height positions, al ways come to a complete stop and disengage the PTO.

d) Insert height adjustment pin into hole corresponding to desired cutting

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

FIGURE 5

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

down onto height

adjustment pin to mow at selected height.

f) To transport, move lever back up t o t r anspor t (or 5” (12.7 cm) cutting

height) position.

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

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

g) Adjust anti-scalp rollers for Norm al O perating Conditions. Place rollers in one

of the positions shown in Figure 10. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize goug ing and roller wear or damage.

For Maximum Deck Flotation, place rollers one hole posit ion lower. Rollers should maintain 1/4 in. (6.4 mm ) clearance to ground. Do Not adjust rollers to support the deck. Be sure roller bolts and nuts are installed with the spring disc washer between head of the bolt and mounting bracket. T or que the 3/8-24x2 Gr 8 hex capscrew to 50-55 ft-lbs (68-75 N-m)

FIGURE 6

4.2.2 Deck Leveling a) Position m ower on a flat surface. b) St op engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

c) Check tire pressure in drive tires. Pr oper inflation pressure for t ires is 10

psi (90 kPa). Adjust if necessar y.

d) Set ant i- scalp rollers to top holes or remove them complet ely for this

adjustment.

e) Raise the deck to the 5” (12.7 cm) heig ht position (also transport position)

and take all force of f of the two large deck lift springs by loosening the nuts at the front of each spr ing. See Figure 7.

f) Lower the deck to t he 1” (2.54 cm) height position. For ce t he left rear deck

support arm downward about 1/4” (6.4 mm) to g et the deck to rest at the 1” height position. Place locking plier s bet ween the rear swivel and spring stop to hold the deck in this position. See Fig ur e 7.

g) Place a 3/4” (19 mm) thick block of wood under each of the two (2) rear

anti- scalp roller brackets and place one under one of t he front center anti-scalp roller brackets.

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

jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose. T ur n t he socket head adjusting screws in until slack is taken out of each chain. Tighten the jam nuts. Tighten the chain bolts in the deck lift ar m s m aking sure they don’t move while tightening.

i) Loosen the four (4) nuts which secure the front swivels (two per side) until

the front chains are loose and front of deck is supported by the 3/4” ( 19 m m ) block. Do not loosen the front chain har dware.

j) On left side, adjust front swivel using the lock ing nut behind the swivel until

the front chain is tight and all slack is removed from linkage. Do not lift fr ont of deck off 3/4” (19 mm) block. Secur e front swivel using locking nut in fr ont of swivel. Repeat for right side.

k) Recheck that the 3/4” ( 19 m m) blocks fit just snug ly under t he br ackets and

that the tension on all the chains is approximately equal. Make sur e all chain attachment bolts are tight. Reposition anti-scalp rollers and tighten securely.

For 72” Deck

Place locking pliers

here to hold spring

For 72” Deck

Apply downward

pressure here

11 ½” (29.2 cm)

Remove force on

deck springs by

loosening nuts here

Jam nut

Socket head

usting screw

G0888

Front of Unit

Swivel

FIGURE 7

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

Adjust spring compression until proper distance is obtained between the two large washers (See Figure 7). Adjustm ent is made by turning the nut at the front of each spring ( c lockwise will shorten the spring, counter-clockwise will lengthen the spring). Lock in position with jam nuts.

NOTE: When above adjustments have been made, the front of the

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

4.2.3 Pump Drive Belt Tension

Self-tensioning - No adjustment necessary.

4.2.4 Mule Drive Belt Tension Adjustment

Self-tensioning idler, adjust as follows :

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.

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

loaded pulley, on left side engine deck support, is positioned between the centers of the two alignment holes in t he left support plate (See Figure 8) . It is necessary to adjust the belt tension when the center of the bolt head is at or below the center of the bottom alignment hole.

c) When adjustm ent is necessary, loosen the idler pulley on the right-hand

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

apply upward pressure to relieve tension on the spring (a 1/2” drive break er bar and 9/16 socket works best).

Reposition the adjusting pulley to the bottom of the slot. NOTE: When installing a new belt, it is necessary to reposition the r ight

adjusting pulley upward in the slot in order to position the cent er of the spring loaded pulley between the alignment holes.

FIGURE 8

4.2.5 Deck Belt T ension

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

necessary.

4.2.6 Belt Guide Adjust ment

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Remove the belt shield on the right side of mower deck. c) Note belt guide bolted to deck near the shield suppor t stud and right-hand

pulley. Guide should be 1/8” ( 3. 2 mm) away from the belt, with bolt-end of

guide near end of slot (See Figur e 9). d) If adjustm ent is necessar y, loosen t he bolt securing the belt guide and

make proper adjustment. Tighten hardware.

FIGURE 9

4.2.7 Brake Link Adjustment .

Check to make sure br ake is adjusted properly.

a) Disengage brake lever (lever down). b) Measure the length of the spring. Measurement should be 2 3/4” (7.0 cm)

between washers (see Figure 10).

c) If adjust m ent is necessar y, adj ust the nyloc nut at the bottom of the spr ing

to achieve 2 3/4” (7 cm). d) Engage the brake lever (lever up). e) The space between the brake spring bracket and the nyloc nut under the

spring should measure the following:

For S/N 603,518 and lower - 1/4” to 5/16” (6.4 – 7.9 mm) For S/N 603,519 and higher - 1/ 16” to 3/16” (1.5-4.8 mm)

f) If adjust m ent is necessary, loosen jam nut above the trunion roller. Adjust

the nyloc nut under the trunion roller until distance list ed above exists

between the spring retainer bracket and t he adj acent nyloc nut. Tighten the

jam nut above the trunion roller. g) If a the correct gap can no longer be achieved because there is no clearance

between nyloc nut below the spring and the jam nut above the trunion or there

are no threads left on the bott om nyloc nut, t he length of the brake rod can be

adjusted. Remove a pin from a yoke at eit her end of the brake rod and

lengthen (or shorten) the brake rod until the correct gap can be achieved by

following steps e) and f).

FIGURE 10

4.2.8 Adjust Throttle Lever Tension

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

parking brake.

b) Tension in thr ot tle lever can be adjusted by adjusting the tightness of the

lever pivot bolt, which is located under the console (See Figure 11).

FIGURE 11

4.2.9 Electric Clutch Adjustment

No adjustment necessary.

4.2.10 Reverse Indicator Adjustment

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Unhook seat latch and tilt seat forward. c) Begin with either the left or rig ht motion control lever. Move lever to the

neutral position and pull lever back until the clevis pin (on arm below pivot

shaft) contacts the end of the slot (just beginning t o put pr essure on

spring), See Figure 12. d) Check where lever is relative to notch in console (should be centered

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

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

slight rearward pressure on the motion contr ol lever, turn the head of the

adjustment bolt in the appropriat e dir ection until lever is centered (keeping

rearward pressure on the lever will keep the pin at the end of the slot and

allow the adjustment bolt to move the lever to the appr opr iate position).

Tighten lock nut.

f) Repeat on opposite side of unit.

FIGURE 12

4.2.11 Motion control linkage adjustment

WARNING

POTENTIAL HAZARD ♦ Engine must be running and drive wheels

must be turning so motion control

adjustment can be performed. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces

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

rotating components and hot surf aces.

CAUTION

POTENTIAL HAZARD ♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

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

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

a) This adjustment m ust be m ade with the dr ive wheels turning. Raise the

rear of machine up and support with jack st ands ( or equivalent support)

just high enough to allow drive wheels to turn fr eely. b) Unhook seat latch and tilt seat forward. c) Remove the electrical connection from the seat safety switch, located

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

reservoir.

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

wiring harness. d) Run the unit at least 5 minutes with the drive levers at full forward speed to

bring hydraulic system oil up to operating tem per ature. e) Loosen lock nuts fr om t he ball joints at each end of the RH pump contr ol

linkage. (See Figure 13).

NOTE: The nut to the front of the unit on the RH rod has l ef t -hand threads.

FIGURE 13

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

start engine. Operator does not have to be in the seat . Run engine at

full throttle and release brake. g) The reverse indicator spring m ust be correct before the following

adjustments can be made. See Section 4.2.10.

NOTE: The motion control lever needs to be in neutral whil e making

any necessary adjustments.

The left rod assembly controls the left wheel and the right r od assem bly

controls the right wheel. h) Bring the RH motion cont rol lever into the neutral position. Adjust RH

pump control rod length by rotating t he double nuts on the rod in the

appropriate direction until the wheels slightly creep in reverse. (See Figure

13) Move the motion control lever to the reverse position and while

applying slight pressure to the lever allow the reverse indicator spr ing to

bring the levers back to neutral. The wheel must stop turning or slig ht ly

creep in reverse. i) When adjustment is complet e, re-tighten lock nuts ont o ball joints at Rear

of the RH pump control linka ge (See Figure 13). j) Bring t he LH motion control lever into the neutral position. Adjust the LH pump

control rod length by rotating t he t racking adjustment k nob in t he appr opriate

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

lever to the reverse position and while applying slight pressure to t he lever

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

wheel must stop turning or slightly creep in r everse ( See Figure 13).

k) Shut off unit. Remove jum per wire from wire harness connector and plug

connector into seat switch.

4.2.12 Caster pivot bearings pre-load adjustment a) Remove dust cap from caster and tighten

nyloc nut until washers are flat and back off 1/4 of a turn to properly set t he pr e- load on the bearings. If disassem bled, make sure the spring washers are reinstalled as shown in Figure 14.

FIGURE 14

5. WASTE DISPOSAL

5.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at

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

5.2 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid,

which is poisonous and can cause severe

burns WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it

touches skin can cause severe burns. HOW TO AVOID THE HAZARD

♦ Wear safety glasses to shield eyes, and

rubber gloves to protect skin and clothing when handling electrolyte.

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

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

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

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

♦ Do not swallow electrolyte.

6. TROUBLE SHOOTING

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

a) Check air pressure in the drive tires; 10 psi.

Semi- pneum atic casters tires do not require inflation.

b) Refer to Tracking Adj ust m ent Knob Section 3.1.3. c) Check reverse indicator and mot ion cont r ol linkage adjustment. See

section 4.2.10 and 4.2.11.

6.2 MOWER CUTS UNEVENLY.

a) Check air pressure in the drive tires; 10 psi.

Semi-pneumatic casters tires do not require inflation.

A higher tire pressure may provide a more uniform cutting height on rough

terrain. A lower tire pressure provides more flotation. b) Check deck support chains. c) Check deck leveling (See Adjust m ent s Section 4.2.2.)

Note: The front of the m ower deck will be approximately 1/4” lower than the

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

(approximately one blade width) from being in line.)

6.3 ENGINE WILL NOT START.

a) Make sur e t he battery has a full charge. See section 4.1. 2 for charging

instructions.

b) Be sure the throttle control is midway between the “SLOW” and “FAST”

positions, and the choke is in the “ON” posit ion for a cold engine or the “OFF”

position for a warm engine. c) Make sure ther e is fuel in the fuel tank and t hat the fuel valve is open. d) Make sur e t he parking brake is set and motion cont r ol levers ar e m oved out

(neutral lock position). e) Check that the PTO is disengaged. f) Check that the spark plug wires are properly connected. g) Check for loose or faulty wiring connections. h) Check for corrosion at all wiring connections. Even minor cor r osion may

cause a faulty connection. Clean connector terminals thor oughly with

electrical contact cleaner, apply dielectric grease and r econnect.

NOTE: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, cont act your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use.

When a problem occur s , do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank.

The following table lists some of t he common causes of trouble. Do not att em pt to service or replace major items or any items that call for special timing of adjustments procedures (such as valves, governor, etc. ) . Have this work done by your Engine Service Dealer.

PROBLEM

Will not start

Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings Skips or misfires

Backfires

Overheats*

High fuel

consumption

FUEL

X X X X X X X X X

ENGINE TROUBLESHOOTING TABLE

IMPROPER

FUEL

X X X X X X X X X X X X X X X X X X

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

X X X X X

X X X X

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X X X

X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

SCREEN

AIR

INSUFFICIENT

BATTERY

CHARGE

X X

7. ELECTRICAL DIAGRAM

8. HYDRAULIC DIAGRAM

9. 2-Year Limited Warranty

Exmark Turf Equipment

Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.

This warranty applies to Exmark turf equipment purchased on or after October 1, 2004 sold in the US or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement that is included in the literature packet. We are not authorized to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

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

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

2. Bring the product and your proof of purchase (sales receipt) to the Exmark Service Dealer.

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

Exmark Customer Service Department The Exmark W arranty Company 2101 Ashland Avenue Beatrice, NE 68310

402-223-6375 or service@exmark.com

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer. and tear, or exposure. filters, fuel, lubricants, tune-up parts, and adjustments. or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance. 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.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

Owner’s Responsibilities

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

As a condition to this warranty, customer shall have read the operator's manual and shall have completed and submitted to Exmark Warranty Company, within the prescribed time, the Exmark warranty registration.

General Conditions

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

Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer.

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

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that

covered by the terms of this warranty.

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

• Attorney's fees.

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

There are no understandings, agreements, representations, or warranties, express or implied, including but not limited to any regarding the merchantability (that product is fit for ordinary use) or fitness for use (that product is fit for a particular purpose), not specified herein, respecting the equipment which is the subject of this warranty.

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

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

NOTES

SERVICE RECORD

Date Description of Work Done Service Done By

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

STANDON

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www.exmark.com

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

FG. CO. INC.

Exmark Z XS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual