Exmark Lawn Mower LZDS User Guide

LAZER Z® DS-SERIES  
For Serial Nos.  
312,000,000 & Higher  
Lazer Z (LZDS) Units  
Part No. 4501-041 Rev. A  
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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.  
Figure 1  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
If additional information is needed, or should  
you require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
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.  
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
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Belt Guide Adjustment...................................42  
Reverse Indicator Adjustment.........................45  
Motion Control Damper Adjustment..............47  
Contents  
Torque Requirements .....................................19  
Periodic Maintenance ........................................30  
4
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Safety  
Safe Operating Practices  
Safety  
Safety Alert Symbol  
This lawn mower meets or exceeds the B71.4  
specifications of the American National Standards  
Institute in effect at the time of production.  
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.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• 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.  
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.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
1. has read and understands the Operator's  
Manual and recognizes the risks involved;  
2. is sufficiently mature to use caution; and  
Figure 2  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
Safety Alert Symbol  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
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.  
Preparation  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• 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.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
• 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.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
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.  
CAUTION  
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.  
Wear hearing protection when operating this  
machine.  
5
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Safety  
• 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.  
WARNING  
Diesel fuel 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.  
• Avoid prolonged breathing of vapors.  
DANGER  
In certain conditions diesel fuel is extremely  
flammable and vapors are explosive.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
A fire or explosion from diesel fuel can burn  
you, others, and cause property damage.  
• Check that the operator's presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
• Fill the fuel tank outdoors on level ground,  
in an open area, when the engine is cold.  
Wipe up any diesel fuel that spills.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
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.  
• Do Not fill the fuel tank completely full.  
Fill the fuel tank to the bottom of the filler  
neck. The empty space in the tank allows  
diesel fuel to expand. Overfilling may  
result in fuel leakage or damage to the  
engine or emission system.  
• Allow engine parts, especially the muffler, to  
cool before touching.  
• Never smoke when handling diesel fuel,  
and stay away from an open flame or  
where diesel fuel fumes may be ignited by  
spark.  
• Remove accumulated debris from muffler and  
engine area.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Store diesel fuel in an approved container  
and keep it out of the reach of children.  
• 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  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can kill  
you.  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Do Not run engine indoors or in a small confined  
area where dangerous carbon monoxide fumes  
can collect.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• 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.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
6
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Safety  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• 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 operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Park machine on level ground. Stop engine, wait  
for all moving parts to stop, remove key and  
engage parking brake:  
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.  
– 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).  
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.  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Do Not mow slopes greater than 15 degrees.  
– Before refueling.  
– Before dumping the grass catcher.  
WARNING  
• Reduce speed and use extreme caution on  
slopes.  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Avoid sudden turns or rapid speed changes.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Do Not operate the machine without  
guards, shields, and safety devices in place  
and working properly.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
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.  
7
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Safety  
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.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Lower the roll bar only when absolutely  
necessary.  
• Do Not wear seat belt when the roll bar is  
down.  
Figure 3  
• Drive slowly and carefully.  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
• Raise the roll bar as soon as clearance  
permits.  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and Do Not contact  
them.  
3. Water  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• In the event of a rollover, take the unit to an  
Authorized Service Dealer to have the ROPS  
inspected.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
Maintenance and Storage  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key. Wait for all  
movement to stop before adjusting, cleaning or  
repairing.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
• 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.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• Use jack stands to support components when  
required.  
Using the Rollover Protection System  
(ROPS)  
• Carefully release pressure from components with  
stored energy.  
A Rollover Protection System (roll bar) is installed  
on the unit.  
• Disconnect battery before making any repairs.  
Disconnect the negative terminal first and the  
8
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Safety  
positive last. Reconnect positive first and negative  
last.  
CAUTION  
If the ignition is in the “ON” position there  
is potential for sparks and engagement of  
components. Sparks could cause an explosion  
or moving parts could accidentally engage  
causing personal injury.  
• 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 hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
Be sure ignition switch is in the “OFF”  
position before charging the battery.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• 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.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
DANGER  
Charging or jump starting the battery may  
produce explosive gases. Battery gases can  
explode causing serious injury.  
WARNING  
Removing standard original equipment parts  
and accessories may alter the warranty, traction,  
and safety of the machine. Failure to use original  
Exmark parts could cause serious injury or  
death. Making unauthorized changes to the  
engine, fuel or venting system, may violate EPA  
and CARB regulations.  
• Keep sparks, flames, or cigarettes away  
from battery.  
• Ventilate when charging or using battery  
in an enclosed space.  
• Make sure venting path of battery is  
always open once battery is filled with  
acid.  
Replace all parts including, but not limited to,  
tires, belts, blades, and fuel system components  
with original Exmark parts.  
• Always shield eyes and face from battery.  
DANGER  
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.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with  
water and call a doctor immediately.  
9
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Safety  
WARNING  
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.  
• If equipped, make sure all hydraulic fluid  
hoses and lines are in good condition and all  
hydraulic connections and fittings are tight  
before applying pressure to hydraulic system.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Use cardboard or paper, not your hands, to  
find hydraulic leaks.  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control levers  
in neutral and shutting off the engine before  
performing any work on the hydraulic system.  
WARNING  
Fuel system components are under high  
pressure. The use of improper components can  
result in system failure, fuel leakage and possible  
explosion.  
Use only approved fuel lines and fuel filters for  
high pressure systems.  
10  
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• 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.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
1-633706  
98-5954  
1-403005  
1-513742  
1-513748  
11  
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Safety  
103-2076  
103-0223  
103-7218  
103-0261  
103-1798  
107-2102  
12  
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Safety  
109-0872  
109-1214  
109-1215  
109-1399  
109-2219  
109-2263  
13  
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Safety  
109-2264  
109-2478  
109-2951  
109-3148  
14  
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Safety  
116-0127  
116-3303  
116-5074  
116-0404  
116-5185  
2. PTO–disengage  
1. PTO–engage  
116-0997  
116-2643  
117–2718  
15  
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Safety  
19426-87881  
19426-87903  
107-9866  
3. Neutral  
1. Fast  
2. Slow  
4. Reverse  
16  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 312,000,000 and Higher  
LZDS902K605; LZDS902K725  
Systems  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
Engine  
• Engine will stop if either the left, the right, or  
both levers are moved from neutral lock position  
while brake is engaged.  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Engine Oil Type: Exmark 4–Cycle Premium  
Engine Oil  
Engine Overheat Protection System  
• RPM: Full Speed: 3850 ±50 RPM (PTO not  
engaged) Idle: 1400 ±100 RPM  
PTO will disengage, an alarm will sound, and the  
coolant temperature gauge will be in the red area  
when the engine temperature reaches an overheat  
condition. The PTO will not re-engage until the  
engine has cooled and the PTO switch is manually  
shut-off and re-engaged.  
Fuel System  
• Capacity: 15.5 gal. (58.6 L)  
• Type of Fuel: Diesel fuel, 40 cetane or higher or  
biodiesel up to B20 (20% biodiesel, 80% petro  
diesel).  
Note: If the engine coolant level is below the  
indicator line on the overflow bottle when the  
engine is cold, the coolant temperature gauge may  
not register correctly during operation and/or  
the warning buzzer may not sound if the engine  
overheats. Refer to Check Engine Coolant Level  
in Maintenance.  
• Fuel Filter: In-line 113 Micron  
Exmark P/N 112-7836.  
• Fuel Shut-Off Valve: 1/4 turn increments  
(“OFF”, right tank, left tank, )  
• Fuel gauge in left hand fuel tank.  
Cooling System  
• Fan: Electric with continuous operation with  
engine running.  
Electrical System  
• Charging System: External Alternator  
• Charging Capacity: 60 amps  
• Battery Type: BCI Group 26  
• Recommended Minimum Battery CCA: 540 CCA  
• Battery Voltage: 12 Volt  
• Coolant Liquid: 50/50 mix of DexCool©  
extended life antifreeze and water.  
• Coolant Capacity: 4 quarts  
Operator Controls  
• Steering and Motion Control:  
• Polarity: Negative Ground  
• Fuses: One 20 amp blade type; One 30 amp blade  
type  
Note: Motion control levers are adjustable to  
two heights.  
Safety Interlock System  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
• 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.)  
– Steering is controlled by varying the position  
of the levers relative to each other.  
17  
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Specifications  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
Drive  
Front Caster  
Smooth  
Tread Size  
Size  
“Multi-Trac C/S”  
26 x 12.00-12  
4
• PTO Engagement Switch: Engages electric clutch  
(to drive belt) which engages mower blades.  
13 x 6.50-6  
Ply Rating  
Pressure  
• Parking Brake Lever: Engages parking brake.  
10 psi (69 kPa)  
• Deck Height Adjustment Lever: Sets cutting  
height to desired position.  
Cutting Deck  
• Cutting Width:  
• Deck Lift Assist Pedal: Foot pedal that assists in  
raising the deck.  
– 60 inch (152.4 cm)  
– 72 inch (182.9 cm)  
• Discharge: Side  
Seat  
• Type: Deluxe suspension seat high back, low  
profile foam-in-place cushion (dampened,  
adjustable spring suspension) and armrests,  
adjustable back angle.  
• Blade Size: (3 ea.)  
– 60 inch Deck: 20.75 inches (52.7 cm)  
– 72 inch Deck: 24.75 inches (62.9 cm)  
• Mounting: Hinged to tilt up for access to  
hydraulic pumps, battery and other components.  
Held in tilted position with scissor—type links.  
Adjustable fore and aft seat track.  
• Blade Spindles: Solid steel spindles with 1.18 inch  
(30 mm) I.D. bearings.  
• Armrests: Molded adjustable flip-up armrests.  
• Deck Drive:  
• Seat Safety Switch: Integrated seat switch.  
Time delay seat switch eliminates rough ground  
cut-outs.  
– Electric clutch mounted on horizontal engine  
shaft. “B” Section belt (with self-tensioning  
idler) from electric clutch to transfer shaft  
mounted on deck.  
Hydrostatic Ground Drive System  
• Hydrostatic Pumps: Two Hydro Gear PW  
variable displacement piston pumps.  
– Blades are driven by one “B” Section belt  
(w/self-tensioning idler) from transfer shaft  
on deck to blade spindles.  
• Wheel Motors: Two Parker/Ross with 1 1/4 inch  
tapered shafts.  
• Deck:  
Full floating deck is attached to out-front support  
frame. Six anti-scalp rollers provide maximum  
turf protection. Deck design allows for bagging,  
mulching or side discharge.  
• Hydraulic Oil Type: Exmark Premium Hydro oil.  
• Hydraulic Oil Capacity: 5.5 qt. (5.2 L)  
• Hydraulic Filter: Replaceable cartridge type.  
P/N 103-2146: 25 microns, No bypass  
• Speeds:  
• Deck Depth:  
– 60 inch Deck: 6.0 inches (15.2 cm)  
– 72 inch Deck: 6.0 inches (15.2 cm)  
• Cutting Height Adjustment:  
– 0-12.0 mph (19.3 km/hr) forward.  
– 0-8.0 mph (12.9 km/hr) reverse.  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
An extra-long cushioned lever is used to adjust  
the cutting height from 1 inch (2.5 cm) to 5 inches  
(12.7 cm) in 1/4 inch (6.4 mm) increments. The  
cutting height adjustment handle has a transport  
position and all adjustments can be made while  
the operator remains seated. Units also have a  
foot operated deck lift assist lever to aid in raising  
the deck.  
Tires & Wheels  
Drive  
Front Caster  
Pneumatic  
(Air-Filled)  
Semi-Pneumatic  
Quantity  
2
2
• Mulching Kit: Optional.  
18  
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Specifications  
Dimensions  
Torque Requirements  
Bolt Location  
Torque  
Overall Width:  
Blade Drive Sheave  
Mounting Nut  
90-110 ft-lb (122-149 N-m)  
60 inch Deck  
53.5 inches (135.9 61.5 inches (156.2  
cm) cm)  
61.4 inches (156.0 74.3 inches (188.7  
cm) cm)  
Deflector Down 72.8 inches (184.9 85.8 inches (217.9  
72 inch Deck  
Cutter Housing Spindle  
Nut  
160-185 ft-lb (217-251  
N-m)  
Without Deck  
Deflector Up  
Blade Mounting Bolt  
(lubricate with anti-seize)  
55-60 ft-lb (75-81 N-m)  
30-35 ft-lb (41-47 N-m)  
30-35 ft-lb (41-47 N-m)  
50-55 ft-lb (68-75 N-m)  
Engine Deck/Front Frame  
Mount Bolts  
cm)  
cm)  
Anti-Scalp Roller Nyloc  
Nut See Figure 12  
Overall Length:  
Anti-Scalp Roller Hex  
Capscrew See Figure 12  
60 inch Deck  
72 inch Deck  
Roll Bar - Up  
81.9 inches (208.0 85.8 inches (217.9  
Engine Mounting Bolts  
1/2-13 inch screws  
M10 screws  
cm)  
cm)  
67-83 ft-lb (99-113 N-m)  
30 ft-lb (41 N-m)  
Roll Bar - Down 92.5 inches (235.0 96.4 inches (244.9  
cm)  
cm)  
Wheel Lug Nuts  
90-95 ft-lb (122-129 N-m)  
72-77 ft-lb (98-104 N-m)  
Wheel Motor Mounting  
Bolts  
Overall Height:  
Wheel Hub Slotted Nut  
211-260 ft-lb  
(286-352 N-m)  
Roll Bar - Up  
Roll Bar - Down  
72.7 inches (184.7 cm)  
53.8 inches (136.7 cm)  
Rollover Protection System 30-35 ft-lb (41-47 N-m)  
(Roll Bar) Mounting Bolts  
Deck Drive Jackshaft Nut 75-80 ft-lb (102-108 N-m)  
Tread Width: (Center to Center of  
Tires, Widthwise)  
Clutch Retaining Bolt  
55-60 ft-lb (75-81 N-m)  
(secured with threadlocker)  
60 inch Deck  
41.9 inches (106.4 45.9 inches (116.6  
cm) cm)  
37.3 inches (94.7 47.3 inches (120.1  
cm) cm)  
72 inch Deck  
Exhaust Muffler Nuts and 228 in-lb (26 N-m)  
Mounting Bolts  
Drive Wheels  
Caster Wheels  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
60 inch Deck  
72 inch Deck  
56.0 inches (142.2 cm)  
60.2 inches (152.9 cm)  
Curb Weight:  
60 inch Deck  
72 inch Deck  
1545 lb (701 kg)  
1645 lb (746 kg)  
19  
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Operation  
Product Overview  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating 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).  
Figure 4  
1. Motion control levers  
5. Engine Controls (right  
console)  
2. Parking brake  
6. Seat belt  
3. Height of cut adjustment 7. Rollover Protection  
System (ROPS)  
4. Fuel cap (both sides)  
Figure 5  
1. Neutral lock position  
(handles out)  
5. Neutral (operate)  
2. Neutral operate position 6. Reverse  
(handles in)  
3. Front of Unit  
4. Forward  
7. Neutral lock  
Throttle Control  
Located on right fuel tank.  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
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Operation  
and moving the throttle lever to the rear will decrease The valve has three positions, each position made  
engine speed. Moving the throttle forward into the  
detent is full throttle.  
in 1/4 turn increments.  
Fuel Flow  
“Off ”  
Valve Handle Position  
Right  
Down  
Left  
Brake Lever  
Right Tank  
Left Tank  
Located on left side of unit, just to the front of the  
console.  
The brake lever engages a parking brake on the drive  
wheels.  
Fuel Gauge  
Located on the left fuel tank.  
Pull the lever up and rearward to engage the brake.  
The fuel gauge monitors the amount of fuel in the left  
tank only. Use the fuel from the right fuel tank first.  
When the right fuel tank is empty, switch to the left  
fuel tank. Fuel gauge will monitor the remaining fuel.  
Push the lever forward and down to disengage the  
brake.  
The unit must be tied down and brake engaged when  
transporting.  
Drive Wheel Release Valves  
Ignition Switch  
Located on the top right front corner of hydrostatic  
pumps.  
Located on right fuel tank.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position).  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running. Unhook seat  
latch and tilt seat up to gain access to pumps.  
With a 5/8 inch wrench, turn both valves one turn  
counterclockwise to release drive system. Turn  
clockwise to reset system. Do Not overtighten. Do  
Not tow machine.  
Note: Brake must be engaged, motion control levers  
out (neutral lock position) and PTO switch “OFF” to  
start engine. (It is not necessary for the operator to  
be in the seat to start the engine.)  
Tracking Adjustment Knob  
Hour Meter  
Located under the seat on the LH pump control link.  
Located on the right fuel tank.  
Rotating this knob allows fine tuning adjustments so  
that the machine tracks straight with the drive levers  
in the full forward position.  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If the  
ignition switch is left on without engine running,  
hour meter will not run.  
Stop machine and wait for all moving parts to stop.  
Engage park brake. Unhook seat latch and tilt seat  
forward to gain access to the tracking knob. Rotate  
the knob clockwise (as viewed from the rear of the  
machine) to cause the machine to track more to the  
right and counterclockwise to cause the machine  
to track more to the left. Adjust in quarter-turn  
increments until the machine tracks straight. Check  
that the machine does not creep when in neutral with  
the park brake disengaged.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Fuel Shut-Off Valve  
Located directly below the right side of console, next  
to the cubby.  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
Important: Do Not rotate the knob too far, as  
this may cause the machine to creep in neutral.  
Refer to the Motion Control Linkage Adjustment  
section in Maintenance.  
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Operation  
PTO Engagement Switch  
Warning Buzzer  
Located behind the seat under the air deflector on  
the electrical panel.  
Located on right fuel tank.  
Switch must be pulled out (up) to engage the blades.  
Switch is pushed in to disengage the blades.  
The buzzer is a warning signal that the engine  
is overheating or the oil pressure is low. See the  
Troubleshooting section.  
Note: If the engine overheats, the PTO will  
automatically disengage. The PTO cannot be engaged  
until the engine has cooled down. To re-engage the  
PTO, push PTO switch in to the disengaged position  
and then pull out to engage. Refer to the Engine  
overheats in the Troubleshooting section.  
Note: If the engine coolant level is below the  
indicator line on the overflow bottle when the engine  
is cold, the warning buzzer may not sound if the  
engine overheats. Refer to Check Engine Coolant  
Level in Maintenance.  
Coolant Temperature Gauge  
Deck Lift Pedal  
Located at the front of the left fuel tank.  
Located at the right front corner of the floor pan.  
The coolant temperature gauge monitors the  
temperature of the engine coolant. An engine  
overheating condition is indicated by the red area  
on the gauge. An alarm will sound and the PTO  
will disengage. Refer to the Warning Buzzer in the  
Troubleshooting section.  
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.  
Pre-Start  
Fill fuel tank on level ground.  
Note: If the engine coolant level is below the  
indicator line on the overflow bottle when the engine  
is cold, the coolant temperature gauge may not  
register correctly during operation. Refer to Check  
Engine Coolant Level in Maintenance.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Voltmeter  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Located next to the Coolant Temperature Gauge at  
the front of the left fuel tank.  
Determining Fuel  
The voltmeter measure the voltage output of the  
alternator. Both high and low voltages will potentially  
damage the battery.  
The engine runs on clean, fresh diesel fuel with  
a minimum octane rating of 40. Purchase fuel in  
quantities that can be used within 30 days to ensure  
fuel freshness.  
Glow Plug Switch and Light  
Use summer grade diesel fuel (No. 2-D) at  
temperatures above 20°F (-7°C) and winter grade  
diesel fuel (No. 1-D or No. 1-D/2-D blend) below  
20° F (-7° C). Use of winter grade diesel fuel at lower  
temperatures provides lower flash point and pour  
point characteristics, therefore easing startability and  
lessening chances of chemical separation of the fuel  
due to lower temperatures (wax appearance, which  
may plug filters).  
Located on the right fuel tank.  
Depress and hold the switch to heat the glow plugs.  
The glow plug light comes on when the glow plug  
switch is depressed. The glow plug light indicates the  
glow plugs are preheating the combustion chamber.  
Low Oil Pressure Light  
Located on the right fuel tank.  
Use of summer grade diesel fuel above 20°F (-7°C)  
will contribute toward longer life of the pump  
components.  
Light will come on when engine oil pressure is low  
or lost.  
22  
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Operation  
Important: Do Not use kerosene or gasoline  
instead of diesel fuel. Failure to observe this  
caution will damage the engine.  
rear part of the seat is secured with the seat  
latch.  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows the fuel to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system.  
If possible, fill the fuel tank after each use. This will  
minimize possible buildup of condensation inside the  
fuel tank.  
Biodiesel Ready  
This machine can also use a biodiesel blended fuel  
of up to B20 (20% biodiesel, 80% petrodiesel). The  
petrodiesel portion should be low or ultra low sulfur.  
Observe the following precautions:  
• The biodiesel portion of the fuel meets  
specification ASTM D6751 or EN14214.  
• The blended fuel composition should meet  
ASTM D975 or EN590.  
Figure 6  
• Painted surfaces may be damaged by biodiesel  
blends.  
1. Roll bar  
2. Raised position  
3. Pin  
4. Hairpin cotter pin  
• Use B5 (biodiesel content of 5%) or lesser blend  
in cold weather.  
Open the Fuel Shut-Off Valve  
• Monitor seals, hoses, gaskets in contact with fuel  
as they may degrade over time.  
Turn the valve to the LH or RH tank.  
• Fuel filter plugging maybe expected for a time  
after converting to biodiesel blends.  
Starting the Engine  
1. Move the motion control levers out to the neutral  
lock position.  
• Contact your distributor if you wish for more  
information on biodiesel.  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
Operating Instructions  
3. Push down on the PTO switch to the “disengage”  
position.  
Raise the Rollover Protection System  
(ROPS)  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
Important: Lower the roll bar only when  
absolutely necessary.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
1. Remove the hairpin cotter pins and remove the  
two roll bar pins (Figure 6).  
5. On a warm engine, place the throttle in the  
“SLOW” position.  
2. Raise the roll bar to the upright position and  
install the two pins and secure them with the  
hairpin cotter pins (Figure 6).  
6. On a cold engine, (below 14°F (-10°C)), place the  
throttle in the “MIDWAY” position.  
Important: Always use the seat belt with the  
roll bar in the raised position. Ensure that the  
Note: Do Not use fuel left over from summer.  
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Operation  
7. Turn ignition switch to the “ON” position.  
Depress the glow plug switch and the glow plug  
light will turn on. Hold switch as required by  
chart below. Turn the ignition switch to the  
“START” position. Release the ignition switch as  
soon as the engine starts.  
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.  
Glow Plug Chart  
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.  
Ambient Temperature  
Above 50°F (10°C)  
Hold Glow Plugs On  
NO NEED  
Approximately 5 seconds  
Approximately 10 seconds  
20 seconds  
50°F (10°C) to 23°F (-5°C)  
Below 23°F (-5°C)  
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.  
Limit of continuous use  
The glow plug light, located near the glow  
plug switch, will illuminate when the switch is  
depressed. The glow plug light indicates the glow  
plugs are preheating the combustion chamber.  
Important: Operator must be in seat before the  
PTO can be engaged.  
1. Set the throttle midway between the “SLOW” and  
“FAST” positions.  
Important: Do Not crank the engine  
continuously for more then ten seconds at a  
time. If the engine does not start, allow a 30  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor and/or fuel  
solenoid.  
2. Pull the PTO switch outward to engage the blades.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
1. Set the throttle midway between the “SLOW” and  
“FAST” positions.  
8. Move the throttle to the “SLOW” (if in  
“MIDWAY”) and let the engine warm up a few  
minutes before moving the throttle to the “FAST”  
position.  
2. Push the PTO switch in to disengage the blades.  
Stopping the Engine  
1. Bring the unit to a full stop.  
Engaging the PTO  
DANGER  
2. Move the motion control levers out to the neutral  
lock position.  
The rotating blades under the mower deck are  
dangerous. Blade contact can cause serious  
injury or kill you.  
3. Engage the parking brake.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Do Not put hands or feet under the mower or  
mower deck when the blades are engaged.  
5. Disengage the PTO.  
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.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
24  
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Operation  
Driving the Machine  
CAUTION  
3. To move forward in a straight line, move both  
levers forward with equal pressure.  
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.  
• Use caution when making turns.  
• Slow the machine down before making sharp  
turns.  
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.  
When the motion control levers are positioned fully  
outward (apart) in the T-slot, the drive system is in  
the neutral lock position (Figure 7).  
Figure 8  
When the motion control levers are moved directly  
inward (together) the drive system is in the neutral  
operate position.  
To turn left or right, pull the motion control lever  
back toward neutral in the desired turn direction.  
The machine will move faster the farther the  
motion control levers are moved from the neutral  
position.  
4. To stop, position both motion control levers in  
the neutral operate position.  
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 7  
1. Neutral lock position  
(handles out)  
5. Neutral (operate)  
2. Neutral operate position 6. Reverse  
(handles in)  
3. Front of Unit  
4. Forward  
7. Neutral lock  
Driving Forward  
1. Release the parking brake.  
Figure 9  
2. Move the motion control levers inward to the  
center to the neutral position.  
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Operation  
To turn right, release pressure on the RH motion  
control lever and the rear of the machine will  
move towards the rear and to the right.  
See the decal on the side of the deck lift plate for  
cut heights.  
5. Move the deck height lever out of the transport  
position (or 5 inch (12.7 cm) cutting height) and  
down onto the height adjustment pin to mow at  
selected height.  
To turn left, release pressure on the LH motion  
control lever and the rear of the machine will  
move towards the rear and to the left.  
3. To stop, position both motion control levers in  
the neutral operate position.  
Note: The foot operated deck lift assist lever  
can be used to momentarily lift the deck to clear  
objects. Be sure that PTO is disengaged.  
Adjusting the Cutting Height  
Adjusting the Anti-Scalp Rollers  
The cutting height of the mower deck is adjusted  
from 1 to 5 inches (2.54 cm to 12.7 cm) in 1/4 inch  
(6.4 mm) increments.  
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 locked position.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
2. Disengage the PTO.  
2. Disengage the PTO.  
3. Engage the park brake.  
3. Raise the deck height lever to the transport  
position (also the 5 inch (12.7 cm) cutting height  
position)(Figure 10).  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
5. After adjusting the height of cut, adjust the  
anti-scalp rollers by removing the bolt and spring  
disc washer.  
The deck can be raised by pulling the deck lever  
up and/or by pushing down on the foot operated  
deck lift assist lever located at the front right  
corner of the floor pan.  
6. Place the rollers in one of the positions shown  
(Figure 11). Rollers will maintain 3/4 inch (19  
mm) clearance to the ground to minimize gouging  
and roller wear or damage.  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
Figure 11  
For cutting heights above 4.0 inches (102 mm) use the  
bottom hole. The rollers will still be effective against  
scalping.  
Figure 10  
1. Lever in transport and 5 inch (12.7 cm) cutting height  
position  
1. Anti-scalp roller  
mounting bracket  
2. Cutting height  
4. Insert the height adjustment pin into the hole  
corresponding to the desired cutting height and  
install the hairpin cotter pin.  
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.  
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Operation  
7. Be sure the roller bolts are installed with the  
spring disc washer between the head of the bolt  
and the mounting bracket.  
CAUTION  
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.  
Note: The foot operated deck lift assist lever  
can be used to momentarily lift the deck to clear  
objects. Be sure that PTO is disengaged.  
8. Torque the 3/8–24 x 2 Gr 8 hex capscrew to  
50–55 ft-lb (68–75 N-m) (Figure 12).  
Do Not drive a unit on a public street or roadway.  
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.  
• Use extreme caution when operating a unit  
on a ramp.  
• Use only a single, full width ramp; Do Not  
use individual ramps for each side of the unit.  
• If individual ramps must be used, use enough  
ramps to create an unbroken ramp surface  
wider than the unit.  
Figure 12  
1. Spring disc washer  
(cone towards bolt head)  
3. 3/8 nyloc-torque to 30-35  
ft-lb (41-47 N-m)  
• 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.  
2. Front right anti-scalp  
bracket shown  
4. 3/8-24 x 2 GR8 torque to  
50-55 ft-lb (68-75 N-m)  
• Avoid sudden deceleration while backing unit  
down a ramp to avoid tipping backward.  
9. If the 3/8 nyloc nut has been removed,  
re-install and torque to 30–35 ft-lb (41–47 N-m)  
(Figure 12).  
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.  
Transporting  
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.  
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  
27  
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Operation  
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.  
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.  
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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  
and engage parking brake before you do any  
maintenance.  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
• Check the park brake adjustment.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check the rollover protections systems (roll bar) pins.  
• Check the seat belt.  
• Check for loose hardware.  
• Check engine coolant level.  
Before each use or daily  
• Clean the engine cooling system.  
• Clean the engine and exhaust system area.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the cutting deck.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the height adjustment shaft bearings.  
• Grease the rear deck struts.  
Every 40 hours  
Every 50 hours  
• Drain fuel filter/water separator.  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
Owner's Manual for additional information.)  
• Check spark arrester (if equipped).  
• Clean the engine cooling system.  
• Change the engine oil. (May need more often under severe conditions.)  
Every 100 hours  
Every 160 hours  
• Lubricate the brake handle pivot.  
• Lubricate the brake rod bushings.  
• Lubricate the motion control bronze bushings.  
• Grease the brake brackets.  
Every 200 hours  
Every 400 hours  
• Replace the fuel filter/water separator (more often in dirty or dusty conditions).  
29  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check the park brake adjustment.  
Every 500 hours  
• Replace the air cleaner elements. (May need more often under severe conditions. See the  
Engine Owner's Manual for additional information.)  
Every 600 hours  
Every 4,000 hours  
Monthly  
Change engine coolant. Dex-Cool© extended life coolant (orange color)  
• Check the battery charge.  
• Change the engine oil if operated less than 100 hours.  
• Grease the front caster wheel hubs.  
• Grease front caster pivots.  
• Grease the deck drive belt idler arm.  
• Grease the mule drive belt idler arm.  
• Grease the pump drive belt idler arm.  
Yearly  
Periodic Maintenance  
Check Battery Charge  
Service Interval: Monthly  
Check Engine Oil Level  
Service Interval: Before each use or daily  
WARNING  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
CALIFORNIA  
Proposition 65 Warning  
2. Check with engine cold.  
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.  
3. Raise radiator to gain access to dipstick.  
CAUTION  
If the radiator prop rod is not securely  
positioned in the notch the radiator may fall.  
Falling radiator could cause serious injury.  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
Be sure the prop rod is engaged securely in  
the notch at the far right side of the slot.  
4. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Remove the dipstick  
and read the oil level.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
5. 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. Exmark 4-Cycle Premium  
Engine Oil is recommended; refer to the Engine  
Owner's manual for an acceptable alternative. Do  
Not overfill.  
Check the voltage of the battery with a digital  
voltmeter. 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: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Important: Make sure the negative battery cable  
is disconnected and the battery charger used for  
charging the battery has an output of 16 volts and  
30  
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Maintenance  
7 amps or less to avoid damaging the battery (see  
chart for recommended charger settings).  
properly sized jumper cables (4 to 6 AWG) with  
short lengths to reduce voltage drop between  
systems. Make sure the cables are color coded or  
labeled for the correct polarity.  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
CAUTION  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
Connecting the jumper cables incorrectly  
(wrong polarity) can immediately damage the  
electrical system.  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
Be certain of battery terminal polarity and  
jumper cable polarity when hooking up  
batteries.  
1 Hour  
16 volts/7  
amps  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
Note: The following instructions are adapted  
from the SAE J1494 Rev. Dec. 2001 – Battery  
Booster Cables – Surface Vehicle Recommended  
Practice (SAE – Society of Automotive  
Engineers).  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
WARNING  
Recommended Jump  
Starting Procedure  
Service Interval: As required  
Batteries contain acid and produce explosive  
gases.  
• Shield the eyes and face from the batteries  
at all times.  
1. Check the weak battery for terminal corrosion  
(white, green, or blue “snow”), it must be cleaned  
off prior to jump starting. Clean and tighten  
connections as necessary.  
• Do Not lean over the batteries.  
Note: Be sure the vent caps are tight and level.  
Place a damp cloth, if available, over any vent  
caps on both batteries. Be sure the vehicles do  
not touch and that both electrical systems are  
off and at the same rated system voltage. These  
instructions are for negative ground systems only.  
CAUTION  
Corrosion or loose connections can cause  
unwanted electrical voltage spikes at anytime  
during the jump starting procedure.  
3. Connect the positive (+) cable to the positive (+)  
terminal of the discharged battery that is wired to  
the starter or solenoid as shown in Figure 13.  
Do Not attempt to jump start with loose or  
corroded battery terminals or damage to the  
engine may occur.  
DANGER  
Jump starting a weak battery that is cracked,  
frozen, has low electrolyte level, or an  
open/shorted battery cell, can cause an  
explosion resulting in serious personal injury.  
Do Not jump start a weak battery if these  
conditions exist.  
2. Make sure the booster is a good and fully charged  
lead acid battery at 12.6 volts or greater. Use  
31  
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Maintenance  
Figure 14  
1. Install bushing in blade prior to installing bushing in  
spindle.  
Figure 13  
1. Positive (+) cable on discharged battery  
2. Positive (+) cable on booster battery  
3. Negative (–) cable on the booster battery  
4. Negative (–) cable on the engine block  
5. Booster battery  
B. Install bushing/blade assembly into spindle.  
6. Discharged battery  
7. Engine block  
4. Connect the other end of the positive cable to the  
positive terminal of the booster battery.  
5. Connect the black negative (–) cable to the other  
terminal (negative) of the booster battery.  
6. MAKE THE FINAL CONNECTION ON  
THE ENGINE BLOCK OF THE STALLED  
VEHICLE (NOT TO THE NEGATIVE POST)  
AWAY FROM THE BATTERY. STAND BACK.  
Figure 15  
1. Use wrench here for  
blade installation. This  
nut has been torqued to  
90–110 ft-lb (122–149  
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.  
7. Start the vehicle and remove the cables in the  
reverse order of connection (the engine block  
(black) connection is the first to disconnect).  
Check Mower Blades  
Service Interval: Before each use or daily  
C. Apply lubricant to threads of blade bolt as  
needed 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).  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lift deck and secure in raised position as stated  
in the Clean Grass Build-Up Under Deck  
procedure.  
3. Inspect blades and sharpen or replace as required.  
4. Reinstall the blades (if they were removed) in the  
following order:  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
32  
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Maintenance  
Run engine at one-third throttle, with brake  
WARNING  
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.  
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.  
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.  
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.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Check Safety Interlock  
System  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
Service Interval: Before each use or daily  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
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  
lock position. The operator does not need to be  
in the seat to start the engine.  
Check Rollover Protections  
Systems (Roll Bar) Pins  
Service Interval: Before each use or daily  
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.  
Make sure latch pin and hair pin are fully installed  
and lanyard is in good condition.  
Check Seat Belt  
Service Interval: Before each use or daily  
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.  
Visually inspect seat belt for wear, cuts, and proper  
operation of retractor and buckle. Replace before  
operating if damaged.  
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.  
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.  
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).  
Service Air Cleaner  
Service Interval: Every 50 hours—Service  
the air cleaner. (May  
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.  
need more often under  
severe conditions. See  
33  
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Maintenance  
the Engine Owner's  
Manual for additional  
information.)  
5. 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 Exmark 4-Cycle Premium Engine Oil on the  
surface of the rubber seal. Turn filter clockwise  
until rubber seal contacts the filter adapter then  
tighten filter an additional 1 full turn.  
Every 600 hours— Replace  
the air cleaner elements.  
(May need more often  
under severe conditions.  
See the Engine Owner's  
Manual for additional  
information.)  
6. Unlatch radiator and lift it up to access oil fill.  
Clean around oil fill cap and remove cap. Fill  
to specified capacity and replace cap. Use oil  
recommended in the Check Engine Oil Level  
section. 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.  
2. Unhook two air filter canister latches to gain  
access to the air cleaner element.  
7. Remove wire or tie wrap from belt spans  
8. Start the engine at idle for 5 minutes. Stop engine  
and wait three minutes, then check the oil level.  
If required, add oil to bring level to the “FULL”  
mark on the dipstick. Do Not overfill.  
3. Remove air cleaner canister cover and remove  
outer element.  
4. Check the condition of the paper element.  
Replace if dirty, bent or damaged.  
9. Check for leaks, including around the oil filter.  
10. Wipe up any spilled oil.  
5. 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.  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
6. Do Not wash or use pressurized air to clean  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
paper element or inner element.  
7. Reinstall elements. Position the cover so that the  
rubber dust ejector is pointing downward and  
secure with retaining clips.  
2. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use Exmark  
Premium Hydro oil. Replace hydraulic reservoir  
cap and tighten until snug. Do Not overtighten.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
Every 100 hours/Yearly  
(whichever comes first)  
(May need more often  
under severe conditions.)  
temperature of the oil. The “HOT” level shows  
the level of oil when it is at 225°F (107°C). The  
“COLD” level shows the level of the oil when  
it is at 75°F (24°C). Fill to the appropriate level  
depending upon the temperature of the oil. For  
example: If the oil is about 150°F (65°C), fill to  
halfway between the “HOT” and “COLD” levels.  
If the oil is at room temperature (about 75°F  
(24°C)), fill only to the “COLD” level.  
Yearly if operated less  
than 100 hours.  
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. Fasten deck belt spans together with mechanics  
wire or tie wrap to prevent oil from draining onto  
belt.  
Check Tire Pressures  
Service Interval: Every 40 hours  
4. Place pan under machine to catch oil. Remove  
the oil drain plug. Allow oil to drain and replace  
oil drain plug.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
34  
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Maintenance  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 10 psi (69 kPa).  
4. Semi-pneumatic caster tires do not need to be  
inflated.  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
1
1
4. Deck  
Drive Belt  
Idler Arm  
Yearly  
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.  
1
1
2
1
200 Hours  
Yearly  
5. Brake  
Brackets  
6. Mule  
Drive Belt  
Idler Arm  
Check Condition Of Belts  
7. Pump  
Drive Belt  
Idler Arm  
1
1
1
2
Yearly  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up. Remove the  
air detector panel on front side of the engine  
compartment to check pump drive belt and  
alternator belt.  
8. Deck  
Rear Struts  
40 Hours  
* See step 3 for special lubrication instructions on  
the front caster pivots and the Lubricate Caster  
Wheel Hubs section for special lubrication  
instructions on the front casters wheel hubs.  
3. Remove left and right belt shields on deck and lift  
up floor pan to inspect deck drive belt.  
4. Check under machine to inspect the mule  
drive belt. Refer to Mule Drive Belt Tension  
Adjustment section in Adjustments.  
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.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
Number 6 (Mule Drive Belt Idler Arm) Located  
Under Engine Frame  
1. Front  
Caster wheel  
hubs  
*0  
*0  
1
2
2
5
*Yearly  
Number 7 (Pump Drive Belt Idler Arm) Located  
Under Engine Frame  
2. Front  
Caster  
Pivots  
*Yearly  
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.  
3. Height  
Adjustment  
Shaft  
40 Hours  
Bearings  
35  
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Maintenance  
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.  
Wheel Hub - Slotted Nut  
Torque Specification  
Service Interval: After the first 100 hours  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Every 500 hours thereafter  
Torque the slotted nut to 211-260 ft-lb (286-352  
N-m).  
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.  
Note: Do Not use anti-seize on wheel hub.  
Lubricate Caster Wheel Hubs  
Service Interval: As required  
11. Insert the second bearing and new seal into the  
wheel.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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.  
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.  
Figure 16  
1. Seal guard  
2. Spacer nut with wrench  
flats  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
Lubricate Brake Handle Pivot  
Service Interval: Every 160 hours  
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.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate bronze bushings on brake handle pivot  
with a spray type lubricant or light oil.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
Lubricate Brake Rod  
Bushings  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Service Interval: Every 160 hours  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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  
2. Unhook seat latch and tilt seat up.  
3. Lubricate bronze bushings on each end of brake  
rod shaft with a spray type lubricant or a light oil  
36  
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Maintenance  
(bushings are located to the inside of the flange  
bearings).  
Change Inline Fuel Filter  
Service Interval: As required  
An inline fuel filter is installed between the fuel tank  
and the fuel pump. Replace when necessary.  
Lubricate Motion Control  
Bronze Bushings  
Replacement Filters  
Service Interval: Every 160 hours  
Exmark P/N 112-7836  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up.  
Change Hydraulic System  
Filter  
3. Lubricate bronze bushings on flange bearings  
securing the motion control arm shafts with a  
light oil or a spray type lubricant.  
Service Interval: After the first 250 hours  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
Drain Fuel Filter/Water  
Separator  
Service Interval: Every 40 hours  
Note: Use only Exmark P/N 103-2146.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Place a drain pan under the fuel filter and loosen  
the drain plug approximately 1 turn.  
2. Raise seat.  
3. Water should drain.  
3. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
4. When fuel begins to flow from the filter, tighten  
the drain plug.  
4. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Important: Water or other contaminants in fuel  
can severely damage fuel pump and/or the other  
engine components.  
Important: Before reinstalling new filter, fill  
it with Exmark Premium Hydro oil and apply  
a thin coat of oil on the surface of the rubber  
seal.  
Change Fuel Filter/Water  
Separator  
Service Interval: Every 400 hours/Yearly  
(whichever comes first)  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
(more often in dirty or  
dusty conditions).  
5. Fill reservoir as stated in Check Hydraulic Oil  
Level section.  
DANGER  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Use of improper components can result in system  
failure, fuel leakage and possible explosion.  
Hydro Oil  
Change Interval  
500 Hours  
• Ensure that an Authorized Service Dealer  
replace the fuel filter and any components for  
the fuel system.  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
• Use only approved fuel lines, hose clamps  
and fuel filters for high pressure systems.  
37  
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Maintenance  
6. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
CAUTION  
Engine coolant is toxic. Swallowing coolant can  
cause poisoning.  
7. Start engine and move throttle control ahead to  
full throttle position. Move the speed control  
levers to the full speed and run for several  
minutes. Shut down machine and recheck oil  
level.  
• Do Not swallow.  
• Keep out of reach of children and pets.  
Change Engine Coolant  
Service Interval: Every 4,000 hours/Every 4  
years (whichever comes  
Note: Do Not change hydraulic system oil (except  
for what can be drained when changing filter), unless  
it is felt the oil has been contaminated or been  
extremely hot.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
©
first) Dex-Cool extended  
life coolant (orange color)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake. Machine must  
be positioned on level surface.  
Check Engine Coolant Level  
Service Interval: Before each use or daily  
2. Unhook seat latch, tilt seat up and tilt hood  
forward to gain access to the cooling area. Do  
Not raise radiator, as it may not fully drain in that  
position.  
Note: If the engine coolant level is below the  
indicator line on the overflow bottle when the  
engine is cold, the coolant temperature gauge may  
not register correctly during operation and/or  
the warning buzzer may not sound if the engine  
overheats.  
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.  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
Allow the engine to cool completely before  
removing the radiator cap or servicing any  
component of the cooling system.  
3. View coolant level in overflow bottle on the left  
side of the engine compartment. Coolant level  
should be at the indicator line on the overflow  
bottle.  
4. If the coolant level is low, open hood or raise  
radiator, remove the cap to the overflow bottle  
and fill to the indicator line. 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.  
CAUTION  
Engine coolant is toxic. Swallowing coolant  
can cause poisoning.  
• Do Not swallow.  
• Keep out of reach of children and pets.  
WARNING  
3. Drain coolant when engine is cool. Coolant may  
be drained from the radiator by removing the  
drain plug in the right rear corner. The engine  
block may be drained by removing the rear  
radiator hose and/or by opening the drain cock  
on the right-hand side of the engine block (see  
Figure 17).  
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.  
38  
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Maintenance  
core. As air is purged from the engine block and  
the coolant level drops, add additional coolant to  
the radiator.  
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.  
Check Spark Arrester  
(if equipped)  
Service Interval: Every 50 hours  
Figure 17  
2. Drain cock  
1. Oil dipstick  
WARNING  
Hot exhaust system components may ignite fuel  
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.  
4. Reinstall all drain plugs and hoses and tighten  
drain cock.  
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 left side of the engine as required  
to bring the level up to the indicator line on the  
bottle.  
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.  
2. Wait for muffler to cool.  
3. If any breaks in the screen or welds are observed,  
replace arrester.  
WARNING  
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  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
• Shut off engine, wait for moving parts to  
stop, engage parking brake and remove  
key, before performing maintenance.  
• Pump drive sheave set screws.  
6. With the cap off the radiator, tilt hood closed and  
put the seat down. Start the engine as stated in  
the Operating Instructions Section. Return the  
seat up and hood forward to the open position.  
• Square head setscrews on Hydro pump control  
arms.  
• Sheave retaining bolt in the end of engine  
crankshaft.  
7. Operate engine until the engine thermostat opens  
and coolant is circulating through the radiator  
• Caster wheel spacer nuts.  
39  
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Maintenance  
• Fuel tank bulkhead fitting nuts.  
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.  
• Bolts retaining stub shaft to engine flywheel.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
Fuel tank studs, where studs are inserted into tank.  
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.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
• Under top cutter housing bearing guard.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands or  
equivalent support.  
• Between the jackshaft and bearings and the  
jackshaft and sheaves.  
Deck Leveling  
1. Position mower on a flat surface.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Copper-Based Anti-seize  
3. Check tire pressure in drive tires. Proper inflation  
pressure for tires is 10 psi (69 kPa). Adjust if  
necessary.  
Copper-based anti-seize is used in the following  
location:  
On threads of Blade Bolts. See Check Mower  
Blades section.  
4. Set anti-scalp rollers to top holes or remove them  
completely for this adjustment.  
5. Raise the deck to the 5 inch (12.7 cm) height  
position (also transport position) and take all force  
off of the two large deck lift springs by loosening  
the nuts at the front of each spring (Figure 18).  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
Dielectric grease should not be applied to sealed  
connectors.  
6. Lower the deck to the 1 inch (2.54 cm) height  
position. Force the left rear deck support arm  
downward about 1/4 inch (6.4 mm) to get the  
deck to rest at the 1 inch height position. Place  
locking pliers between the rear swivel and spring  
stop to hold the deck in this position (Figure 18).  
7. Place a 3/4 inch (19 mm) thick block of wood  
under each of the two rear anti- scalp roller  
brackets and place one under one of the front  
center anti-scalp roller brackets.  
8. Loosen the two top chain bolts in slots in the rear  
deck lift arms. Loosen jam nuts and back off the  
socket head adjusting screws on the bottom of  
the arms until the chains are just loose. Turn the  
socket head adjusting screws in until slack is taken  
out of each chain. Tighten the jam nuts. Tighten  
40  
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Maintenance  
the chain bolts in the deck lift arms making sure  
they don’t move while tightening.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
9. Loosen the four nuts which secure the front  
swivels (two per side) until the front chains are  
loose and front of deck is supported by the 3/4  
inch (19 mm) block. Do Not loosen the front  
chain hardware.  
Deck Belt Tension  
Self-tensioning - No adjustment necessary.  
10. On left side, adjust front swivel using the locking  
nut behind the swivel until the front chain is tight  
and all slack is removed from linkage. Do Not lift  
front of deck off 3/4 inch (19 mm) block. Secure  
front swivel using locking nut in front of swivel.  
Repeat for right side.  
Mule Drive Belt Tension  
Adjustment  
Self-tensioning idler, adjust as follows:  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
11. Recheck that the 3/4 inch (19 mm) blocks fit just  
snugly under the brackets and that the tension on  
all the chains is approximately equal. Make sure  
all chain attachment bolts are tight. Reposition  
anti-scalp rollers and tighten securely.  
2. Check to make sure the center of the bolt head  
in the center of the spring loaded pulley, on left  
side engine deck support, is positioned between  
the centers of the two alignment holes in the  
left support plate (Figure 19 and Figure 20). It  
is necessary to adjust the belt tension when the  
center of the bolt head is at or below the center of  
the bottom alignment hole.  
3. When adjustment is necessary, loosen the idler  
pulley on the right-hand side so it can move up  
and down in the slot.  
Figure 18  
Place a wrench on the 3/8 inch nut in the center  
of the spring loaded pulley and apply upward  
pressure to relieve tension on the spring (a 1/2  
inch drive breaker bar and 9/16 inch socket works  
best).  
1. Apply downward pressure here  
2. Place locking pliers here to hold spring  
3. 13–1/2 inches (34.3 cm) for cut heights at 2 inches or  
above or 14 inches (35.6 cm) for cut heights below 2  
inches  
4. Remove force on deck springs by loosening nuts here  
Reposition the adjusting pulley to the bottom of  
the slot.  
5. Swivel  
6. Front of unit  
Note: When installing a new belt, it is necessary  
to reposition the right adjusting pulley upward in  
the slot in order to position the center of the spring  
loaded pulley between the alignment holes.  
7. Socket head adjusting screw  
8. Jam nut  
12. Raise deck lift lever to the 5 inch (12.7 cm)  
cutting height position (Figure 10). Adjust spring  
compression until proper distance is obtained  
between the two large washers (Figure 18).  
Adjustment is made by turning the nut at the  
front of each spring (clockwise will shorten the  
spring, counterclockwise will lengthen the spring).  
Lock in position with jam nuts.  
Note: When above adjustments have been made,  
the front of the deck will be slightly lower than the  
rear of the deck.  
41  
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Maintenance  
Belt Guide Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove the belt shield on the right side of mower  
deck.  
3. Note belt guide bolted to deck near the shield  
support stud and right-hand pulley. Guide should  
be 1/8 inch (3.2 mm) away from the belt, with  
bolt-end of guide near end of slot (Figure 21).  
4. If adjustment is necessary, loosen the bolt securing  
the belt guide and make proper adjustment.  
Tighten hardware.  
Figure 19  
2. Alignment holes  
1. Front of unit  
Figure 21  
1. End of slot  
2. Belt guide  
Parking Brake Adjustment  
Service Interval: After the first 100 hours  
Figure 20  
3. Right side idler pulley  
1. Spring idler pulley  
2. Front of unit  
Every 500 hours thereafter  
(adjustable)  
Check to make sure brake is adjusted properly. This  
procedure must be followed after the first 100 hours  
or when a brake component has been removed or  
replaced.  
Alternator Belt Tension  
Stop engine, wait for all moving parts to stop and  
1. Drive the machine onto a level surface.  
remove key. Engage parking brake.  
2. Disengage the blade control switch (PTO), move  
the motion control levers to the neutral locked  
position and set the parking brake.  
Tilt seat and remove air deflector panel  
To tighten alternator belt, loosen both upper and  
lower alternator mounting bolts. Rotate alternator  
out, away from engine and retighten hardware to  
secure in place.  
3. Stop the engine, wait for all moving parts to stop,  
and remove the key.  
4. Raise the back of the machine up and support the  
machine with jack stands.  
When properly tensioned, the alternator belt will  
deflect 1/4 to 3/8 inch (7-9 mm) while applying 22  
pounds of force to the belt midway between fan and  
alternator.  
42  
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Maintenance  
spring. Clearance should measure 1/8 to 3/16  
inch (3.2-4.8 mm). If necessary, adjust the nyloc  
nut accordingly.  
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.  
12. If the correct gap can no longer be achieved  
because there is no clearance between the nyloc  
nut below the spring and the jam nut, or there  
are no threads left in the bottom nyloc nut, the  
length of the brake rod can be adjusted. Remove  
a pin from a yoke at either end of the brake rod  
and lengthen (or shorten) the brake rod until the  
correct gap can be achieved.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
13. If a brake component has been removed or  
replaced, see the steps below; otherwise proceed  
to step 14.  
5. Remove the rear tires from the machine.  
6. Remove any debris from the brake area.  
7. Engage the parking brake (lever up).  
Burnishing the Brake Procedure:  
8. Loosen the jam nut (item 9 in Figure 22) just  
above the trunnion roller 2-3 turns.  
A. Clear the area of any flammable material  
before starting the burnishing process.  
B. While sitting in the operator’s seat, start the  
engine, and release the park brake.  
WARNING  
Engine must be running and drive wheels  
must be turning so adjustments 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.  
C. Increase the throttle to high idle.  
D. Bring both drive levers out of neutral and  
push them into full forward position.  
Figure 22  
E. Pull the park brake lever up until the engine  
rpm starts to drop. Hold the park brake lever  
in this position for 15 seconds.  
1. Lever down  
(disengaged)  
6. Remove pin to adjust  
rod length for additional  
brake adjustment  
2. Lever up (engaged)  
7. Trunnion roller  
F. Release the brake lever.  
3. Nyloc nut below trunnion 8. Spring retainer bracket  
roller  
G. Move the drive levers into the full reverse  
position. Repeat steps E and F.  
4. Nyloc nut below spring  
9. Jam nut above trunnion  
roller  
H. Move the drive levers back to the neutral lock  
position.  
5. 1/8 to 3/16 inch (3.2 to  
4.8 mm)  
I. Return the throttle to low idle, and stop the  
engine.  
9. Tighten the bottom nyloc nut (item 3 in Figure 22)  
until the brake spring is completely compressed,  
then loosen one-half turn.  
J. Allow the brake bands and drums to cool.  
Repeat steps 7 through 11.  
14. Install the tires and torque the lug nuts to 90-95  
ft-lb (122-129 N-m).  
10. Tighten the jam nut against the trunnion roller  
11. Check the clearance between the bottom of the  
brake bracket and the nyloc nut just under the  
15. Remove the jack stands.  
43  
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Maintenance  
Electric Clutch Adjustment  
No adjustment necessary. However when the clutch  
brake has worn to the point where the clutch no  
longer engages consistently, the shim can be removed  
to extend the clutch life.  
Figure 24  
1. Brake mounting bolt  
2. Shim  
B. Using needle nose pliers, or by hand, take  
hold of the tab and remove the shim (Do Not  
discard the shim until proper clutch function  
has been confirmed).  
Figure 23  
1. Armature  
5. Brake spacer  
6. Re-gap shim  
7. Brake pole  
2. Field shell  
3. Rotor  
C. Using a pneumatic line, blow out any debris  
from under the brake pole and around the  
brake spacers.  
4. Brake mounting bolt  
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13  
N-m) +/-0.5 ft-lb (0.7 N-m).  
Removing the Shim:  
1. Stop engine, wait for all moving parts to stop,  
and remove key. Engage parking brake. Allow  
the machine to cool completely before starting  
these instructions.  
E. Using a 0.010 inch thick feeler gauge, verify  
that a gap is present between the rotor and  
armature face on both sides of the brake pole  
as shown. (Due to the way the rotor and  
armature faces wear (peaks and valleys) it is  
sometimes difficult to measure the true gap.)  
2. Using a pneumatic line, blow out any debris  
from under the brake pole and around the brake  
spacers.  
3. Check the condition of the wire harness leads,  
connectors, and terminals. Clean or repair as  
necessary.  
4. Verify that 12V is present at the clutch connector  
when the PTO switch is engaged.  
G011733  
5. Measure the gap between the rotor and armature.  
If the gap is greater than .04 inch (1 mm), proceed  
with the following steps:  
1
Figure 25  
1. Feeler gauge  
A. Loosen both brake mounting bolts one-half  
to one full turn (see Figure 24).  
Note: Do Not remove the brake pole from  
the field shell/armature. The brake pole has  
worn to match the armature and needs to  
continue to match after the shim is removed  
to ensure proper brake torque.  
44  
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Maintenance  
5. If adjustment is needed, loosen the nut against the  
yoke and while applying slight rearward pressure  
on the motion control lever, turn the head of the  
adjustment bolt in the appropriate direction until  
lever is centered (keeping rearward pressure on  
the lever will keep the pin at the end of the slot  
and allow the adjustment bolt to move the lever  
to the appropriate position). Tighten lock nut.  
6. Repeat on opposite side of unit.  
Figure 26  
1. Feeler gauge  
• If the gap is less than 0.010 inch, then  
reinstall the shim and reference the  
Troubleshooting section.  
• If the gap is sufficient, proceed to the  
safety check in step F.  
F. Perform the following safety check:  
a. Sit on the seat and start the engine.  
b. Make sure the blades Do Not engage with  
the PTO switch “off ” and the clutch  
disengaged.  
Figure 27  
If the clutch does not disengage,  
reinstall the shim and reference the  
Troubleshooting section.  
1. Turn bolt here  
2. Lever centered in notch  
3. End of slot  
4. Yoke  
5. Loosen here  
6. Reverse indicator  
c. Engage and disengage the PTO switch  
ten consecutive times to ensure the clutch  
is functioning properly. If the clutch  
does not engage properly, reference the  
Troubleshooting section.  
Motion Control Linkage  
Adjustment  
WARNING  
Reverse Indicator  
Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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.  
2. Unhook seat latch and tilt seat forward.  
3. Begin with either the left or right motion control  
lever. Move lever to the neutral position and pull  
lever back until the clevis pin (on arm below pivot  
shaft) contacts the end of the slot (just beginning  
to put pressure on spring). (Figure 27).  
4. Check where lever is relative to notch in console  
(should be centered allowing lever to pivot  
outward to the neutral lock position).  
45  
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Maintenance  
because of the jumper wire being used. Run  
engine at full throttle and release brake.  
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.  
7. The reverse indicator spring must be correct  
before the following adjustments can be made.  
See the Reverse Indicator Adjustment section.  
Note: The motion control lever needs to be in  
neutral while making any necessary adjustments.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands or  
equivalent support.  
The left rod assembly controls the left wheel and  
the right rod assembly controls the right wheel.  
8. Bring the motion control lever into the neutral  
position. Adjust RH pump control rod length  
by rotating the double nuts on the rod in the  
appropriate direction until the wheels slightly  
creep in reverse (Figure 28). Move the motion  
control lever to the reverse position and while  
applying slight pressure to the lever allow the  
reverse indicator spring to bring the levers back to  
neutral. The wheel must stop turning or slightly  
creep in reverse. When adjustment is complete,  
tighten lock nuts onto ball joints.  
1. This adjustment must be made with the drive  
wheels turning. First raise the rear of machine  
up and support with jack stands (or equivalent  
support) just high enough to allow the drive  
wheels to rotate freely.  
2. Unhook seat latch and tilt seat forward.  
3. Remove the electrical connection from the seat  
safety switch, located directly to the left of the seat  
switch assembly beside the hydraulic oil reservoir.  
Temporarily install a jumper wire across the  
terminals in the connector of the main wiring  
harness.  
9. Bring the LH motion control lever into the  
neutral position. Adjust the LH pump control rod  
length by rotating the tracking adjustment knob in  
the appropriate direction until the wheels slightly  
creep in reverse. Move the motion control lever  
to the reverse position and while applying slight  
pressure to the lever allow the reverse indicator  
spring to bring the levers back to neutral. The  
wheel must stop turning or slightly creep in  
reverse (Figure 29).  
4. Run the unit at least 5 minutes with the drive  
levers at full forward speed to bring hydraulic  
system oil up to operating temperature.  
5. Loosen lock nuts from the ball joints at each end  
of the pump control linkage (Figure 28).  
Figure 29  
Figure 28  
Left-Hand Side of Unit  
Right-Hand Side of Unit  
1. Turn LH tracking adjustment knob. (Do Not loosen any  
nuts on LH side)  
1. Turn here to adjust  
2. Loosen here (right-hand  
thread)  
10. Shut off unit. Remove jumper wire from wire  
harness connector and plug connector into seat  
switch.  
6. Start engine. Brake must be engaged and  
motion control levers out to start engine.  
Operator does not have to be in the seat  
46  
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Maintenance  
Motion Control Damper  
Adjustment  
The top damper mounting bolt can be adjusted to  
obtain a more desired motion control lever resistance.  
See Figure 30 for mounting options.  
Figure 31  
1. Spring disc washers  
Figure 30  
1. Motion control bracket  
2. Least resistance (softest feel)  
3. Medium resistance (medium feel)  
4. Most resistance (firmest feel)  
5. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt must  
protrude past end of nyloc nut after torque.  
6. Damper  
7. Damper must move freely on bolt.  
Caster Pivot Bearings  
Pre-Load Adjustment  
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 31.  
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Maintenance  
CAUTION  
Cleaning  
Excessive debris around engine and exhaust  
system area can cause engine, exhaust area, and  
hydraulic system to overheat which can create  
a fire hazard.  
Clean Engine Cooling  
System  
Clean all debris from engine and exhaust system  
area.  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
conditions.)  
2. Remove air deflector panel from behind seat.  
3. Clean around flywheel, cylinder head, injectors,  
and injector pump.  
4. Clean all debris from the exhaust system area.  
5. Wipe up any excessive grease or oil around the  
engine and exhaust area.  
CAUTION  
Excessive debris around the engine cooling  
air intake and inside of the pump drive belt  
compartment and damaged or missing rubber  
baffles can cause the engine and hydraulic  
system to overheat which can create a fire hazard.  
6. Reinstall the air deflector panel.  
• Clean all debris from inside of pump drive  
belt compartment daily.  
Important: Do Not use water to clean  
engine. Use low pressure compressed air. See  
Engine Owner's Manual.  
• Clean debris from radiator screen and core  
daily.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Clean the Radiator  
Service Interval: Every 50 hours (May be  
required more often in dry  
2. Clean all debris from inside of pump drive belt  
compartment.  
or dirty conditions.)  
1. Stop engine, wait for all rotating parts to stop and  
remove key. Engage parking brake.  
2. Allow engine to cool.  
3. Wipe debris from screen in engine cover.  
4. Rotate engine cover forward and wipe debris  
from radiator core as required.  
3. Rotate seat and engine cover forward.  
5. Clean debris from radiator fins with compressed  
air.  
4. While holding fan up, remove the four screws  
attaching the fan to the shroud. Disconnect and  
remove the fan.  
5. Using compressed air, blow out debris stuck  
between the fins of the entire radiator, both from  
the top down and from the bottom up.  
6. If debris remains, it may be necessary to use water  
from a low pressure hose. If the radiator is clean,  
proceed to step 8.  
7. Cover the engine with a piece of cardboard, or a  
plastic sheet. Squirt water down through the fins.  
Blow through with low pressure air from both  
directions. If debris remains, repeat until clean.  
Important: If debris or air can not be blown  
through the radiator, see Cleaning of the  
Radiator section.  
6. Inspect seals in engine cover and replace if  
necessary.  
Clean Engine and Exhaust  
System Area  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
8. Re-assemble the fan to the radiator. Reconnect  
the fan.  
conditions.)  
9. Start the engine to ensure the fan is functioning  
properly.  
48  
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Maintenance  
Battery Disposal  
DANGER  
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.  
Clean Debris From Machine  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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  
• In the event of an accident, flush with water  
and call a doctor immediately.  
Service Interval: Before each use or daily  
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.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Raise deck to the transport (5 inch (12.7 cm)  
cutting height) position. Lift the front of unit  
and support unit using jack stands or equivalent  
support.  
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.  
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.  
Waste Disposal  
Motor Oil Disposal  
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.  
49  
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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.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not engaged.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery. See Check  
Battery Charge and Recommended  
Jump Starting Procedure sections in  
Maintenance.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
6. Replace the blown fuse.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle is not in the correct position. 4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
7. Clean or replace the air cleaner element.  
8. Seat switch is not functioning properly.  
8. Check the seat switch indicator. Replace  
seat if needed.  
9. Electrical connections are corroded, loose 9. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
10. Relay or switch is defective.  
1. Engine load is excessive  
10. Contact an Authorized Service Dealer.  
Engine loses power  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Vent hole in the fuel cap is plugged.  
6. Dirt in fuel filter.  
5. Clean or replace the fuel cap.  
6. Replace the fuel filter.  
7. Dirt, water, or stale fuel is in the fuel  
system.  
7. Contact an Authorized Service Dealer.  
50  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats.  
1. Engine load is excessive.  
1. Reduce the ground speed.  
2. Oil level in the crankcase is low.  
3. Dirty air filter.  
4. Coolant level is low.  
2. Add oil to the crankcase.  
3. Clean or replace the air cleaner element.  
4. Add coolant.  
5. Debris on or around radiator.  
5. Remove debris (see Clean the Radiator  
section in Maintenance).  
6. Water pump or alternator belt is worn,  
loose, or broken.  
6. Contact an Authorized Service Dealer.  
Mower pulls left or right (with levers fully  
forward)  
1. Tracking needs adjustment.  
1. Adjust the tracking.  
2. Tire pressure in drive tires not correct.  
2. Adjust tire pressure in the drive tires.  
3. Reverse indicator and motion control  
linkage need adjustment.  
3. Adjust the reverse indicator and the  
motion control linkage.  
Machine does not drive  
1. By pass valve is not closed tight.  
1. Tighten the by pass valve.  
2. Change the belt.  
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.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Uneven cutting height.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. 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.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
7. Belt is damaged.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
7. Install new belt.  
Blades do not rotate.  
1. Drive belt is worn, loose or broken.  
2. Drive belt is off pulley.  
1. Check the belt tension.  
2. Check belt for damage; replace if  
necessary. Install drive belt and check belt  
guide for correct position.  
3. Deck belt is worn, loose or broken.  
4. Deck belt is off pulley.  
3. Install new deck belt.  
4. Install deck pulley and check the idler  
pulley, idler arm and spring for correct  
position and function.  
5. Broken or missing idler spring.  
6. Clutch has disengaged.  
5. Replace the spring.  
6. Engine has overheated; determine cause  
of overheat (see Engine overheats).  
51  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Warning buzzer emits continuous beep. (See  
also Engine overheats).  
1. Temperature is increasing on coolant  
temperature gauge.  
1. Turn unit off and allow engine and engine  
components to cool.  
2. Coolant level is low.  
2. Add coolant.  
3. Debris on or around radiator.  
3. Remove debris.  
4. Water pump or alternator belt is worn,  
loose or broken.  
4. Contact Authorized Service Dealer.  
Warning buzzer emits intermittent beep.  
Clutch will not engage.  
1. Oil level is low.  
1. Check oil level.  
2. Oil leaking from engine.  
2. Contact Authorized Service Dealer.  
1. Fuse is blown.  
1. Replace fuse. Check coil resistance,  
battery charge, charging system, and  
wiring connections and replace if  
necessary.  
2. Low voltage supply at the clutch.  
2. Check coil resistance, battery charge,  
charging system, and wiring connections  
and replace if necessary.  
3. Damaged coil.  
3. Replace clutch.  
4. Inadequate current supply.  
4. Repair or replace clutch lead wire or  
electrical system. Clean connector  
contacts.  
5. Remove shim or replace clutch.  
6. Determine cause of overheat (see Engine  
overheats).  
5. Rotor/armature airgap is too large.  
6. Engine has overheated.  
52  
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Schematics  
Schematics  
Electrical Diagram  
R
O
T
A
Y
N
Y
A
R
R
A
O
OR  
E
T
T
T
A
L
   O
P
REL  
N
   H
MTER  
A
REL  
R
E
T
L
   2
A
ONEC  
3
1
   5
   5
   3
TER  
   4
   3
   1
   4
   1
W
R
2
2
TB"  
O
A
L
2
1
T
TMEP  
T
   A
T
   O
S
         T
G
P
RAIL  
SDNER  
   S
S
SIGNAL  
   F
S
HOLD"  
+
P
S
3
2
1
5
4
3
2
1
5
4
3
2
1
2
1
1
1
1
1
1
1
1
1
1
1
CK  
CK  
A
C
A
A
CK  
A
CK  
WB/L  
      B
A
O
W
O
WR/ED  
CK  
RDE  
O
O
C/KGREN  
A
WB/L  
A
         K
T
O
C/KGREN  
DGKREN  
YLE  
         W
E
      L
A
P
PINK  
D
BL  
L
A
YLE  
YLE  
B
O
I
YLE  
BL  
V
PNIK/BL  
OARNGE/BL  
CK  
A
B
Y
W
A
3
   1
O
   5
   4
   G
REL  
21  
   2
F
UMP  
1
2
12345  
C A K B L  
W O N R / B  
O R A N G E  
C A K B L  
A
UEG  
METR  
A
C
L
O
V
ABC  
B
K
C
W
T
AND  
A
O
L
B
/
6
   G
SWITCH  
3218  
C A K B L  
C A K B L  
C
N
A
W
O
B
R
87654321  
D
B
C A K  
P I N K / B L  
E
L
2A  
C A K / W B H L I T E  
W
1A  
O
C A K  
O R A N G E / B L  
   B
              N
GL  
2
A
1
AB  
IDOE  
12AB  
Y
A
T
Y
Y A G R  
L
A
R
E
A
   1
   4
D
T
   5
   2
S
REL  
T
A
13  
12345  
   S
MULIODE  
O R A N G E  
Y A G R  
D K G R E E N  
T L B L U E  
   1
O
T
   6
BRAKE  
   3
   9
3
2
   P
SWITCH  
   8
   2
1423  
V I O L E T  
   7
4
   1
417256389  
OL  
TOIN  
R
D K G R E E N  
O
   2
A
12  
LHM  
CNOT  
Y A G R  
1
O
T
BA  
   P
LUTCH  
T L G R E E N  
T L B L U E  
B
   2
OL  
TOIN  
R
12  
O
1
R
CONT  
   1
T
2
A
21  
   S
SWITCH  
R E D  
R E D  
2
C
W
A
O
FSUE  
12  
BL  
4
GL  
N
TBLUE  
L
W
1
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B
R
B
Y
A
L
E
D
C
T
1
A
ABC  
   S
MODLEINPUT  
A
N
A
21  
FSUE  
F
AN  
30AMP  
T
2
OL  
R
B
Y
A
C
T
ABC  
A
A
   S
MDULECONT  
CK  
A
K
CK  
CK  
C
A
A
A
WB/L  
L
C
CK  
C
O
B
A
A
/
A
WB/L  
WB/L  
N
   K
C
CK  
O
O
RED  
BL  
A
W
A
A
C
W
CK  
Y
YLE  
A
O
A
R
O
A
AN  
PNIK  
   L
B
BL  
R
R
O
T
O
O
YLE  
B
BL  
B
YEL  
P
PINK/BL  
GR  
YLE  
   1
   2
   A
   B
   1
   2
   3
   4
   5
   1
   2
   3
   4
   5
   1
   1
   2
   1
   4
   5
   3
   1
   2
   3
   4
   5
   1
   4
B+  
   3
1
2
   5
   5
   2
   5
   5
ONUD  
R
   4
   3
   1
   1
   4
   3
1
   3
   1
   4
G
2
2
2
Y
L
AN  
F
Y
FUSE  
A
Y
Y
THC  
O
   2
IGNSW  
A
THC  
A
SUP  
A
T
A
G
SWITCH  
O
   P
L
REL  
T
AN  
F
REL  
   P
U
REL  
G017016  
53  
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Schematics  
Electrical Schematic  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of two years.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. or Canada. This warranty may only be  
assigned or transferred to a second (or third) owner by an  
authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
Owner’s Responsibilities  
If your product requires warranty service it must be returned  
to an authorized Exmark service dealer within the warranty  
period. This warranty extends only to turf equipment operated  
under normal conditions. You must read the operator’s  
manual. You must also properly service and maintain your  
Exmark product as described in the operator’s manual. Such  
routine maintenance, whether performed by a dealer or by  
you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
*
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
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.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
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 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.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
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.  
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.  
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.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-589_C  
55  
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Notes:  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
57  
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Figure 32  
This page may be copied for personal use.  
1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the  
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold  
along the appropriate line to match the recommended slope.  
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.  
3. Example of how to compare slope with folded edge.  
59  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
©2011 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4501-041 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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