Exmark 4500-466 Lawn Mower User Manual

LAZER Z
ADVANTAGE SERIES
MODELS
®
For Serial Nos.
790,000 & Higher
Part No. 4500-466 Rev. B
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
Important: When the mower is used or operated
on any California forest, brush or grass covered
land, a working spark arrester must be attached
to the muffler. If not, the operator is violating
state law, Section 4442 Public Resource Code. To
acquire a spark arrester 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 conforme 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 Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
© 2009—Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
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
operation.
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, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Figure 1
1. Model and serial number location
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Model No.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
Serial No.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Deck Removal ............................................... 41
Pump Drive Belt Tension............................... 41
Deck Belt Tension ........................................ 41
Adjusting the Parking Brake........................... 41
Electric Clutch Adjustment............................ 42
Motion Control Linkage Adjustment ............. 42
Motion Control Damper Adjustment............. 43
Motion Control Neutral Lock Pivot
Adjustment ............................................... 43
Motion Control Handle Adjustment .............. 44
Motion Control Full Forward Tracking
Adjustment ............................................... 44
Caster Pivot Bearings Pre-Load
Adjustment ............................................... 44
Cleaning ........................................................... 45
Clean Engine and Exhaust System
Area .......................................................... 45
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 45
Clean Hydro Fan Cooling Guards .................. 45
Clean Debris From Machine .......................... 46
Clean Grass Build-Up Under Deck ................ 46
Waste Disposal .............................................. 46
Troubleshooting ................................................... 47
Schematics ........................................................... 49
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 10
Specifications ....................................................... 14
Model Numbers ............................................ 14
Systems ......................................................... 14
Dimensions................................................... 16
Torque Requirements .................................... 18
Product Overview ................................................ 18
Operation ............................................................. 19
Controls ........................................................ 19
Pre-Start........................................................ 22
Operating Instructions .................................. 22
Transporting ................................................. 27
Maintenance ......................................................... 29
Recommended Maintenance Schedule(s) ........... 29
Periodic Maintenance ....................................... 30
Check Engine Oil Level ................................. 30
Check Mower Blades ..................................... 31
Check Safety Interlock System ....................... 31
Check Rollover Protections Systems (Roll
Bar) Knobs................................................ 32
Check Seat Belt.............................................. 32
Check for Loose Hardware ............................ 32
Service Air Cleaner ........................................ 32
Change Engine Oil ........................................ 33
Check Hydraulic Oil Level ............................. 33
Check Tire Pressures ..................................... 34
Check Condition Of Belts.............................. 34
Lubricate Grease Fittings............................... 34
Lubricate Brake Handle Pivot ........................ 35
Lubricate Deck Lift Pivot............................... 35
Check Spark Plugs ......................................... 35
Change Hydraulic System Filter and
Fluid ......................................................... 35
Wheel Hub - Slotted Nut Torque
Specification.............................................. 36
Check Engine Coolant Level (Kawasaki
Liquid-Cooled Only) ................................. 37
Change Engine Coolant (Kawasaki
Liquid-Cooled Only) ................................. 37
Check Spark Arrester (if equipped)................. 38
Thread Locking Adhesives............................. 38
Copper-Based Anti-seize .............................. 38
Dielectric Grease........................................... 38
Adjustments ..................................................... 39
Deck Leveling ............................................... 39
4
Safety
Safety
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
Safety Alert Symbol
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
This Safety Alert Symbol (Figure 2) is used both in
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents
Preparation
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
Figure 2
1. Safety alert symbol
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.
CAUTION
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
Wear hearing protection when operating this
machine.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
Safe Operating Practices
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
5
Safety
DANGER
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite gasoline vapors. A fire or
explosion from gasoline can burn you and
others and cause property damage.
• Fill the fuel tank outdoors in an open
area, when the engine is cold. Wipe up
any gasoline that spills.
• Always place gasoline containers on the
ground away from your vehicle before
filling.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• 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.
• Do Not fill the fuel tank completely
full. Add gasoline to the fuel tank until
the level is 1/4 to 1/2 inch (6–13 mm)
below the bottom of the filler neck. This
empty space in the tank allows gasoline
to expand.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
spark.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• Store gasoline in an approved container
and keep it out of the reach of children.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Add fuel before starting the engine.
Never remove the cap of the fuel tank or
add fuel when engine is running or when
the engine is hot.
WARNING
• 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.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• 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.
6
Safety
• 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.
• Never mow with the discharge deflector raised,
removed or altered unless there is a grass
collection system or mulch kit in place and
working properly.
• Do Not change the engine governor setting or
overspeed the engine.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
– Before clearing blockages.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
– Before refueling.
– Before dumping the grass catcher.
CAUTION
Fuel tank vent is located inside the roll
bar tube. Removing or modifying the roll
bar could result in fuel leakage and violate
emissions regulations.
• Do Not remove roll bar.
• Do Not weld, drill, or modify roll bar in
any way.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
Operation
WARNING
Operating engine parts, especially the
muffler, become extremely hot. Severe burns
can occur on contact and debris, such as
leaves, grass, brush, etc. can catch fire.
• Allow engine parts, especially the muffler,
to cool before touching.
• Remove accumulated debris from muffler
and engine area.
WARNING
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
WARNING
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can
kill you.
• NEVER carry passengers. DO NOT operate
the mower when people, especially children, or
pets are in the area.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
Do Not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
• Be sure all drives are in neutral and parking brake
is engaged before starting engine. Use seat belts
with the roll bar in the raised and locked position.
7
Safety
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Slope Operation
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
Figure 3
1. Safe Zone-Use the mower here on slopes less than 15
degrees
2. Danger Zone-Use a walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
3. Water
DANGER
Operating on wet grass or steep slopes can
cause sliding and loss of control. Wheels
dropping over edges, ditches, steep banks, or
water can cause rollovers, which may result
in serious injury, death or drowning.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Do Not mow slopes when grass is wet.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Do Not mow near drop-offs or near water.
• Do Not mow slopes greater than 15
degrees.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Reduce speed and use extreme caution
on slopes.
• Be aware that operating on wet grass, across steep
slopes or down hill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and loss of braking and steering.
• Avoid sudden turns or rapid speed
changes.
• Keep the roll bar in the raised and locked
position and use seat belt.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
(Figure 3).
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
Using the Rollover Protection System
(ROPS)
A Rollover Protection System (roll bar) is installed
on the unit.
8
Safety
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
negative terminal first and the positive last.
Reconnect positive first and negative last.
WARNING
There is no rollover protection when the roll
bar is down. Wheels dropping over edges,
ditches, steep banks, or water can cause
rollovers, which may result in serious injury,
death or drowning.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Keep the roll bar in the raised and locked
position and use seat belt.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
• Lower the roll bar only when absolutely
necessary.
• Drive slowly and carefully.
• Charge batteries in an open well ventilated area,
away from spark and flames. Unplug charger
before connecting or disconnecting from battery.
Wear protective clothing and use insulated tools.
• Raise the roll bar as soon as clearance
permits.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Do Not wear seat belt when the roll bar
is down.
• Check all bolts frequently to maintain proper
tightness.
• Check carefully for overhead clearances (i.e.
branches, doorways, and electrical wires) before
driving under any objects and Do Not contact
them.
• In the event of a rollover, take the unit to an
Authorized Service Dealer to have the ROPS
inspected.
• Frequently check for worn or deteriorating
components that could create a hazard.
• All replacement parts must be the same as
or equivalent to the parts supplied as original
equipment.
Maintenance and Storage
WARNING
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
• Keep engine and engine area free from
accumulation of grass, leaves, excessive grease
or oil, and other debris which can accumulate
in these areas. These materials can become
combustible and may result in a fire.
• Let engine cool before storing and Do Not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Use jack stands to support components when
required.
• Carefully release pressure from components with
stored energy.
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury. Fluid
accidentally injected into the skin must be
surgically removed within a few hours by a
doctor familiar with this form of injury or
gangrene may result.
• 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 performing any work on
the hydraulic system.
9
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• 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.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
1-303508
1-633922
1-403005
98-5954
103-2076
10
Safety
109-3148
109-7232
1. Fast
2. Slow
3. Neutral
4. Reverse
107-2102
109-7330
107-2112
109-7929
11
Safety
116-0090
109-8483
1. Throttle–fast
2. Throttle–slow
3. Choke–on
4. Choke–off
116-0157
1. See Operator’s manual
116-0165
109-9361
Deck Drive Belt Routing
109-9477
116-0205
12
Safety
116-0906
For Kawasaki Liquid-Cooled Only
116-0211
Message Display
1.
2.
3.
4.
5.
Fuel
Empty
Half
Full
Battery
6.
7.
8.
9.
10.
Hour meter
PTO
Parking brake
Neutral
Operator presence
switch
116-0752
1. Latch
2. Unlatch
PTO Switch Symbols
1. PTO–disengage
109-7069
13
2. PTO–engage
Specifications
Specifications
Model Numbers
Serial Nos: 790,000 and Higher
LZAS20BV484; LZAS20KC484; LZAS23KC524; LZAS25KC604; LZAS26LKA604; LZAS27KC524;
LZAS27KC604; LZAS29KA724
Systems
– Kawasaki Liquid-Cooled: 20 amps
• Battery Type: BCI Group U1
Engine
• Recommended Minimum Battery CCA: 260 CCA
• Engine Specifications: See your Engine Owner’s
Manual
• RPM:
– All units except LZAS20BV484 and
LZAS20KC484: Full Speed: 3750 ±50 RPM
(PTO not engaged) Idle: 1500 ±100 RPM
– LZAS20BV484 and LZAS20KC484: Full
Speed: 3750 +0/-50 RPM (PTO not engaged)
Idle: 1500 ±100 RPM
• Battery Voltage: 12 Volt
• Low Voltage Light — RH control panel
• Polarity: Negative Ground
• Fuses:
All units:
– 25 amp main fuse
– 25 amp charging system fuse
Fuel System
– 10 amp PTO fuse
• Capacity: 12.0 gal. (45.4 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher.
• Fuel Filter:
– Briggs & Stratton:
– 15 amp accessory fuse
Safety Interlock System
• LCD indicators appear for the PTO, park brake,
drive levers, and operator presence in the message
display on the RH control panel.
Briggs & Stratton P/N 691035
– Kohler:
• PTO must be disengaged, brake engaged, and
motion control levers out (neutral lock) to start
engine. (It is not necessary for the operator to be
in the seat to start the engine.)
Kohler P/N 24 050 13
– Kawasaki:
• Operator must be in seat when PTO is engaged,
brake is disengaged, or motion control levers are
moved in or engine will stop.
Kawasaki P/N 49019-7001
• Fuel Shut-Off Valve:
All Units: 1/4 turn increments (“ON”, “OFF”).
• Fuel level eight segment display — right hand
control panel.
• Low fuel indicator light.
• Engine will stop if either the left, the right, or
both levers are moved from neutral lock position
while brake is engaged.
Cooling System (Kawasaki
Liquid-Cooled Only)
Electrical System
• Charging System: Flywheel Alternator
• Charging Capacity:
– Briggs & Stratton: 16 amps
– Kohler and Kawasaki Air-Cooled: 15 amps
• Fan: Continuous operation with engine running.
• Coolant Liquid: 50/50 mix of DexCool©
extended life antifreeze and water.
• Coolant Capacity: 3.1 quarts
14
Specifications
Operator Controls
• Armrests:
– Standard seat: foam padded adjustable flip-up
armrests.
– Suspension seat: molded adjustable flip-up
armrests.
• Seat Safety Switch:
• Steering and Motion Control:
•
•
•
•
•
•
Note: Motion control levers are adjustable to
two heights.
– Separate levers, on each side of the console,
control speed and direction 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 (in
slots) locks the drive system in neutral.
PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.
Parking Brake Lever: Engages parking brake.
Parking Brake Release Button: Releases parking
brake.
Deck Height Adjustment Lever: Sets cutting
height to desired position.
Deck Lift Pedal: Foot pedal that lifts deck.
Transport Lock:
– Latching position: Automatically latches at
the transport position.
– Unlatching position: Deck does not latch at
the transport position.
Integrated seat switch. Time delay seat switch
eliminates rough ground cut-outs.
Hydrostatic Ground Drive System
• Two unitized hydrostatic transmissions:
12cc Parker axial piston pump
•
•
•
•
•
240cc Parker geroler motor
Hydraulic Oil Type: Exmark Premium Hydro oil.
Hydraulic Oil Capacity: 52 oz (1.5 L) per side
Hydraulic Filter: P/N 116-0164
Speeds:
– 0-10 mph (16.1 km/hr) forward.
– 0-5.5 mph (8.9 km/hr) reverse.
Drive wheel release valves allow machine to be
moved when engine is not running.
Tires & Wheels
Drive
Front Caster
Pneumatic
(Air-Filled)
Semi-Pneumatic
Quantity
2
2
Tread
Turf Master
Smooth
Size (72 Deck)
24 x 12.00-12
13 x 6.50-6
Size (60 Deck)
24 x 12.00-12
13 x 5.00-6
Size (48 & 52
Decks)
24 x 9.50-12
13 x 5.00-6
Ply Rating
4
Pressure
13 psi (90 kPa)
Seat
• Type: Standard seat with high back, extra
wide foam padded seat cushion with internal
suspension, thick bolstering, armrests, integral
safety switch.
Optional seat accessories for units with standard
seats:
– Custom ride suspension system to enhance
Standard Seat. Adds approximately 3 inches
(7.6 cm) to seat height.
– Deluxe suspension seat with high back, low
profile foam-in-place cushion (dampened,
adjustable spring suspension), armrests, and
integral safety switch. Seat height remains the
same.
– Seat Isolation System for reduced vibration,
to enhance ride of standard seat, standard seat
with Custom Ride Seat Suspension or Deluxe
Suspension Seat. Adds approximately 1 inch
(2.5 cm) to seat height.
• Mounting: Adjustable fore and aft on seat tracks.
Cutting Deck
• Cutting Width:
– 48 inch Deck:
– 52 inch Deck:
– 60 inch Deck:
– 72 inch Deck:
• Discharge: Side
15
(121.9 cm)
(132.1 cm)
(152.4 cm)
(182.9 cm)
Specifications
Dimensions
• Blade Size: (3 ea.)
– 48 inch Deck: 16.25 inches (41.3 cm)
Overall Width:
– 52 inch Deck: 18.00 inches (45.7 cm)
48 inch Deck
52 inch Deck
Without Deck
45.7 inches
(116.1 cm)
45.7 inches
(116.1 cm)
• Blade Spindles: Solid steel spindles with 1.00 inch
(25 mm) I.D. bearings.
Deflector Up
51.8 inches
(131.6 cm)
56.3 inches
(143.0 cm)
• Deck Drive:
Deflector Down
59.6 inches
(151.4 cm)
64.8 inches
(164.6 cm)
60 inch Deck
72 inch Deck
– 60 inch Deck: 20.50 inches (52.1 cm)
– 72 inch Deck: 24.50 inches (62.2 cm)
Electric clutch:
– 48 and 52 inch Decks: “B” Section belt with
self-tensioning idler.
Without Deck
– 60 and 72 inch Decks: 5V Section belt with
self-tensioning idler.
53.0 inches
(134.6 cm)
59.1 inches
(150.1 cm)
Deflector Up
62.5 inches
(158.8 cm)
73.5 inches
(186.7 cm)
Deflector Down
72.8 inches
(184.9 cm)
84.9 inches
(215.6 cm)
• Deck:
Full floating deck is attached to out-front support
frame. Anti-scalp rollers provide maximum turf
protection. Deck design allows for bagging,
mulching or side discharge.
Overall Length:
– 48 inch Deck: 3 anti-scalp rollers
– 52 inch Deck: 3 anti-scalp rollers
– 60 inch Deck: 4 anti-scalp rollers
– 72 inch Deck: 4 anti-scalp rollers
48 inch Deck
52 inch Deck
Roll Bar - Up
79.2 inches
(201.2 cm)
79.2 inches
(201.2 cm)
Roll Bar - Down
80.9 inches
(205.5 cm)
80.9 inches
(205.5 cm)
60 inch Deck
72 inch Deck
Roll Bar - Up
83.1 inches
(211.1 cm)
86.1 inches
(218.7 cm)
Roll Bar - Down
84.8 inches
(215.4 cm)
87.8 inches
(223.0 cm)
• Deck Depth:
– 48 inch Deck: 5.5 inches (14 cm)
– 52 inch Deck: 5.5 inches (14 cm)
– 60 inch Deck: 5.5 inches (14 cm)
– 72 inch Deck: 5.5 inches (14 cm)
• Cutting Height Adjustment:
Overall Height:
Foot activated lever is used to adjust the cutting
height from 1 inch (2.5 cm) to 5 1/2 inches (14
cm) in 1/4 inch (6.4 mm) increments.
• Mulching Kit: Optional.
16
Roll Bar - Up
Roll Bar - Down
70.5 inches (179.1 cm)
46.8 inches (118.9 cm)
Specifications
Accessory Weight Table Worksheet:
Tread Width: (Center to Center of
Tires, Widthwise)
Use the table below to determine if extra weight
is required for the unit. Identify the accessories
and correct deck size and place the corresponding
values in the Accessory Score column. If the Total
Accessory Score meets the following, add the
recommended weight kit.
48 inch Deck
52 inch Deck
Drive Wheels
36.2 inches
(91.9 cm)
36.2 inches
(91.9 cm)
Caster Wheels
32.8 inches
(83.3 cm)
32.8 inches
(83.3 cm)
60 inch Deck
72 inch Deck
41.6 inches
(105.7 cm)
43.6 inches
(110.7 cm)
Light Kit
2
2
2
39.5 inches
(100.3 cm)
47.1 inches
(119.6 cm)
Michigan
Seat/CRSS
11
10
3
Bagger
0
0
3
Pneumatic
Caster
Tires
7
6
5
Mulch Kit
-3
-3
-5
Striper Kit
-3
0
0
OCD02
-6
-6
-4
Hitch Kit
1
1
1
Sunshade
Kit
2
3
2
Note: The 72 inch deck does not require a weight kit.
Drive Wheels
Caster Wheels
48 inch 52 inch 60 inch Accessory
Deck
Deck
Deck Score
Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
48 inch
Deck
52 inch
Deck
60 inch
Deck
72 inch
Deck
48.0 inches
(121.9 cm)
48.0 inches
(121.9 cm)
50.6 inches
(128.5 cm)
53.6 inches
(136.1 cm)
Curb Weight:
48 inch
Deck
52 inch
Deck
60 inch
Deck
72 inch
Deck
Total Accessory Score
20HP
1081 lb
Briggs & (490 kg)
Stratton
Units
20HP
Kohler
Units
1115 lb
(506 kg)
23HP
Kohler
Units
—
1108 lb
(503 kg)
—
—
25HP
Kohler
Units
—
—
1165 lb
(528 kg)
—
—
26HP
Kawasaki
Units
27HP
Kohler
Units
—
—
29HP
Kawasaki
Units
—
1177 lb
(534 kg)
—
1108 lb
(503 kg)
1165 lb
(528 kg)
—
—
—
1234 lb
(560 kg)
Total Accessory Score
Required Weight Kit(s)
0–9
None required
10 – 19
*116-1173 Under toe
board mount weight kit
20 and Higher
*Two 116-1173 Under toe
board mount weight kits
or one 116-1173 Under toe
board mount weight kit
and one 116-1238 Front
toe board mount weight kit
*48 and 52 inch units that come with an under toe
board weight as standard, can add an additional toe
board weight for primary accessory weighting (scores
10-19); and front toe board weight kit for secondary
accessory weighting (scores 20 and higher). Other
units should install a first under toe board kit for
primary accessory weighting (scores 10-19); and a
second under toe board kit for secondary accessory
weighting (scores 20 and higher).
17
Product Overview
Product Overview
*60 inch units which already have an under toe board
mount weight as standard requires 116-1238 front toe
board top mount kit instead of 116-1173.
Torque Requirements
Bolt Location
Torque
Blade Drive Sheave
Mounting Nut
140-145 ft-lb (190-197
N-m)
Blade Mounting Bolt
(lubricate with anti-seize)
55-60 ft-lb (75-81 N-m)
Anti-Scalp Roller Nyloc
Nut See Figure 19
30-35 ft-lb (41-47 N-m)
Anti-Scalp Roller Hex
Capscrew See Figure 19
50-55 ft-lb (68-75 N-m)
Engine Mounting Bolts
(Briggs & Stratton 20HP)
(Kohler 20-27HP)
(Kawasaki 26HP
Liquid-Cooled)
(Kawasaki 29HP)
27-33
27-33
17-21
27-33
Wheel Lug Nuts
90-95 ft-lb (122-129 N-m)
Wheel Motor Mounting
Bolts
72-77 ft-lb (98-104 N-m)
Wheel Hub Slotted Nut
minimum 200 ft-lb
(271 N-m)
Rollover Protection
System (Roll Bar) 1/2
inch Mounting Bolts
75-80 ft-lb (102-108 N-m)
ft-lb
ft-lb
ft-lb
ft-lb
(37-45
(37-45
(23-28
(37-45
N-m)
N-m)
N-m)
N-m)
Figure 4
1. Rollover Protection
System (ROPS)
2. Engine Controls (right
console)
3. Seat belt
4. Motion control levers
Clutch Retaining Bolt
55-60 ft-lb (75-81 N-m)
(secured with threadlocker)
Hydro Park Brake Cable
67-89 ft-lb (91-121 N-m)
Anchor 1/2 inch Mounting
Bolt (secured with
threadlocker)
18
5. Fuel cap
6. Height of cut adjustment
7. Parking brake
Operation
Choke Control
Operation
Located on right console (black lever) (see Figure 6).
Note: Determine the left and right sides of the
machine from the normal operating position.
The 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 to the
rear, to the detent, will put the choke in the “OFF”
position. Do Not run a warm engine with choke in
the “ON” position.
Controls
Motion Control Levers
The motion control levers located on each side of
the console control the forward and reverse motion
of the machine.
Moving the levers forward or backward turns
the wheel on the same side forward or reverse
respectively. Wheel speed is proportional to the
amount the lever is moved.
Moving the levers outward from the center position
into the T-slot locks them in the neutral position
(Figure 5).
When the motion control levers are in the neutral
position, the LCD indicator appears in the message
display on the RH console (see Figure 9).
Figure 6
Right Console
1.
2.
3.
4.
5.
6.
7.
8.
Warning Buzzer (Kawasaki Liquid-Cooled Only)
Fuses
Module display
Ignition switch
PTO engagement switch
Throttle
Choke
Coolant temperature gauge (Kawasaki Liquid-Cooled
Only)
Throttle Control
Located on right console (red lever) (see Figure 6).
The throttle is used to control engine speed. Moving
the throttle lever forward will increase engine speed
and moving the throttle lever to the rear will decrease
engine speed. Moving the throttle forward into the
detent is full throttle.
Figure 5
1. Neutral lock position
(handles out)
2. Neutral operate position
(handles in)
3. Front of Unit
Brake Lever
4. Forward
Located on right side of unit, just to the front of the
RH motion control lever.
5. Neutral (operate)
The brake lever engages a parking brake on the drive
wheels.
6. Reverse
19
Operation
Note: The LCD indicator appears in the message
display on the RH console when the park brake is
engaged (see Figure 9).
disengaged to start engine. (It is not necessary for the
operator to be in the seat to start the engine.)
Pull the lever up and rearward to engage the brake.
Hour Meter
Depress the release button and push downward to
disengage the brake.
Located on the right console in the message display
(see Figure 6 and Figure 9).
The hour meter records the number of hours that
the engine has run.
Figure 7
1. Release button
2. Park brake
The unit must be tied down and brake engaged when
transporting.
Figure 9
1.
2.
3.
4.
5.
Ignition Switch
Located on right console (see Figure 6).
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. Rotate clockwise to
the next position to engage the starter (key must be
held against spring pressure in this position). Allow
the key to return to the “on” position immediately
after the engine starts.
LCD Indicators
Low fuel indicator light
Fuel level bar display
Low voltage indicator light
Hour/Voltage display
Hours are recorded when the key is on and the engine
is running (battery voltage is 12.8V or higher) or
when the key is on and the operator is in the seat.
The hour meter is recording when the decimal point
is flashing in Hour/Voltage display.
Hours are displayed when the key is off and when
the machine is running.
Note: If the ignition key is turned to the “ON”
position for a few seconds before cranking the
engine, the battery voltage will display in the area
where the hours are normally displayed.
Note: The LCD indicators appear when each
control meets the “safe to start” mode (e.g. the
indicator turns on when the operator is in the seat.)
Figure 8
1. Off
2. On
3. Start
Note: Brake must be engaged, motion control
levers out (neutral lock position) and PTO switch
20
Operation
Fuel Shut-Off Valve
Located behind and below the seat.
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 jobsite, and when
parked inside a building.
Align valve handle with the fuel line to open. Rotate
90° to close.
Fuel Gauge
Figure 10
1. Handle in “released” position
2. Handle in “operating” position
Located on the right console in the message display
(see Figure 6 and Figure 9).
The fuel level is shown on a bar display. The indicator
light appears when the fuel level is low (approximately
one gallon remaining in the tank).
To release the drive system (see item 1 in Figure 10),
rotate the handle 1/4 turn to the vertical position
until it hits against the stop.
To reset the drive system (see item 2 in Figure 10),
rotate the handle 1/4 turn to the horizontal position
until it hits against the stop.
Drive Wheel Release Valves
WARNING
Note: The handle must be horizontal and against
the stop for operation.
Hands may become entangled in the rotating
drive components below the engine deck,
which could result in serious injury or death.
Do Not tow machine.
PTO Engagement Switch
Stop engine, remove key, allow all the moving
parts to stop before accessing the drive wheel
release valves.
Located on right console (see Figure 6).
Switch must be pulled out (up) to engage the blades.
Switch is pushed in to disengage the blades.
WARNING
The LCD indicator will appear when the PTO switch
is disengaged (see Figure 9).
The engine and hydraulic drive units can
become very hot. Touching a hot engine or
hydraulic drive units can cause severe burns.
Low Voltage Indicator
Allow the engine and hydraulic drive units to
cool completely before accessing the drive
wheel release valves.
Located on the right console in the message display
(see Figure 6 and Figure 9).
A low voltage condition (less than 12.3 volts) exists
when the LCD indicator appears on the message
display while the engine is running.
Located on the back of the unitized hydraulic drive
units, below the engine deck.
If the ignition key is turned to the “ON” position for
a few seconds before cranking the engine, the battery
voltage will display in the area where the hours are
normally displayed.
During normal operating conditions, the drive wheel
release valves are positioned horizontally. If the
machine has to be pushed by hand, the valves must
be in the “released” position (see Figure 10).
Note: The indicator normally appears when the
engine is off and the key switch is turned to the
“ON” position.
21
Operation
Coolant Temperature Gauge
(Kawasaki Liquid-Cooled Only)
In the non-latching position, the deck will
automatically return to the cutting height when the
pedal is lowered (see item 3 in Figure 12).
Located on the right console (see Figure 6).
The coolant temperature gauge monitors the
temperature of the engine coolant. During normal
operating conditions the gauge should be in the green
range. An engine overheating condition is when the
bar display goes to the yellow or red range and an
alarm sounds. Refer to the Warning Buzzer section.
Figure 12
1. Latching position
2. Transport lock control
Pre-Start
Figure 11
1. Green
2. Yellow
3. Non-latching position
3. Red
4. Bar display
Fill fuel tank. For best results use only clean, fresh
regular grade unleaded gasoline with an octane rating
of 87 or higher.
Do Not add oil to gasoline.
Warning Buzzer (Kawasaki
Liquid-Cooled Only)
Do Not overfill fuel tank. Never fill the fuel tank so
that the fuel level rises above a level that is 1/2 inch
(13 mm) below the bottom of the filler neck to allow
for fuel expansion and prevent fuel spillage.
Located on the side of the right hand console (see
Figure 6).
The buzzer is a warning signal that the engine is
overheating. See the Troubleshooting section.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Deck Lift Pedal
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
Located at the right front corner of the floor pan.
Push the pedal forward with your foot to raise the
cutting deck. Allow the pedal to move rearward to
lower the cutting deck to the cut height that has been
set.
Operating Instructions
Transport Lock
Important: The roll bar is an integral and
effective safety device. Keep the roll bar in the
raised and locked position when operating the
mower. Lower the roll bar temporarily only when
absolutely necessary.
1. The knob must be completely latched with the
tabs interlocking as shown in Figure 13 to lock
the roll bar in the raised, operate position.
Raise the Rollover Protection System
(ROPS)
Located on the height of cut adjustment plates to the
right of the parking brake.
Position in the transport latching position to
automatically latch the cutting deck when raised to
the transport position (see item 1 in Figure 12).
22
Operation
2. Apply forward pressure to the upper hoop of the
roll bar.
3. Pull the knob and rotate 90° to hold in the
unlatched position to lower the roll bar.
4. To return to the operate position, raise the roll
bar, and then rotate knobs 90° so that the tabs
interlock partially. Apply forward pressure to the
roll bar upper hoop and observe that the knobs
return to the completely latched position.
Figure 14
1. Engaged
2. Partially engaged — Do
Not operate with ROPS
in this condition.
Important: Always use the seat belt with the
roll bar in the operate (raised) position. Ensure
that the rear part of the seat is secured with the
seat latch.
Open the Fuel Shut-Off Valve
The fuel shut off valve is located behind and below
the seat. Rotate the valve and align with the fuel line
to open.
Figure 13
1.
2.
3.
4.
5.
Starting the Engine
Roll bar upper hoop
Knob in “latched” position
Pull knob to unlatch
Rotate 90° to hold unlatched
Knob in “unlatched” position
1. Move the motion control levers out to the neutral
lock position.
2. Pull up and back on the parking brake lever to
engage the parking brake.
3. Push down on the PTO switch to the “disengage”
position.
5. Make sure the knobs are fully engaged with the
roll bar in the raised position. The upper hoop of
the roll bar may need to be pushed forward or
pulled rearward to get both knobs fully engaged
(see Figure 14).
Note: It is not necessary for the operator to be
in the seat to start the engine.
4. Place the throttle midway between the “SLOW”
and “FAST” positions.
5. On a cold engine, push the choke lever forward
into the “ON” position.
On a warm engine, leave the choke in the “OFF”
position.
6. 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 than ten seconds at a
time. If the engine does not start, allow a 60
second cool-down period between starting
23
Operation
Stopping the Engine
attempts. Failure to follow these guidelines
can burn out the starter motor.
1. Bring the unit to a full stop.
7. If the choke is in the “ON” position, gradually
return choke to the “OFF” position as the engine
warms up.
2. Disengage the PTO.
3. Move the motion control levers out to the neutral
lock position.
Engaging the PTO
4. Engage the parking brake.
5. Place the throttle midway between the “SLOW”
and “FAST” positions.
DANGER
The rotating blades under the mower deck
are dangerous. Blade contact can cause
serious injury or kill you.
6. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
Do Not put hands or feet under the mower
or mower deck when the blades are engaged.
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
8. Close the fuel shut-off valve, located behind and
below the seat, when the machine will not be in
use for a few days, when transporting, or when
the unit is parked inside a building.
DANGER
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. Thrown objects or blade
contact can cause serious injury or death.
Driving the Machine
CAUTION
Never operate the mower with the discharge
deflector raised, removed, or altered unless
there is a grass collection system or mulch
kit in place and working properly.
Machine can spin very rapidly by positioning
one lever too much ahead of the other.
Operator may lose control of the machine,
which may cause damage to the machine
or injury.
The PTO push-pull switch engages the cutting blades.
Be sure that all persons are clear of the mower deck
and discharge area before engaging PTO.
• Use caution when making turns.
• Slow the machine down before making
sharp turns.
Important: Operator must be in seat before the
PTO can be engaged.
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 stop.
1. Set the throttle midway between the “SLOW”
and “FAST” positions.
2. Pull the PTO switch outward to engage the
blades.
3. Place the throttle in the “FAST” position to begin
mowing.
When the motion control levers are positioned fully
outward (apart) in the T-slot, the drive system is in
the neutral lock position (Figure 15).
Disengaging the PTO
Note: The “N” LCD indicator appears when both
levers are in the neutral lock position.
1. Set the throttle midway between the “SLOW”
and “FAST” positions.
When the motion control levers are moved directly
inward (together) the drive system is in the neutral
operate position.
2. Push the PTO switch in to disengage the blades.
24
Operation
Figure 16
1. Front of Unit
2. Forward
3. Neutral
4. Reverse
Driving in Reverse
1. Move the motion control levers inward to the
neutral operate position.
2. To move rearward in a straight line, move both
levers rearward with equal pressure.
Figure 15
1. Neutral lock position
(handles out)
2. Neutral operate position
(handles in)
3. Front of Unit
4. Forward
To turn left or right, release pressure on the
motion control lever toward the desired turn
direction.
5. Neutral (operate)
6. Reverse
3. To stop, position both motion control levers in
the neutral operate position.
Driving Forward
1. Release the parking brake.
Adjusting the Cutting Height
2. Move the motion control levers inward to the
center to the neutral position.
The cutting height of the mower deck is adjusted
from 1 to 5 1/2 inches (2.5 cm to 14 cm) in 1/4 inch
(6.4 mm) increments.
3. To move forward in a straight line, move both
levers forward with equal pressure.
1. Stop the machine and move the motion control
levers outward to the neutral locked position.
To turn left or right, pull the motion control lever
back toward neutral in the desired turn direction.
2. Disengage the PTO.
3. Position the transport lock in the latching
position.
The machine will move faster the farther the
motion control levers are moved from the neutral
position.
4. Raise and lock the deck to the 5 1/2 inch (14 cm)
transport position (Figure 17).
4. To stop, position both motion control levers in
the neutral operate position.
The deck is raised by pushing the foot operated
deck lift pedal forward. The pedal is located at the
front right corner of the floor pan.
Note: When changing the cutting height
positions, always come to a complete stop
and disengage the PTO.
25
Operation
Figure 18
For cutting heights above 3.5 inches (90 mm) use the
bottom hole. The rollers will still be effective against
scalping.
1. Anti-scalp roller
mounting bracket
2. Cutting height
Figure 17
1. Deck foot pedal
2. Height adjustment pin
3. Cut of height decal
4. Transport lock control
For Maximum Deck Flotation, place the rollers
one hole position lower. Rollers should maintain
1/4 inch (6.4 mm) clearance to the ground. Do
Not adjust the rollers to support the deck.
5. Insert the height adjustment pin into the hole
corresponding to the desired cutting height.
7. Be sure the roller bolts are installed with the
spring disc washer between the head of the bolt
and the mounting bracket (Figure 19).
See the decal on the side of the deck lift plate for
cut heights.
8. Torque the 3/8–24 x 2 Gr 8 hex capscrew to
50–55 ft-lb (68–75 N-m) (Figure 19).
6. Push the deck lift pedal, release the transport lock
and allow the deck to lower to the cutting height.
Adjusting the Anti-Scalp Rollers
It is recommended to change the anti-scalp roller
position, when the height of cut has changed.
1. Stop the machine and move the motion control
levers outward to the neutral lock position.
2. Disengage the PTO.
3. Engage the park brake.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. Adjust the anti-scalp rollers by removing the
bushing, spring disc washer and bolt.
Figure 19
6. Place the rollers in one of the positions shown
(Figure 18). Rollers will maintain 3/4 inch (19
mm) clearance to the ground to minimize gouging
and roller wear or damage.
1. Spring disc washer
3. 3/8 nyloc-torque to 30-35
(cone towards bolt head)
ft-lb (41-47 N-m)
2. Front right anti-scalp
4. 3/8-24 x 2 GR8 torque to
bracket shown
50-55 ft-lb (68-75 N-m)
26
Operation
Transporting
WARNING
Loading a unit on a trailer or truck increases
the possibility of backward tip-over.
Backward tip-over could cause serious injury
or death.
Transporting a Unit
Use a heavy-duty trailer or truck to transport the
machine. Lock brake and block wheels. Securely
fasten the machine to the trailer or truck with straps,
chains, cable, or ropes. Be sure that the trailer or truck
has all necessary lighting and marking as required by
law. Secure a trailer with a safety chain.
• 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.
CAUTION
• If individual ramps must be used, use
enough ramps to create an unbroken
ramp surface wider than the unit.
This unit does not have proper turn
signals, lights, reflective markings, or a
slow moving vehicle emblem. Driving on a
street or roadway without such equipment
is dangerous and can lead to accidents
causing personal injury. Driving on a street
or roadway without such equipment may also
be a violation of State laws and the operator
may be subject to traffic tickets and/or fines.
• 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.
Do Not drive a unit on a public street or
roadway.
Loading a Unit
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for 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 full width ramp, 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 truck do not exceed 15°. A steeper angle
may cause mower deck components to get caught as
the unit moves from ramp to trailer or truck. Steeper
angles may also cause the unit to tip backward. If
loading on or near a slope, position the trailer or
truck so it is on the down side of the slope and the
ramp extends up the slope. This will minimize the
ramp angle. The trailer or truck should be as level
as possible.
27
Operation
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a ramp.
Both maneuvers can cause the unit to tip backward.
28
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could
seriously injure you or other bystanders.
The engine can become very hot. Touching
a hot engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine
area.
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).
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
After the first 100 hours
• Check the wheel hub slotted nut torque specifications.
• Check the wheel lug nuts.
• Check the park brake adjustment.
Before each use or daily
•
•
•
•
•
•
•
•
•
•
•
Check the engine oil level.
Check the mower blades.
Check the safety interlock system.
Check the rollover protections systems (roll bar) knobs.
Check the seat belt.
Check for loose hardware.
Check engine coolant level.
Clean the engine and exhaust system area.
Clean the hydro fan cooling guards.
Clean the grass and debris build-up from the machine and cutting deck.
Clean the grass build-up from under the cutting deck.
Every 50 hours
•
•
•
•
Check the hydraulic oil level.
Check the tire pressures.
Check the condition of the belts.
Check spark arrester (if equipped).
Every 100 hours
• Change the engine oil. (May need more often under severe conditions.)
• Lubricate the deck lift pivots.
• Remove the engine shrouds and clean the cooling fins.
Every 200 hours
• Service the air cleaner. (May need more often under severe conditions. See the Engine
Owner’s Manual for additional information.)
• Lubricate the brake handle pivot.
• Check the spark plugs.
29
Maintenance
Maintenance Service
Interval
Every 500 hours
Every 4,000 hours
Yearly
Maintenance Procedure
•
•
•
•
Change the hydraulic filter and fluid.
Check the wheel hub slotted nut torque specifications.
Check the wheel lug nuts.
Check the park brake adjustment.
• Change engine coolant. Dex-Cool© extended life coolant (orange color)
• Grease the deck and pump idler pivots.
• Grease the front caster pivots.
Periodic Maintenance
battery performance and life, recharge batteries in
storage when the open circuit voltage drops to 12.4
volts.
Check Engine Oil Level
Note: To prevent damage due to freezing, battery
should be fully charged before putting away for
winter storage.
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. Clean area around dipstick. Remove dipstick
and wipe oil off. Reinsert the dipstick according
to the engine manufacturer’s recommendations.
Remove the dipstick and read the oil level.
4. If the oil level is low, wipe off the area around the
oil fill cap, remove cap and fill to the “FULL”
mark on the dipstick. Use oil as specified in
Engine Owner’s Manual. Do Not overfill.
Check the voltage of the battery with a digital
voltmeter or with the message display. If the ignition
key is turned to the “on” position for a few seconds,
the battery voltage will be displayed in the area where
the hours are normally displayed. Locate the voltage
reading of the battery in the table and charge the
battery for the recommended time interval to bring
the 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 charging the battery has an output of
16 volts and 7 amps or less to avoid damaging
the battery (see chart for recommended charger
settings).
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Check Battery Charge
Service Interval: As required
WARNING
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
Allowing batteries to stand for an extended period of
time without recharging them will result in reduced
performance and service life. To preserve optimum
30
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 2 Hours
amps
Maintenance
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
11.7–12.0
0–25%
14.4 volts/4 3 Hours
amps
11.7 or less
0%
14.4 volts/2 6 Hours or
More
amps
Charging
Interval
Check Mower Blades
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Figure 21
1. Use wrench here for blade installation. This nut has
been torqued to 140–145 ft-lb (190–197 N-m)
2. Torque to 55-60 ft-lb (75-81 N-m) Apply lubricant to
threads as needed to prevent seizing. Copper-based
anti-seize preferable. Grease acceptable substitute.
2. Lift deck and secure in raised position as stated in
the Clean Grass Build-Up Under Deck section.
3. Inspect blades and sharpen or replace as required.
4. Reinstall the blades (if they were removed) in the
following order:
C. Apply lubricant to threads of blade bolt to
prevent seizing. Copper-based anti-seize
preferable. Grease acceptable substitute.
Install blade bolt finger tight. Place wrench
on the top spindle nut then torque the blade
bolts to 55-60 ft-lb (75-81 N-m).
A. Install bushing through blade with bushing
flange on bottom (grass) side of blade.
WARNING
Incorrect installation of the blade or
components used to retain the blade can
be dangerous. Failure to use all original
components and assembled as shown could
allow a blade or blade component to be
thrown out from under the deck resulting in
serious personal injury or death.
Figure 20
1. Install bushing in blade prior to installing bushing in
spindle.
Always install the original Exmark blades,
blade bushings, and blade bolts as shown.
B. Install bushing/blade assembly into spindle.
Make sure the splines on the bushing are
engaged in the spindle before tightening the
bolt.
Check Safety Interlock
System
Service Interval: Before each use or daily
Note: To prevent engine cut-outs on rough terrain
the seat kill switch has a 1/2 second delay.
1. Check starting circuit. Starter should crank with,
parking brake engaged, PTO disengaged and
motion control levers moved out in the neutral
31
Maintenance
Check Rollover Protections
Systems (Roll Bar) Knobs
lock position. The operator does not need to be
in the seat to start the engine.
Try to start with operator in seat, parking brake
disengaged, PTO disengaged and motion control
levers in the neutral lock position - starter must
not crank.
Service Interval: Before each use or daily
Check that both the mounting hardware and the
knobs are in good working condition. Make sure the
knobs are fully engaged with the ROPS in the raised
position. The upper hoop of the roll bar may need
to be pushed forward or pulled rearward to get both
knobs fully engaged.
Try to start with operator in seat, parking brake
engaged, PTO engaged and motion control
levers in the neutral lock position - starter must
not crank.
Try to start with operator in seat, parking
brake engaged, PTO disengaged, and the left
motion control lever in, starter must not crank,
repeat again with the right lever in, then with
both levers in - starter must not crank.
2. 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 initiate shutdown after approximately 1/2
second has elapsed (seat has time delay kill switch
to prevent cut-outs on rough terrain).
Figure 22
1. Engaged
Run engine at one-third throttle, engage PTO
and raise off of seat (but do not get off of
machine) engine must initiate shutdown after
one second has elapsed if the handles are in. The
delay will be 1/2 second if the handles are out.
2. Partially engaged — Do
Not operate with ROPS
in this condition.
Check Seat Belt
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 initiate
shutdown after 1/2 second has elapsed.
Service Interval: Before each use or daily
Visually inspect seat belt for wear, cuts, and proper
operation of retractor and buckle. Replace before
operating if damaged.
Again, run engine at one-third throttle, brake
engaged, and move left motion control lever
in - engine must initiate shutdown after 1/2
second has elapsed.
Check for Loose Hardware
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Visually inspect machine for any loose hardware
or any other possible problem. Tighten hardware
or correct the problem before operating.
Repeat again moving the right lever in, then
moving both levers in - engine must initiate
shutdown after 1/2 second has elapsed whether
operator is on seat or not.
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
Service Air Cleaner
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
Service Interval: Every 200 hours—Service
the air cleaner. (May
need more often under
severe conditions. See
the Engine Owner’s
32
Maintenance
Manual for additional
information.)
6. Use oil recommended in engine owner’s manual.
Do Not overfill. Start the engine and check for
leaks.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
7. Wipe up any spilled oil from engine deck
mounting surfaces.
2. Loosen retaining clips and remove air cleaner
compartment cover.
Check Hydraulic Oil Level
3. Remove paper element. Check the condition
of the paper element. Replace if dirty, bent or
damaged.
Service Interval: Every 50 hours
1. Stop engine and wait for all moving parts to stop.
Engage parking brake.
4. Check the condition of the inner element. Replace
whenever it appears dirty, typically every other
time the paper element is replaced. Clean the base
around the inner element before removing, so
dirt does not get into the engine.
2. Wait until the unit cools before checking the
hydraulic oil.
3. Slide the seat all the way forward to access the
caps on the LH and RH hydro drives.
5. Do Not wash or use pressurized air to clean
paper element or inner element.
4. Clean the area around hydraulic reservoir cap and
remove cap.
6. Reinstall elements. Position the cover so that the
rubber dust ejector is pointing downward and
secure with retaining clips.
5. Wipe the dipstick clean and re-insert the cap back
into the hydro. Lightly tighten the cap.
Change Engine Oil
6. Remove the cap again and check the level of the
oil on the dipstick. See Figure 23 for oil levels.
Service Interval: After the first 5 hours
Every 100 hours/Yearly
(whichever comes first)
(May need more often
under severe conditions.)
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Drain oil while engine is warm from operation.
3. The oil drain hose is located on right hand side
of engine at the rear. Place pan under machine
to catch oil. Remove plug from end of drain
hose. Allow oil to drain and replace oil drain plug.
Torque plug to 20-24 ft-lb.
Figure 23
1. Full
4. Replace the oil filter every other oil change. Clean
around oil filter and unscrew filter to remove.
Before reinstalling new filter, apply a thin coating
of oil on the surface of the rubber seal. Turn
filter clockwise until rubber seal contacts the filter
adapter then tighten filter an additional 1/2 to
3/4 turn.
2. Add
Note: The oil level on the dipstick will be
incorrect if the oil is checked when the unit is hot.
7. If the dipstick oil level is at the “add” mark add
Exmark Premium Hydro oil.
8. Replace hydraulic reservoir cap and tighten until
snug. Do Not overtighten.
5. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
33
Maintenance
Check Tire Pressures
* See step 3 for special lubrication instructions on
the front caster pivots.
Service Interval: Every 50 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check tire pressure in drive tires.
3. Inflate drive tires to 13 psi (90 kPa).
4. 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.
3. 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 thread plug back
in. Place cap back on.
Check Condition Of Belts
Service Interval: Every 50 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove left and right belt shields on deck and lift
up floor pan to inspect deck drive belt.
3. Check under machine to inspect the pump drive
belt.
Lubricate Caster Wheel Hubs
Service Interval: As required
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Note: No adjustments are required for belt
tension.
Lubricate Grease Fittings
Note: See chart for service intervals.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lubricate fittings with one to two pumps of
NGLI grade #2 multi-purpose gun grease.
Figure 24
1. Seal guard
Refer to the following chart for fitting locations
and lubrication schedule.
2. Remove caster wheel from caster forks.
3. Remove seal guards from the wheel hub.
4. 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) from
the wheel assembly.
5. Pry out seals, and inspect bearings for wear or
damage and replace if necessary.
Lubrication Chart
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
1. Deck and
Pump Idler
Pivots
1
2
Yearly
2. Front
Caster
Pivots
*0
2
*Yearly
2. Spacer nut with wrench
flats
34
Maintenance
Lubricate Deck Lift Pivot
6. Pack the bearings with a NGLI grade #1
multi-purpose grease.
Service Interval: Every 100 hours
7. Insert one bearing, one new seal into the wheel.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Note: Seals (Exmark P/N 103-0063) must be
replaced.
2. Lubricate deck lift pivot with a spray type
lubricant or light oil.
8. If the axle assembly has had both spacer nuts
removed (or broken loose), apply a thread locking
adhesive to one spacer nut and thread onto the
axle with the wrench flats facing outward. Do
Not thread spacer nut all of the way onto the end
of the axle. Leave approximately 1/8 inch (3 mm)
from the outer surface of the spacer nut to the
end of the axle inside the nut.
Check Spark Plugs
Service Interval: Every 200 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owner’s
Manual.
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
Change Fuel Filter
10. 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.
Service Interval: As required
A fuel filter is installed between the fuel tank and the
engine. Replace when necessary.
11. Insert the second bearing and new seal into the
wheel.
Replacement Filters
12. Apply a thread locking adhesive to the 2nd spacer
nut and thread onto the axle with the wrench flats
facing outward.
Briggs & Stratton
Briggs & Stratton P/N
691035
Kohler
Kohler P/N 24 050 13
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,
then re-torque to 20-25 in-lb (2-3 N-m). Make
sure axle does not extend beyond either nut.
Kawasaki (Air-Cooled &
Liquid-Cooled)
Kawasaki
P/N 49019-7001
Note: It is important to reinstall the fuel line hoses
and secure with plastic ties the same as they were
originally installed at the factory to keep the fuel line
away from components that could cause fuel line
damage.
14. Reinstall the seal guards over the wheel hub and
insert wheel into caster fork. Reinstall caster bolt
and tighten nut fully.
Important: To prevent seal and bearing damage,
check the bearing adjustment often. Spin the
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.
Reapply thread locking adhesive.
Change Hydraulic System
Filter and Fluid
Service Interval: Every 500 hours
Note: Only use Exmark Hydro Filter–Part No.
116-0164 for summer or winter.
Lubricate Brake Handle Pivot
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Service Interval: Every 200 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
2. Lubricate brake handle pivot with a spray type
lubricant or light oil.
35
Maintenance
unless it is felt the oil has been contaminated or been
extremely hot.
Changing oil unnecessarily could damage hydraulic
system by introducing contaminants into the system.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Wheel Hub - Slotted Nut
Torque Specification
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Service Interval: After the first 100 hours
Every 500 hours thereafter
3. Remove the pump drive belt.
When tightening the slotted nut on the wheel motor
tapered shaft:
4. Place a catch pan under the hydro.
1. Remove and discard the cotter pin.
5. Carefully clean area around the filters. It is
important that no dirt or contamination enter the
hydraulic system.
2. Torque the slotted nut to 200 ft-lb (271 N-m).
3. Check distance from bottom of slot in nut to
inside edge of hole. Two threads (0.1 inch) or less
should be showing.
6. Using a socket, unscrew filters to remove and
allow oil to drain.
7. Before installing the new filters, apply a thin coat
of Exmark Premium Hydro oil on the surface of
the two rubber seals.
8. Install the new filters and torque to 14 ft-lb (19
N-m).
9. Fill the hydraulic system as stated in Check
Hydraulic Oil Level section.
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Hydro Oil
Change Interval
Exmark Premium Hydro
Oil (Preferred)
500 Hours
Mobil 1 15W50
250 Hours
Figure 25
1. 0.1 inch max
2. No more than two
threads (0.1 inch max)
should be showing here.
10. Remove the catch pan and properly dispose of
hydro oil and filter according to local codes.
4. If more than two threads (0.1 inch) are showing
remove nut and install washer (P/N 1-523157)
between hub and nut.
11. Re-install the pump drive belt.
5. Torque the slotted nut to 200 ft-lb (271 N-m).
12. Start engine and move throttle control ahead to
full throttle position. Move the speed control
levers to the full speed and run for one minute.
Shut down the machine, allow the hydros to cool
and recheck oil level.
6. Then tighten nut until the next set of slots line up
with the cross hole in shaft. Do Not loosen nut
to align the slot. If required, tighten to the next
set of slots.
7. Install new cotter pin (P/N 1-806800).
13. Remove the jack stands.
Note: Do Not use anti-seize on wheel hub.
Note: Do Not change the hydraulic system oil
(except for what can be drained when changing filter),
36
Maintenance
Check Engine Coolant Level
(Kawasaki Liquid-Cooled
Only)
Change Engine Coolant
(Kawasaki Liquid-Cooled
Only)
Service Interval: Before each use or daily
Service Interval: Every 4,000 hours/Every 4
years (whichever comes
© extended
first) Dex-Cool©
life coolant (orange color)
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake. Machine must
be positioned on level surface.
3. View coolant level in overflow bottle located at
the right rear of the engine below the radiator.
Coolant level should be at the indicator line on
the overflow bottle.
2. Place a drain pan under the drain plug.
3. Drain coolant when engine is cool. Coolant may
be drained from the radiator by turning the drain
plug counterclockwise.
WARNING
Engine coolant is hot and pressurized and
radiator and surrounding parts are hot. Spray
or steam from hot, pressurized liquid in the
engine cooling system and touching a hot
radiator may cause severe burns.
Allow the engine to cool completely before
removing the radiator cap or servicing any
component of the cooling system.
CAUTION
Engine coolant is toxic. Swallowing coolant
can cause poisoning.
Figure 26
1.
2.
3.
4.
• Do not swallow.
• Keep out of reach of children and pets.
4. If the coolant level is low, remove the radiator
cap and fill to the bottom of the filler neck.
Units should only be filled with a 50/50 mix
of Dex-Cool© extended life coolant and water.
Dex-Cool© can be identified by its orange color.
Coolant drain plug (black head)
Oil drain hose
Oil filter
Spark plug
4. Rotate the drain plug clockwise and remove pan.
5. Fill radiator with a 50/50 mix of water and
Dex-Cool© coolant as specified in the Check
Engine Coolant Level section, allowing some
room (approximately 1/2 inch (12.7 mm)) for
expansion. Add 50/50 coolant mix to overflow
bottle on the right side of the engine as required
to bring the level up to the indicator line on the
bottle.
37
Maintenance
2. Wait for muffler to cool.
WARNING
3. If any breaks in the screen or welds are observed,
replace arrester.
Engine compartment contains open belt
drives, fans, and other rotating components
that can cause injury. Fingers, hands, loose
clothing, or jewelry can get caught by the
rotating fan and drive shaft.
4. If plugging of the screen is observed, remove
arrester and shake loose particles out of the
arrester and clean screen with a wire brush (soak
in solvent if necessary). Reinstall arrester on
exhaust outlet.
• Do Not operate machine without the
covers in place.
• Keep fingers, hands, and clothing clear of
rotating components.
Thread Locking Adhesives
• Shut off engine, wait for moving parts to
stop, engage parking brake and remove
key, before performing maintenance.
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
• ROPS spring pin housing.
6. With the cap off the radiator, start the engine as
stated in the Operating Instructions Section.
• Hydro pump control arm, linkage bolt, and
attachment bolt.
7. Operate engine until the engine thermostat opens
and coolant is circulating through the radiator
core. As air is purged from the engine block and
the coolant level drops, add additional coolant to
the radiator.
• Hydro cooling fan screw.
8. When the radiator is completely full and no
additional coolant can be added, continue running
and install the radiator cap. Make sure that the
cap is completely seated by pressing down firmly
while turning until the cap stops. Once the cap is
installed, the engine may be stopped.
Thread locking adhesives are required for some
hardware on engines — see the Engine manual.
• Hydro park brake cable anchor mounting bolt
• Sheave and clutch retaining bolt in the end of
engine crankshaft.
Copper-Based Anti-seize
Copper-based anti-seize is used in the following
location:
Check Spark Arrester
(if equipped)
On threads of Blade Bolts. See Check Mower
Blades section.
Service Interval: Every 50 hours
Dielectric Grease
WARNING
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
Hot exhaust system components may ignite
gasoline vapors even after the engine is
stopped. Hot particles exhausted during
engine operation may ignite flammable
materials. Fire may result in personal injury
or property damage.
Do Not refuel or run engine unless spark
arrester is installed.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
38
Maintenance
Adjustments
Note: 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.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Figure 27
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
1. Foot lever
2. Cut of height pin
3. Transport lock
6. Insert the height adjustment pin into the 3 inch
(7.6 cm) cutting height location.
Deck Leveling
7. Release the transport lock and allow the deck to
lower to the cutting height.
1. Position the mower on a flat surface.
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
8. Raise the discharge deflector.
3. Check the tire pressure in the drive tires. Proper
inflation pressure for tires is 13 psi (90 kPa).
Adjust if necessary.
9. Measure from the level surface to the front tip of
the center blade. The measurement should read
3 inches (7.6 mm).
4. Position the transport lock in the latching
position.
Note: In most conditions, the back tips on the
side blades should be adjusted 1/4 inch (6.4 mm)
higher than the front.
5. Push the foot pedal all the way forward and the
deck will latch at the 5 1/2 inch (14 cm) transport
position (Figure 27).
39
Maintenance
12. Re-measure until all four sides are the correct
height. Tighten all the nuts on the deck lift arm
assemblies.
13. Lower discharge deflector.
14. If the four deck links do not have enough
adjustment to achieve accurate cut height with the
desired rake, the single point adjustment can be
utilized to gain more adjustment (see Figure 30).
Figure 28
1. 3 1/4 inches (8.3 cm)
2. Back blade tip
3. Front blade tip
4. 3 inches (7.6 cm)
5. Level surface
10. Loosen the whizlock nut on the side of the yoke
and the jam nut on top. Fine tune the screw
adjuster by turning it to get 3 inch (7.6 mm)
height (see Figure 29).
Figure 30
To increase the height, turn the adjuster screw
clockwise; to decrease, turn counterclockwise.
1. Single point height adjustment bolt
2. Front height-of-cut plate mounting bolt
3. Rear height-of-cut plate mounting bolt
15. To adjust the single point system, first loosen the
front and rear height-of-cut plate mounting bolts.
16. If the deck is too low, tighten the single point
adjustment bolt by rotating it clockwise. If
the deck is too high, loosen the single point
adjustment bolt by rotating it counterclockwise.
Note: Loosen or tighten the single point
adjustment bolt enough to move the height-of-cut
plate mounting bolts at least 1/3 the length of
the available travel in their slots. This will regain
some up and down adjustment on each of the
four deck links.
Figure 29
1. Whizlock nut
2. Adjuster screw
3. Jam nut
4. Yoke
17. Re-tighten front and rear height-of-cut plate
mounting bolts.
Important: Torque the front and rear
height-of-cut plate mounting bolts to 27-33
ft-lb (37-45 N-m).
11. The back tips of the side blades should measure
3 1/4 inches (8.3 cm). Fine tune rear adjusters
as required.
18. Repeat steps 9 through 13.
40
Maintenance
Deck Removal
7. Disconnect the deck strut and panhard from the
deck.
Before servicing or removing the deck, the spring
loaded deck arms must be locked out.
8. Raise the front of the machine and slide the deck
left or right to remove.
9. Lower the front of the machine.
WARNING
Deck lift arm assemblies have stored energy.
Removing the deck with out releasing the
stored energy can cause serious injury or
death.
Pump Drive Belt Tension
Do Not attempt to disassemble the deck
from the front frame without locking out the
stored energy.
Deck Belt Tension
Self-tensioning - No adjustment necessary.
Self-tensioning - No adjustment necessary.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Adjusting the Parking Brake
2. Remove the height adjustment pin and lower the
deck to the ground.
Service Interval: After the first 100 hours
3. Place the height adjustment pin in the 3 inch (7.6
cm) cutting height location. This locks the deck
lift arms in the lowest position when the deck is
removed.
Check to make sure brake is adjusted properly.
Every 500 hours thereafter
1. Drive the machine onto a level surface.
2. Disengage the blade control switch (PTO), move
the motion control levers to the neutral locked
position and set the parking brake.
4. Remove the floorpan and belt shields.
5. Insert 1/2 inch socket driver into the square hole
on the idler bracket and carefully rotate the deck
idler counterclockwise to remove the belt.
3. Stop the engine, wait for all moving parts to stop,
and remove the key.
6. Remove and retain the hardware on both sides of
the deck as shown in Figure 31.
4. Raise the back of the machine up and support the
machine with jack stands.
5. Remove the rear tires from the machine.
6. Remove any debris from the brake area.
7. Rotate the drive wheel release handle to the
“released” position. Refer to the Drive Wheel
Release Valves section in Operation.
8. Disengage the park brake.
9. Using hands and fingers only, push the caliper
lever arm to engage the brake pads on the rotor
until the lever stops. While holding the lever at the
stopped position, use the other hand or fingers
to pull the cable threaded end tight through the
swivel. Spin the standard nut against the swivel
(see Figure 32).
Figure 31
1.
2.
3.
4.
Panhard rod (right side only)
Deck strut
Rear deck lift attachment shoulder bolt and nut.
Front deck lift attachment shoulder bolt and nut.
41
Maintenance
16. Install the rear tires and torque lug nuts to 90-95
ft-lb (122-129 N-m).
17. Remove jack stands.
Electric Clutch Adjustment
No adjustment necessary.
Motion Control Linkage
Adjustment
Located on either side of the fuel tank, below the seat
are the pump control linkages. Rotating the pump
linkage with a 1/2 inch wrench allows fine tuning
adjustments so that the machine does not move in
neutral. Any adjustments should be made for neutral
positioning only.
Figure 32
Left Hand Brake Shown
1. Cable anchor
2. Threaded rod
3. Push lever this direction
4. Caliper lever arm
5. Standard nut (shown
against swivel)
WARNING
6. Lock nut
7. Pull cable threaded rod
this direction
8. Hold threaded rod here
9. Swivel (pivot head)
Engine must be running and drive
wheels must be turning so motion control
adjustment can be performed. Contact with
moving parts or hot surfaces may cause
personal injury.
Keep fingers, hands, and clothing clear of
rotating components and hot surfaces.
Note the order of the standard nut and lock nut
(no nut on the cable anchor side of the swivel).
10. Release hold on the caliper lever and cable. The
wheel hub should turn by hand in both directions
relative to the caliper; some friction/resistance
is acceptable.
1. Prior to starting the engine, push the deck lift
pedal and remove the height of cut pin. Lower
deck to the ground.
2. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
3. Remove the electrical connection from the seat
safety switch, located under the bottom cushion
of the seat. The switch is a part of the seat
assembly.
4. Temporarily install a jumper wire across the
terminals in the connector of the main wiring
harness.
5. Start engine. Brake must be engaged and
motion control levers out to start engine.
Operator does not have to be in the seat
because of the jumper wire being used. Run
engine at full throttle and release brake.
6. Run the unit at least 5 minutes with the drive
levers at full forward speed to bring hydraulic oil
up to operating temperature.
11. If there is no movement between the hub rotor
and the caliper then back off the standard nut one
turn from the swivel and repeat step 10 (drive
release valves must be in the “released” position
on the hydros).
12. If the hub rotor moves very freely relative to the
caliper, then tighten the standard nut one turn
against the swivel and repeat step 10.
13. Once step 10 is achieved, hold the threaded rod
end with a tool and tighten the lock nut against
the standard nut. Do Not allow the cable to turn
when the nuts are tightened.
14. Rotate the drive wheel release handle to the
“operating” position. Refer to the Drive Wheel
Release Valves section in Operation.
15. Repeat on the opposite side of machine.
42
Maintenance
Note: The motion control lever needs to be in
neutral while making any necessary adjustments.
7. Bring the motion control levers into the neutral
position. Adjust pump control rod lengths
by rotating the double nuts on the rod in the
appropriate direction until the wheels slightly
creep in reverse (Figure 33). Move the motion
control levers to the reverse position and while
applying slight pressure to the lever allow the
reverse indicator springs to bring the levers back
to neutral. The wheels must stop turning or
slightly creep in reverse.
Figure 34
RH Motion Control Shown
1. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt must
protrude past end of nyloc nut after torque. A T-40 Torx
bit will be necessary to hold the stud from turning.
2. Most resistance (firmest feel)
3. Damper
4. Medium resistance (medium feel)
5. Least resistance (softest feel)
Figure 33
Motion Control Neutral Lock
Pivot Adjustment
1. Double nuts
8. Shut off unit. Remove jumper wire from wire
harness and plug connector into seat switch.
The flanged nut can be adjusted to obtain a more
desired motion control lever resistance (Figure 35).
9. Remove the jack stands.
10. Raise the deck and re-install the height of cut pin.
11. Check that the machine does not creep in neutral
with the park brakes disengaged.
Motion Control Damper
Adjustment
The top damper mounting bolt can be adjusted to
obtain a more desired motion control lever resistance.
See Figure 34 for mounting options.
Figure 35
1. Flanged nut
2. Jam nut
1. Loosen the jam nut.
2. Tighten or loosen the flanged nut to the desired
feel.
For more resistance, tighten the flanged nut.
For less resistance, loosen the flanged nut
3. Tighten jam nut.
43
Maintenance
Motion Control Handle
Adjustment
1. Loosen the screws on a cover plate (see Figure 37).
Adjusting the height:
2. Slide the cover plate backward or forward to
adjust the travel of the lever and tighten the
screws.
The motion control levers can be adjusted higher or
lower for maximum operator comfort.
3. Drive the machine and check the full forward
tracking.
1. Remove the two bolts holding the control lever to
the control arm shaft (Figure 36).
4. Repeat steps 1 through 3 until desired tracking
is obtained.
Figure 37
RH Motion Control Shown
Figure 36
1. Bolts
2. Control lever
3. Control arm shaft
4. Nuts
5. Slotted holes
1. Screw
2. Cover plate
2. Move the control lever to the next set of holes.
Secure the lever with the two bolts.
3. Motion control lever
Caster Pivot Bearings
Pre-Load Adjustment
3. Repeat the adjustment for the opposite control
lever.
Remove dust cap from caster and tighten nyloc nut
until washers are flat and back off 1/4 of a turn
to properly set the pre-load on the bearings. If
disassembled, make sure the spring disc washers are
reinstalled as shown in Figure 38.
Adjusting the Tilt
The motion control levers can be tilted fore or aft for
maximum operator comfort.
1. Loosen the upper bolt holding the control lever
to the control arm shaft.
2. Loosen the lower bolt just enough to pivot the
control lever fore or aft Figure 36. Tighten both
bolts to secure the control in the new position.
3. Repeat the adjustment for the opposite control
lever.
Motion Control Full Forward
Tracking Adjustment
If the machine travels or pulls to one side when the
motion control levers are in the full forward position,
adjust the cover plates.
44
Maintenance
Cleaning
Clean Engine and Exhaust
System Area
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
CAUTION
Excessive debris around engine cooling air
intake and exhaust system area can cause
engine, exhaust area, and hydraulic system
to overheat which can create a fire hazard.
Figure 38
1. Spring disc washers
Clean all debris from engine and exhaust
system area.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Clean all debris from rotating engine air intake
screen, around engine shrouding, and exhaust
system area.
3. Wipe up any excessive grease or oil around the
engine and exhaust system area
Remove Engine Shrouds and
Clean Cooling Fins
Service Interval: Every 100 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove cooling shroud clean-out covers (Kohler)
or cooling shrouds (Kawasaki) from engine and
clean cooling fins. Also clean dust, dirt and oil
from external surfaces of engine which can cause
inadequate cooling.
3. Make sure cooling shroud clean-out covers or
cooling shrouds are reinstalled. Operating the
engine without cooling shroud clean-out covers
or cooling shrouds will cause engine damage due
to overheating.
Clean Hydro Fan Cooling
Guards
Service Interval: Before each use or daily
45
Maintenance
Waste Disposal
Removing debris from the hydro fan cooling guards
will allow the hydro system to run cooler and improve
the life of the hydro system.
Motor Oil Disposal
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Slide seat all the way back, then lift the seat to
access the LH and RH hydro drive area.
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
recycling center or according to your state and local
regulations.
3. Remove accumulated debris from the hydro fan
cooling guards.
Battery Disposal
Clean Debris From Machine
DANGER
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Battery electrolyte contains sulfuric acid,
which is poisonous and can cause severe
burns. Swallowing electrolyte can be fatal or
if it touches skin can cause severe burns.
2. Clean off any oil, debris, or grass build-up on the
machine and cutting deck, especially under deck
belt shields, around the fuel tank, around engine
and exhaust area.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• Do Not swallow electrolyte.
Clean Grass Build-Up Under
Deck
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.
Service Interval: Before each use or daily
If a battery is being replaced or if the unit containing
the battery is no longer operating and is being
scrapped, take the battery to a local certified recycling
center. If no local recycling is available return the
battery to any certified battery reseller.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Raise deck to the transport (5 1/2 inch (14 cm)
cutting height) position. Lift the front of unit
and support unit using jack stands or equivalent
support.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
3. Clean out any grass build-up from underside of
deck and in discharge deflector.
46
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do not attempt to service or replace major
items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.
Problem
Starter does not crank
Possible Cause
1. PTO is engaged.
1. Disengage the PTO.
2. Parking brake is not engaged.
3. Drive levers are not in neutral lock
position.
4. Battery does not have a full charge.
5. Electrical connections are corroded, loose
or faulty.
2. Set the parking brake.
3. Ensure the drive levers are in the neutral
lock position.
4. Charge the battery.
5. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
6. Replace the blown fuse.
7. Contact an Authorized Service Dealer.
8. Replace module.
6. Fuse is blown.
7. Relay or switch is defective.
8. Faulty module.
Engine will not start, starts hard, or fails to
keep running
Corrective Action
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shutoff valve is closed.
3. Oil level in the crankcase is low.
4. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. Add oil to the crankcase.
4. Be sure the throttle control is midway
between the “SLOW” and “FAST”
positions, and the choke is in the “ON”
position for a cold engine or the “OFF”
position for a warm engine.
5. Replace the fuel filter.
6. Contact an Authorized Service Dealer.
5. Dirt in fuel filter.
6. Dirt, water, or stale fuel is in the fuel
system.
7. Air cleaner is dirty.
8. Seat switch is not functioning properly.
9. Electrical connections are corroded, loose
or faulty.
10.
11.
12.
13.
Relay or switch is defective.
Faulty spark plug.
Spark plug wire is not connected.
Faulty module.
47
7. Clean or replace the air cleaner element.
8. Check the seat switch indicator. Replace
seat if needed.
9. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
10. Contact an Authorized Service Dealer.
11. Clean, adjust or replace spark plug.
12. Check the spark plug wire connection.
13. Replace module.
Troubleshooting
Problem
Engine loses power
Engine overheats. (Coolant temperature
gauge is approaching the red zone or warning
buzzer emits beep.)
Possible Cause
Corrective Action
1. Engine load is excessive
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. Dirt in fuel filter.
6. Dirt, water, or stale fuel is in the fuel
system.
2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstructions from the cooling
fins and air passages.
5. Replace the fuel filter.
6. Contact an Authorized Service Dealer.
1. Temperature is increasing on coolant
temperature gauge.
1. Refer to Check Engine Coolant Level
section in the Maintenance.
2. Coolant level is low.
2. Refer to Check Engine Coolant Level
section in the Maintenance.
3. Remove debris.
4. Reduce the ground speed.
5. Add oil to the crankcase.
6. Remove the obstructions from the cooling
fins and air passages.
3.
4.
5.
6.
Debris on or around radiator.
Engine load is excessive.
Oil level in the crankcase is low.
Cooling fins and air passages for the
engine are plugged.
Mower pulls left or right (with levers fully
forward)
1. Tire pressure in drive tires not correct.
1. Adjust tire pressure in the drive tires.
Machine does not drive
1. Drive release handle not in “operating”
position.
1. Position handle in “operating” position;
see Drive Wheel Release Valves section
in Operation.
2. Drive or pump belt is worn, loose or
broken.
3. Drive or pump belt is off a pulley.
4. Broken or missing idler spring.
5. Hydraulic fluid level is low or too hot.
2. Change the belt.
Uneven cutting height.
1. Blade(s) not sharp.
1. Sharpen the blade(s).
2. Cutting blade(s) is/are bent.
3. Mower deck is not level.
2. Install new cutting blade(s).
3. Level mower deck from side-to-side and
front-to-rear.
4. Clean the underside of the mower.
5. Adjust tire pressure in the drive tires.
6. Contact an Authorized Service Dealer.
7. Replace blades, spindles and (or) check
for damage to mower deck.
4.
5.
6.
7.
Abnormal vibration
Blades do not rotate.
3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to reservoir or let it
cool down.
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.
Tips of adjacent blades are at an uneven
cutting height. Blades tips should be even
within 3/16 inch which is approximately
one blade thickness.
1. Cutting blade(s) is/are bent or unbalanced.
1. Install new cutting blade(s).
2. Blade mounting bolt is loose.
3. Engine mounting bolts are loose.
4. Loose engine pulley, idler pulley, or blade
pulley.
5. Engine pulley is damaged.
6. Blade spindle is bent.
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
1. Drive belt is worn, loose or broken.
1. Check the belt tension.
2. Deck belt is worn, loose or broken.
3. Deck belt is off pulley.
2. Install new deck belt.
3. Install belt on clutch and deck pulleys,
idlers, and tensioning idler per routing
decal on deck.
4. Replace the spring.
5. Refer to belt routing decal on deck.
4. Broken or missing idler spring.
5. Drive belt not routed correctly.
48
RECTIFIER
START
TERMINAL R
TERMINAL S
49
NONE
B+R+I+A
B+R+I+S
2. RUN
3. START
CIRCUIT "MAKE"
TERMINAL S
TERMINAL B
TERMINAL R
TERMINAL A
1. OFF
POSITION
IGNITION
TERMINAL I
TERMINAL I
BATTERY
TERMINAL B
CONNECTIONS
ACCESSORY
TERMINAL
TERMINAL A
A
B
2
1
2
1
2
1
2
1
1
2
1
2
B
A
PINK
LT. GREEN
NOTE:
CONNECTORS VIEWED FROM MATING CONNECTOR
BRAKE
SWITCH
LH NEUTRAL
SWITCH
RH NEUTRAL
SWITCH
ACCESSORY
PINK
4
5
BROWN
2
PINK
6
8
START RELAY
1
3
4
2 3 1 5 4
3
5
1
2
PINK
B
BROWN
BLACK
BLUE
BROWN
PINK
PTO CLUTCH
A
A B
2 1
TVS DIODE
AB
A B
BLACK
GRAY
BROWN
ORANGE
RED
9
1
7
10 1
8
6
6
12
5
HOUR METER/MODULE
12 3
ORANGE
VIOLET
2
3
1
32
1
5 4 3 1 2
RED
1
ORANGE
9
2
GREEN
3
VIOLET
GRAY
1 2
PINK
IGNITION SWITCH
7
BLACK
1
BLUE
SEAT SWITCH
BLACK
4
PINK
IGNITION SWITCH
45
11 2
YELLOW
9
TAN
8
2
4
4
4
7
5
6
8
BLACK
7
8
7
VIOLET
BLACK
RED
6
FUSE BLOCK
5
3
WHITE
7
BROWN
PTO SWITCH
PINK
B
C
1
START
FUEL SOLENOID
MAG
REGULATOR
B+
C A B
A
FUEL SENDER
1
4
5
3
6
2
5
2
GROUND
4
3
6
1
G008587
ENGINE
Schematics
Schematics
Electrical Diagram — Air–Cooled
NONE
B+R+I+A
B+R+I+S
2. RUN
3. START
CIRCUIT "MAKE"
TERMINAL S
TERMINAL B
TERMINAL R
TERMINAL A
1. OFF
POSITION
START
TERMINAL S
TERMINAL I
IGNITION
RECTIFIER
TERMINAL R
BATTERY
TERMINAL B
TERMINAL I
ACCESSORY
TERMINAL A
CONNECTIONS
IGNITION SWITCH
TERMINAL
2
1
2
1
2
1
1
2
1
2
1
2
B
A
NOTE:
CONNECTORS VIEWED FROM MATING CONNECTOR
BRAKE
SWITCH
LH NEUTRAL
SWITCH
RH NEUTRAL
SWITCH
A
B
3
2
1
START RELAY
3
4
TVS
DIODE
AB
B
PTO
CLUTCH
A
ALARM
(+)
ALARM
PULSE
1
BLUE
BLACK
GRAY
BROWN
PINK
1
5
1
A B
A B
PINK
BROWN
PINK
ORANGE
2 1
1
2 3 1 5 4
PINK
PINK
2
SEAT SWITCH
PINK
LT. GREEN
1 2
7 4 5 9 3 6 8 1 2
BROWN
BROWN
BLACK
PINK
9
32
1
5 4 3 1 2
PINK
8
1
BLACK
ORANGE
VIOLET
RED
4
6
12
HOUR METER/MODULE
1
7
6
8
FUSE BLOCK
5
3
7
VIOLET
RED
1 3 2 4 5 6 7 8
2
1
9 12 3 10 1 8 6 5 11 2 4 7
ORANGE
4
BLACK
PINK
IGNITION SWITCH
45
RED
VIOLET
GRAY
7
PINK
ORANGE
50
GREEN
BLACK
PINK
BLUE
TAN
YELLOW
BROWN
WHITE
B
C
GREEN
START
MAG
FUEL SOLENOID
B+
REGULATOR
C A B
BLACK
A
FUEL SENDER
BLACK
PTO SWITCH
2
1
1
4
5
3
6
2
4
5
6
1
TERM (3)
1
3
TERM (1)
1
GROUND
ENGINE
TEMP
SENDER
TERM (2)
1
TERM (4)
1
1
G008588
TEMPERATURE
GAUGE
Schematics
Electrical Diagram — Liquid–Cooled
A
BK
BK
-
GND
S
B
BU
SW2
(PTO SWITCH)
C FUEL SENDER
PK
+
2
BK
BN
BN
3
5
BN
8
F3
B
PK
1
BN V
4
A
PTO
CLUTCH
4
10A
BK
BN
7
U2
TVS DIODE
5
SW5
BK
8
3
(NEUT_L)
SW4
(NEUT_R)
PTO
PK
ACCESSORIES
FUEL
GROUND
PK
6
2
Y
LTGR
PK
BRAKE
4
W
7
9
(BRAKE)
SW6
GND
15A
F4
HOUR METER
11
BK
8
10
T
PK
7
1
12
OR
B+
KEY_S
GN
(SEAT)
SW7
BN
PK
OR
GY
R
R
OR
PK
5
I
SW1
(IGNITION)
2
B
GN
GY
GY
1
S
V
3
R
PK
4
OPTIONAL
NEUTRAL
FUEL_SOLENOID
SEAT
5
2
OR
KEY_A
MAGNETO
51
START_RELAY
3
BU
1
4
A
K2
R 1
25A
F1
V
25A
F2
2
PK
R
W
BU
V
4
6
5
1
2
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GREY
LT GR = LIGHT GREEN
OR = ORANGE
PK = PINK
R = RED
T = TAN
V = VIOLET
W = WHITE
(START RELAY)
6
5
V
A
R
B+
MAG
START
REG
START = BRIS
ON = BRIA
OFF = no connections
KEY SW
I
B
S
viewed from back
+
FUEL
SOLINIOD
-
AC
AC
STARTER
MODULES
IGNITION
KAW TWINSPARK PLUG
Ignition switch terminal locations
G008613
SPARK PLUG
Schematics
Electrical Logic Schematic — Air-Cooled
GN
(+)
(s)
(P)
S
3
BK
2 -
1
O
4
TEMP GAUGE
PK
OR
PK
OR
ALARM 2 TONE
+
-
BK
BK
A
GND
S B
BU
SW2
C FUEL SENDER
PK
+
2
PK
3
BN
BN
BK
BN
B
BN V
A
PTO
CLUTCH
4
PK
1
4
BK
BN
7
U2
SW4
8
3
(NEUT_L)
TVS DIODE BK
5
SW5
PTO
(PTO SWITCH)
F3
(NEUT_R)
FUEL
GROUND
5
8
10A
2
Y
PK
6
11
F4
SW6
GND
15A
W
7
9
(BRAKE)
4
8
HOUR METER
LTGR
BK
SEAT
PK
NEUTRAL
FUEL_SOLENOID
BRAKE
10
T
PK
12
1
OR
SW7
GN
(SEAT)
BN
PK
OR
GY
R
OR
R
2
B
4
A
V
3
R
5
I
GY PK
GY PK
1
S
GN
4
OR
KEY_A
MAGNETO
OPTIONAL
ACCESSORIES
B+
5
2
7
KEY_S
52
START_RELAY
3
BU
1
SW1
(IGNITION)
K2
(START RELAY)
25A
F1
V
2
25A
F2
4
6
5
1
2
GN
PK
R
W
BU
V
I
B+
MAG
START
REG
TEMP SW
FUEL
SOLENOID
-
AC
AC
SPARK PLUG
OFF = no connections
ON = BRIA
START = BRIS
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GREY
LT GR = LIGHT GREEN
OR = ORANGE
PK = PINK
R = RED
T = TAN
V = VIOLET
W = WHITE
R 1
6
5
V
S
R
A
KEY SW
B
Ignition switch terminal locations
viewed from back
+
SPARK PLUG
G008614
STARTER
IGNITION
MODULES
Schematics
Electrical Schematic — Liquid-Cooled
Schematics
Hydraulic Diagram
53
Exmark Lazer Z and Lazer Z AS Turf Equipment
3 Year Limited Commercial Warranty
5 Year or 750 Hours Limited Consumer Warranty
General Warranty Conditions and Products Covered
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company,
pursuant to an agreement between them, jointly warrant on the terms and
conditions herein, that we will repair, replace or adjust any part on these
products and found by us (in the exercise of our reasonable discretion) to
be defective in factory materials or workmanship.
This warranty may only be assigned or transferred to a second (or third)
owner by an authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase by an
Exmark Service Dealer before obtaining any warranty service.
Contact any Exmark Service Dealer to arrange service at their dealership.
To locate a dealer convenient to you, access our website at
www.exmark.com. U.S. or Canada customers may also call
402-223-6375.
If for any reason you are dissatisfied with the Service Dealer’s analysis or
with the assistance provided, contact us at:
Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310
402-223-6375 or
service@exmark.com
Commercial Warranty Conditions
This warranty applies to Exmark Lazer Z and Lazer Z AS turf equipment
sold in the U.S. or Canada for a period of three years for commercial
usage.
This warranty includes the cost of parts and labor for a period of two
years and the cost of parts for one additional year. This warranty does not
cover pickup and delivery charges to and from any authorized Exmark
Service Dealer.
Owner’s Responsibilities
The Exmark Lazer Z or Lazer Z AS 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 read the operator’s manual. You must
also properly service and maintain your Exmark product as described in
the operator’s manual. Such routine maintenance, whether performed by
a dealer or by you, is at your expense.
Consumer Warranty Conditions
This warranty applies to Exmark Lazer Z and Lazer Z AS turf equipment
sold in the U.S. or Canada for a period of five years or 750 hours
(whichever occurs first) for residential usage.
Residential usage means use of the product on the same lot as your home.
Use at more than one location is considered commercial use, and the
commercial use warranty detailed above would apply.
General Conditions
The sole liability of Exmark and Exmark Warranty Company with respect
to this warranty shall be repair or replacement of defective components as
set forth herein. Neither Exmark nor Exmark Warranty Company
shall be liable for any incidental or consequential loss or damage.
This warranty only includes the cost of parts and labor. For the first
warrantable service repair, Exmark will cover up to $45 for associated
pick-up and delivery charges to and from any authorized Exmark Service
Dealer. Additional transportation charges may apply, contact your Dealer
for details.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other extraordinary repair
charges or charges relating to repairs or replacements outside of
normal business hours at the place of business of the authorized
Exmark Service Dealer.
• Rental of like or similar replacement equipment during the period of
any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that covered by the
terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
• Attorney's fees.
No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the
above exclusions and limitations may not apply to you.
Warranty Exceptions
Warranty Exceptions
Warranty Period
• Bags, Belts and Tires
90 days
• Battery
1 Year Prorated
• Engine
2 years*
* The Engine warranty is covered by the engine manufacturer. Please
refer to the engine manufacturer’s warranty statement that is included in
the literature packet.
Items and Conditions Not Covered
This warranty does not cover the following:
• Any damage or deterioration due to normal use, wear and tear, or
exposure.
• Cost of regular maintenance service or parts, such as filters, fuel,
lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or required
replacement or repair due to normal wear, accidents, or lack of proper
maintenance.
• Any repairs necessary due to use of parts, accessories or supplies,
including gasoline, oil or lubricants, incompatible with the turf
equipment or other than as recommended in the operator's manual or
other operational instructions provided by Exmark.
There are no other express warranties except for engine and special
emission system coverage.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
All warranty work must be performed by an authorized Exmark Service
Dealer using Exmark approved replacement parts.
G4500-434
54
Notes:
55
Notes:
56
Service Record
Date:
Description of Work Done:
57
Service Done By:
58
59
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
ROLL OVER PROTECTION SYSTEM (ROPS)
DECK LIFT ASSIST KIT
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
© 2009 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-466 Rev. B
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com