LAZER Z® XS
DIESEL MODELS
For Serial Nos.
790,000 & Higher
Part No. 4500-501 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.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Figure 1
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
1. Model and serial number location
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.
Model No.
Serial No.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
numbers on the product. Write the numbers in the
space provided.
3
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Caster Pivot Bearings Pre-Load
Contents
Introduction ........................................................... 3
Lubricate Motion Control Bronze
Wheel Hub - Slotted Nut Torque
4
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Safety
• Never let children or untrained people operate
Safety
Safety Alert Symbol
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents
or service the equipment. Local regulations may
restrict the age of the operator.
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
Preparation
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
Figure 2
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
CAUTION
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
Wear hearing protection when operating this
machine.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
Safe Operating Practices
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
5
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Safety
DANGER
WARNING
In certain conditions diesel fuel is extremely
flammable and vapors are explosive.
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.
A fire or explosion from diesel fuel can burn
you, others, and cause property damage.
• Avoid prolonged breathing of vapors.
• Fill the fuel tank outdoors in an open
area, when the engine is cold. Wipe up
any diesel fuel that spills.
• Keep face away from nozzle and diesel
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• Do Not fill the fuel tank completely full.
Add diesel fuel to the fuel tank until the
level is 1/4 to 1/2 inch (6–13 mm) below
the bottom of the filler neck. This empty
space in the tank allows diesel fuel to
expand.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
Operation
• Never smoke when handling diesel fuel,
and stay away from an open flame or
where diesel fuel fumes may be ignited
by spark.
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.
• 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.
• Allow engine parts, especially the muffler,
to cool before touching.
• Remove accumulated debris from muffler
and engine area.
• 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.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
WARNING
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can
kill you.
Do Not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
6
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Safety
• 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.
• 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.
• Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• 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.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
• Do Not change the engine governor setting or
overspeed the engine.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
Slope Operation
– Before checking, cleaning or working on the
mower.
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.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
DANGER
– Before clearing blockages.
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.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
– Before refueling.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
– Before dumping the grass catcher.
• Do Not mow slopes greater than 15
degrees.
WARNING
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
• Reduce speed and use extreme caution
on slopes.
• Avoid sudden turns or rapid speed
changes.
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
• Keep the roll bar in the raised and locked
position and use seat belt.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• NEVER carry passengers. DO NOT operate
the mower when people, especially children, or
pets are in the area.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
7
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Safety
Using the Rollover Protection System
(ROPS)
A Rollover Protection System (roll bar) is installed
on the unit.
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.
Figure 3
1. Safe Zone-Use the mower here on slopes less than 15
degrees
2. Danger Zone-Use a walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
• Lower the roll bar only when absolutely
necessary.
• Do Not wear seat belt when the roll bar
is down.
3. Water
• Drive slowly and carefully.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Raise the roll bar as soon as clearance
permits.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Check carefully for overhead clearances (i.e.
branches, doorways, and electrical wires) before
driving under any objects and Do Not contact
them.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• In the event of a rollover, take the unit to an
Authorized Service Dealer to have the ROPS
inspected.
• 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.
Maintenance and Storage
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Keep engine, engine area, and pump drive belt
compartment 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.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
• Let engine cool before storing and do not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
8
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Safety
• Park machine on level ground. Never allow
untrained personnel to service machine.
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.
• Use jack stands to support components when
required.
• Carefully release pressure from components with
stored energy.
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
negative terminal first and the positive last.
Reconnect positive first and negative last.
• 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.
• 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 body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
• Use cardboard or paper, not your hands,
to find hydraulic leaks.
• 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.
• 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.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Check all bolts frequently to maintain proper
tightness.
WARNING
Fuel system components are under high
pressure. The use of improper components
can result in system failure, fuel leakage and
possible explosion.
• Frequently check for worn or deteriorating
components that could create a hazard.
• All replacement parts must be the same as
or equivalent to the parts supplied as original
equipment.
Use only approved fuel lines and clamps for
high pressure systems.
9
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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
10
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Safety
103-2076
103-0223
103-7218
103-0261
103-1798
107-2102
11
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Safety
107-2112
109-1399
109-0872
109-2219
109-1214
109-2263
109-1215
12
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Safety
109-2264
109-2478
109-2951
109-3148
13
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Safety
116-0997
109-6855
109-7949
19426-87881
116-0127
19426-87903
116-0404
14
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Safety
107-9866
3. Neutral
1. Fast
2. Slow
4. Reverse
15
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Specifications
Specifications
Model Numbers
Serial Nos: 790,000 and Higher
LXS25KD605; LXS25KD665; LXS25KD725
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
• RPM: Full Speed: 3850 ±50 RPM (No Load)
Idle: 1400 RPM
Cooling System
• Fan: Electric with continuous operation with
engine running.
Fuel System
• Coolant Liquid: 50/50 mix of DexCool©
• Capacity: 15.5 gal. (58.6 L)
extended life antifreeze and water.
• Type of Fuel: Diesel fuel, 40 cetane or higher or
biodiesel up to B20 (20% biodiesel, 80% petro
diesel).
• Coolant Capacity: 4 quarts
Operator Controls
• Steering and Motion Control:
• Fuel Filter: In-line 113 Micron
Exmark P/N 112-7836.
Note: Motion control levers are adjustable to
two heights.
• Fuel Shut-Off Valve: 1/4 turn increments
(“OFF”, right tank, left tank, )
– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.
• Fuel gauge in left hand fuel tank.
Electrical System
– Steering is controlled by varying the position
of the levers relative to each other.
• Charging System: External Alternator
• Charging Capacity: 60 amps
• Battery Type: BCI Group 26
• Battery Voltage: 12 Volt
– Moving motion control levers outward (in
slots) locks the drive system in neutral.
• PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.
• Parking Brake Lever: Engages parking brake.
• Polarity: Negative Ground
• Deck Height Adjustment Lever: Sets cutting
height to desired position.
• Fuses: One 20 amp blade type; One 30 amp blade
type
• Deck Lift Assist Lever: Foot pedal that assists
in raising the deck.
Safety Interlock System
• 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.)
Seat
• Type: Deluxe suspension seat high back, low
profile foam-in-place cushion (dampened,
adjustable spring suspension) and armrests,
adjustable back angle.
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Specifications
• 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.
• Discharge: Side
• Blade Size: (3 ea.)
– 60 inch Deck: 20.75 inches (52.7 cm)
– 66 inch Deck: 22.75 inches (57.8 cm)
– 72 inch Deck: 24.75 inches (62.9 cm)
• Armrests: Molded adjustable flip-up armrests.
• Seat Safety Switch: Incorporated into the
Safety Interlock System. Time delay seat switch
eliminates rough ground cut-outs.
• Blade Spindles: Solid steel spindles with 1.18 inch
(30 mm) I.D. bearings.
• Deck Drive:
Hydrostatic Ground Drive System
– Electric clutch mounted on horizontal engine
shaft. “B” Section belt (with self-tensioning
idler) from electric clutch to transfer shaft
mounted on deck.
• Hydrostatic Pumps: Two Hydro Gear PW
variable displacement piston pumps.
• Wheel Motors: Two Parker/Ross with 1 1/4 inch
tapered shafts.
– Blades are driven by one “B” Section belt
(w/self-tensioning idler) from transfer shaft
on deck to blade spindles.
• 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:
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.
– 0-12.0 mph (19.3 km/hr) forward.
– 0-8.0 mph (12.9 km/hr) reverse.
• Deck Depth:
• Drive wheel release valves allow machine to be
moved when engine is not running.
– 60 inch Deck: 6.0 inches (15.2 cm)
– 66 inch Deck: 6.0 inches (15.2 cm)
– 72 inch Deck: 6.0 inches (15.2 cm)
• Cutting Height Adjustment:
Tires & Wheels
Drive
Front Caster
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.
Pneumatic
(Air-Filled)
Semi-Pneumatic
Deck Size
Quantity
60, 66, & 72
2
All Decks
2
Tread Size
“Multi-Trac
C/S”
Smooth
Size
26 x 12.00-12
4
13 x 6.50-6
• Mulching Kit: Optional.
Ply Rating
Pressure
10 psi (69 kPa)
Cutting Deck
• Cutting Width:
– 60 inch (152.4 cm)
– 66 inch (167.6 cm)
– 72 inch (182.9 cm)
17
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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
66 inch
Deck
72 inch
Deck
Cutter Housing Spindle
Nut
160-185 ft-lb (217-251
N-m)
Without
Deck
53.5 inches 57.3 inches 61.5 inches
(135.9 cm) (145.5 cm) (156.2 cm)
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)
Deflector
Up
61.4 inches 68.0 inches 74.3 inches
(156.0 cm) (172.7 cm) (188.7 cm)
Engine Deck/Front Frame
Mount Bolts
Deflector
Down
72.8 inches 79.4 inches 85.8 inches
(184.9 cm) (201.7 cm) (217.9 cm)
Anti-Scalp Roller Nyloc
Nut See Figure 10
Overall Length:
Anti-Scalp Roller Hex
Capscrew See Figure 10
60 inch
Deck
66 inch
Deck
72 inch
Deck
Engine Mounting Bolts
Wheel Lug Nuts
15-20 ft-lb (20-27 N-m)
90-95 ft-lb (122-129 N-m)
72-77 ft-lb (98-104 N-m)
Roll Bar -
Up
81.9 inches 83.4 inches 85.8 inches
(208.0 cm) (211.8 cm) (217.9 cm)
Wheel Motor Mounting
Bolts
Roll Bar -
Down
92.5 inches 94.0 inches 96.4 inches
(235.0 cm) (238.8 cm) (244.9 cm)
Wheel Hub Slotted Nut
minimum 125 ft-lb
(169 N-m)
Rollover Protection System 30-35 ft-lb (41-47 N-m)
(Roll Bar) Mounting Bolts
Overall Height:
Roll Bar - Up
Roll Bar - Down
Deck Drive Jackshaft Nut 75-80 ft-lb (102-108 N-m)
72.7 inches (184.7 cm)
53.8 inches (136.7 cm)
Clutch Retaining Bolt
55-60 ft-lb (75-81 N-m)
(secured with threadlocker)
Tread Width: (Center to Center of
Tires, Widthwise)
60 inch
Deck
66 inch
Deck
72 inch
Deck
Drive
Wheels
41.9 inches 45.9 inches 45.9 inches
(106.4 cm) (116.6 cm) (116.6 cm)
Caster
Wheels
37.3 inches 42.3 inches 47.3 inches
(94.7 cm)
(107.4 cm) (120.1 cm)
Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
60 inch Deck
66 inch Deck
72 inch Deck
56.0 inches
(142.2 cm)
57.6 inches
(146.3 cm)
60.2 inches
(152.9 cm)
Curb Weight:
60 inch Deck
66 inch Deck
72 inch Deck
1545 lb (701 kg) 1595 lb (723 kg) 1645 lb (746 kg)
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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. The levers control the flow of hydraulic
oil from the hydrostatic pump to the drive wheel
motor for each side.
Moving the levers forward or backward turns the
wheel on the same side forward or in reverse. 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 4
1. Motion Control Lever
2. Parking Brake Lever
3. Height-of-Cut Lever
5. Controls
6. Seat Belt
7. Roll Bar
Throttle Control
Located on right fuel tank.
4. Fuel Cap (Both Sides)
The throttle is used to control engine speed. Moving
the throttle lever forward will increase engine speed
and moving the throttle lever to the rear will decrease
engine speed. Moving the throttle forward into the
detent is full throttle.
Brake Lever
Located on left side of unit, just to the front of the
console.
The brake lever engages a parking brake on the drive
wheels.
Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the
brake.
The unit must be tied down and brake engaged when
transporting.
Ignition Switch
Located on right fuel tank.
The ignition switch is used to start and stop the
engine. The switch has three positions “OFF”, “ON”
19
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Operation
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.
The valve has three positions, each position made
in 1/4 turn increments.
PTO Engagement Switch
Fuel Flow
“Off ”
Valve Handle Position
Located on right fuel tank.
Right
Down
Left
Switch must be pulled out to the “ROTATE”
position to engage the blades. Switch is pushed in to
the “STOP” position to stop the blades.
Right Tank
Left Tank
Coolant Temperature Gauge
Fuel Gauge
Located at the front of the left fuel tank.
Located on the left fuel tank.
The coolant temperature gauge monitors the
temperature of the engine coolant. An engine
overheating condition is indicated by the red area
on the gauge and an alarm will sound. Refer to the
Warning Buzzer in the Troubleshooting section.
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.
Drive Wheel Release Valves
Voltmeter
Located on the top right front corner of hydrostatic
pumps.
Located next to the Coolant Temperature Gauge at
the front of the left fuel tank.
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Operation
The voltmeter measure the voltage output of the
alternator. Both high and low voltages will potentially
damage the battery.
Use of summer grade diesel fuel above 20°F (-7°C)
will contribute toward longer life of the pump
components.
Important: Do Not use kerosene or gasoline
instead of diesel fuel. Failure to observe this
caution will damage the engine.
Glow Plug Switch and Light
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.
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.
Low Oil Pressure Light
Observe the following precautions:
Located on the right fuel tank.
• The biodiesel portion of the fuel meet
specification ASTM D6751 or EN14214.
Light will come on when engine oil pressure is low
or lost.
• The blended fuel composition should meet
ASTM D975 or EN590.
Warning Buzzer
• Painted surfaces may be damaged by biodiesel
blends.
Located behind the seat under the air deflector on
the electrical panel.
• Use B5 (biodiesel contend of 5%) or lesser blend
in cold weather.
The buzzer is a warning signal that the engine
is overheating or the oil pressure is low. See the
Troubleshooting section.
• Monitor seals, hoses, gaskets in contact with fuel
as they may be degrade over time.
• Fuel filter plugging maybe expected for a time
after converting to biodiesel blends.
Pre-Start
• Contact your distributor if you wish for more
information on biodiesel.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Filling the Fuel Tank
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the
cap. Add fuel to both fuel tanks, until the level is
1/4 to 1/2 inch (6 to 13 mm) below the bottom
of the filler neck. This space in the tank allows
the fuel to expand. Do Not fill the fuel tanks
completely full.
Determining Fuel
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.
3. Install fuel tank caps securely. Wipe up any fuel
that may have spilled.
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).
4. If possible, fill the fuel tank after each use. This
will minimize possible buildup of condensation
inside the fuel tank.
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Operation
2. Pull up and back on the parking brake lever to
engage the parking brake.
Operating Instructions
3. Push in on the PTO switch to the “STOP”
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. On a warm engine, place the throttle in the
“SLOW” position.
1. Remove the hairpin cotter pins and remove the
5. On a cold engine, (below 14°F (-10°C)), place the
throttle in the “MIDWAY” position.
2. Raise the roll bar to the upright position and
install the two pins and secure them with the
Note: Do Not use fuel left over from summer.
Important: Always use the seat belt with the
roll bar in the raised position. Ensure that the
rear part of the seat is secured with the seat
latch.
6. 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.
Glow Plug Chart
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)
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: 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.
Figure 5
1. Roll bar
2. Raised position
3. Pin
4. Hairpin cotter pin
7. 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.
Open the Fuel Shut-Off Valve
Turn the valve to the LH or RH tank.
Starting the Engine
1. Move the motion control levers out to the neutral
lock position.
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Operation
5. Place the throttle midway between the “SLOW”
and “FAST” positions.
Engaging 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.
DANGER
The rotating blades under the mower deck
are dangerous. Blade contact can cause
serious injury or kill you.
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
Do Not put hands or feet under the mower
or mower deck when the blades are engaged.
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.
DANGER
An uncovered discharge opening will allow
objects to be thrown in an operator’s or
bystander’s direction. Also, contact with the
blade could occur. Thrown objects or blade
contact can cause serious injury or death.
Driving the Machine
CAUTION
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.
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.
• Use caution when making turns.
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.
• Slow the machine down before making
sharp turns.
Important: Operator must be in seat before the
PTO can be engaged.
Important: To begin movement (forward or
backward) the operator must be in the seat, the
brake lever must be disengaged (pushed down)
before the motion control levers can be moved in
or the engine will stop.
1. Set the throttle to the “MIDWAY” position.
2. Pull the PTO switch outward to the “ROTATE”
position.
When levers are centered in the T-slot the drive
system is in the neutral position. With levers moved
out in the T-slot the drive system is in the neutral lock
3. Place the throttle in the “FAST” position to begin
mowing.
Disengaging the PTO
1. Set the throttle to the “MIDWAY” position.
2. Push the PTO switch in to the “STOP” position
to disengage the blades.
Stopping the Engine
1. Bring the unit to a full stop.
2. Disengage the PTO.
3. Move the motion control levers out to the neutral
lock position.
4. Engage the parking brake.
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Operation
Figure 6
1. Handles Out (Neutral
Lock)
5. Neutral
2. Handles In (Neutral)
6. Reverse
3. Front of Unit
4. Forward
7. Neutral Lock
Figure 7
1. Handles Out (Neutral
4. Forward
Driving Forward
Lock)
1. Release the parking brake.
2. Handles In (Neutral)
3. Front of Unit
5. Reverse
2. Move the motion control levers inward to the
center to the neutral unlocked position.
Driving in Reverse
3. To move forward in a straight line apply equal
forward pressure to both levers.
1. Move the motion control levers inward to the
center to the neutral unlocked position.
To turn left or right, pull the motion control lever
back toward neutral in the direction desired.
2. To move rearward in a straight line applying equal
pressure pull both motion control levers rearward.
The machine will move faster the farther the
motion control levers are moved away from
neutral.
To turn left or right, release pressure on the
motion control lever toward the direction desired.
3. To stop, push the motion control levers to the
neutral position.
4. To stop, pull the motion control levers back to
the neutral position.
Adjusting the Cutting Height
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.
1. Stop the machine and move the motion control
levers outward to the neutral locked position.
2. Disengage the PTO.
3. Raise the deck height lever to the transport
position (also the 5 inch (12.7 cm) cutting height
The deck can be raised by pulling the deck lever
up and/or by pushing down on the foot operated
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Operation
deck lift assist lever located at the front right
corner of the floor pan.
6. Place the rollers in one of the positions shown
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 9
For cutting heights above 4.0 inches (102 mm) use the
bottom hole. The rollers will still be effective against
scalping.
Figure 8
1. Anti-scalp roller
mounting bracket
2. Cutting height
1. Lever in transport and 5 inch (12.7 cm) cutting height
position
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.
4. Insert the height adjustment pin into the hole
corresponding to the desired cutting height and
install the hairpin cotter pin.
See the decal on the side of the deck lift plate for
cut heights.
7. Be sure the roller bolts are installed with the
spring disc washer between the head of the bolt
and the mounting bracket.
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.
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.
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
Adjusting the Anti-Scalp Rollers
It is recommended to change the anti-scalp roller
position when the height of cut has changed.
1. Stop the machine and move the motion control
levers outward to the neutral locked position.
2. Disengage the PTO.
3. Engage the park brake.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. After adjusting the height of cut, adjust the
anti-scalp rollers by removing the bolt and spring
disc washer.
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Operation
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 10
• Do Not exceed a 15° angle between ramp
and ground or between ramp and trailer
or truck.
1. Spring disc washer
3. 3/8 nyloc-torque to 30-35
ft-lb (41-47 N-m)
4. 3/8-24 x 2 GR8 torque to
50-55 ft-lb (68-75 N-m)
(cone towards bolt head)
2. Front right anti-scalp
bracket shown
• Avoid sudden acceleration while driving
unit up 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)
• Avoid sudden deceleration while backing
unit down a ramp to avoid tipping
backward.
Transporting
Loading a Unit
Transporting 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.
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.
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.
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck do not exceed 15°. A steeper angle
may cause mower deck components to get caught as
the unit moves from ramp to trailer or truck. Steeper
angles may also cause the unit to tip backward. If
loading on or near a slope, position the trailer or
truck so it is on the down side of the slope and the
ramp extends up the slope. This will minimize the
ramp angle. The trailer or truck should be as level
as possible.
Do Not drive a unit on a public street or
roadway.
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Operation
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a ramp.
Both maneuvers can cause the unit to tip backward.
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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.
• 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.
• Remove accumulated debris from engine.
• Clean the grass and debris build-up from the machine and cutting deck.
• Clean the grass build-up from under the 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
• 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.)
• Clean the engine cooling system.
Every 50 hours
Every 100 hours
Every 160 hours
• Change the engine oil. (May need more often under severe conditions.)
• 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).
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Maintenance
Maintenance Service
Interval
Maintenance Procedure
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)
• Check the wheel hub slotted nut torque specifications.
• Check the wheel lug nuts.
Every 500 hours
Every 600 hours
• Replace the air cleaner elements. (May need more often under severe conditions. See the
Engine Owner’s Manual for additional information.)
•
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.
• Lubricate the caster wheel hubs.
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
3. Raise radiator to gain access to dipstick.
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
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. Use oil as specified in
Engine Owner’s Manual. Do Not overfill.
Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the battery
in the table below 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
cables are disconnected and the battery charger
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Maintenance
used for charging the battery has an output of
16 volts and 7 amps or less to avoid damaging
the battery (see chart for recommended charger
settings).
Voltage
Reading
Percent
Charge
Maximum Charging
Charger
Settings
Interval
12.6 or
greater
100%
No
Charging
Required
16 volts/7
amps
12.4 – 12.6 75–100%
12.2 – 12.4 50–75%
30 Minutes
16 volts/7
amps
Figure 12
1. Use wrench here for
1 Hour
16 volts/7
amps
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.
blade installation. This
nut has been torqued to
90–110 ft-lb (122–149
N-m)
12.0–12.2
11.7–12.0
25–50%
0–25%
2 Hours
3 Hours
14.4 volts/4
amps
14.4 volts/4
amps
11.7 or less 0%
6 Hours or
More
14.4 volts/2
amps
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).
Check Mower Blades
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lift deck and secure in raised position as stated
in the Clean Grass Build-Up Under Deck
procedure.
WARNING
Incorrect installation of the blade or
components used to retain the blade can
be dangerous. Failure to use all original
components and assembled as shown could
allow a blade or blade component to be
thrown out from under the deck resulting in
serious personal injury or death.
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.
Always install the original Exmark blades,
blade bushings, and blade bolts as shown.
Check Safety Interlock
System
Service Interval: Before each use or daily
Figure 11
1. Install bushing in blade prior to installing bushing in
spindle.
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
B. Install bushing/blade assembly into spindle.
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Maintenance
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.
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.
Check Seat Belt
Service Interval: Before each use or daily
Visually inspect seat belt for wear, cuts, and proper
operation of retractor and buckle. Replace before
operating if damaged.
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
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).
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.
Run engine at one-third throttle, engage PTO
and raise offof seat (but do not get off of
machine) engine must initiate shutdown after
1/2 second has elapsed.
Service Air Cleaner
Service Interval: Every 50 hours—Service
the air cleaner. (May
Run engine at one-third throttle, with brake
disengaged, move levers in and raise off seat (but
do not get off of machine) engine must initiate
shutdown after 1/2 second has elapsed.
need more often under
severe conditions. See
the Engine Owner’s
Manual for additional
information.)
Again, run engine at one-third throttle, brake
engaged, and move left motion control lever in
- engine must initiate shutdown.
Every 600 hours— Replace
the air cleaner elements.
(May need more often
under severe conditions.
See the Engine Owner’s
Manual for additional
information.)
Repeat again moving the right lever in, then
moving both levers in - engine must initiate
shutdown whether operator is on seat or not.
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
2. Unhook two air filter canister latches to gain
access to the air cleaner element.
3. Remove air cleaner canister cover and remove
outer element.
4. Check the condition of the paper element.
Replace if dirty, bent or damaged.
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Maintenance
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
1. Stop engine and wait for all moving parts to stop.
Engage parking brake.
6. Do Not wash or use pressurized air to clean
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.
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.
Note: The baffle is labeled “HOT” and
“COLD”. The oil level varies with the
Change Engine Oil
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.
Service Interval: After the first 5 hours
Every 100 hours/Yearly
(whichever comes first)
(May need more often
under severe conditions.)
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.
Check Tire Pressures
Service Interval: Every 40 hours
3. Fasten deck belt spans together with mechanics
wire or tie wrap to prevent oil from draining onto
belt.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
4. Place pan under machine to catch oil. Remove
the oil drain plug. Allow oil to drain and replace
oil drain plug.
2. Check tire pressure in drive tires.
3. Inflate drive tires to 10 psi (69 kPa).
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 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.
4. Semi-pneumatic caster tires do not need to be
inflated.
Note: Do Not add any type of tire liner or foam
fill material to the tires. Excessive loads created by
foam filled tires may cause failures to the hydro drive
system, frame, and other components. Foam filling
tires will void the warranty.
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 engine owner’s manual. Do Not
overfill.
Check Condition Of Belts
Service Interval: Every 40 hours
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.
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.
9. Check for leaks, including around the oil filter.
10. Wipe up any spilled oil.
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Maintenance
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.
Number 6 (Mule Drive Belt Idler Arm) Located
Under Engine Frame
Lubrication Chart
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
Number 7 (Pump Drive Belt Idler Arm) Located
Under Engine Frame
1. Front
Caster wheel
hubs
*0
*0
1
2
2
5
*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.
2. Front
Caster
Pivots
*Yearly
3. Height
Adjustment
Shaft
40 Hours
Lubricate Caster Wheel Hubs
Bearings
Service Interval: Yearly
1
1
4. Deck
Drive Belt
Idler Arm
Yearly
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
1
1
2
1
200 Hours
Yearly
5. Brake
Brackets
6. Mule
Drive Belt
Idler Arm
7. Pump
Drive Belt
Idler Arm
1
1
1
2
Yearly
8. Deck
40 Hours
Rear Struts
Figure 13
1. Seal guard
2. Spacer nut with wrench
flats
* 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.
2. Remove caster wheel from caster forks.
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Maintenance
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.
Service Interval: Every 160 hours
7. Insert one bearing, one new seal into the wheel.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Note: Seals (Exmark P/N 103-0063) must be
replaced.
2. Unhook seat latch and tilt seat up.
8. If the axle assembly has had both spacer nuts
removed (or broken loose), apply a thread locking
adhesive to one spacer nut and thread onto the
axle with the wrench flats facing outward. Do
Not thread spacer nut all of the way onto the end
of the axle. Leave approximately 1/8 inch (3 mm)
from the outer surface of the spacer nut to the
end of the axle inside the nut.
3. Lubricate bronze bushings on each end of brake
rod shaft with a spray type lubricant or a light oil
(bushings are located to the inside of the flange
bearings).
Lubricate Motion Control
Bronze Bushings
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
Service Interval: Every 160 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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.
2. Unhook seat latch and tilt seat up.
3. Lubricate bronze bushings on flange bearings
securing the motion control arm shafts with a
light oil or a spray type lubricant.
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.
Drain Fuel Filter/Water
Separator
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.
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
14. Reinstall the seal guards over the wheel hub and
insert wheel into caster fork. Reinstall caster bolt
and tighten nut fully.
2. Place a drain pan under the fuel filter and loosen
the drain plug approximately 1 turn.
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.
3. Water should drain.
4. When fuel begins to flow from the filter, tighten
the drain plug.
Important: Water or other contaminants in fuel
can severely damage fuel pump and/or the other
engine components.
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Maintenance
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.
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.
Change Inline Fuel Filter
Service Interval: As required
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.
An inline fuel filter is installed between the fuel tank
and the fuel pump. Replace when necessary.
Replacement Filters
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.
Exmark P/N 112-7836
Change Hydraulic System
Filter
Changing oil unnecessarily could damage hydraulic
system by introducing contaminates into the system.
Service Interval: After the first 250 hours
Wheel Hub - Slotted Nut
Torque Specification
Every 500 hours/Yearly
(whichever comes
first) thereafter
(Every 250 hours/Yearly if
using Mobil 1 15W50)
Service Interval: After the first 100 hours
Every 500 hours thereafter
When tightening the slotted nut on the wheel motor
tapered shaft:
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. Torque the slotted nut to 125 ft-lb (169 N-m).
2. Raise seat.
2. Check distance from bottom of slot in nut to
inside edge of hole. Two threads (0.1 inch) or less
should be showing.
3. Carefully clean area around filter. It is important
that no dirt or contamination enter hydraulic
system.
3. If more than two threads (0.1 inch) are showing
remove nut and install washer (P/N 1-523157)
between hub and nut.
4. Unscrew filter to remove and allow oil to drain
from reservoir.
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Maintenance
4. Torque the slotted nut to 125 ft-lb (169 N-m).
Change Engine Coolant
Service Interval: Every 4,000 hours/Every 4
years (whichever comes
5. Then tighten nut until the next set of slots line up
with the cross hole in shaft.
©
first) Dex-Cool extended
life coolant (orange color)
6. Replace cotter pin.
Note: Do Not use anti-seize on wheel hub.
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
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.
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. 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.
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.
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.
Allow the engine to cool completely before
removing the radiator cap or servicing any
component of the cooling system.
WARNING
CAUTION
Engine coolant is toxic. Swallowing coolant
can cause poisoning.
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.
• Do Not swallow.
• Keep out of reach of children and pets.
Allow the engine to cool completely before
removing the radiator cap or servicing any
component of the cooling system.
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
CAUTION
Engine coolant is toxic. Swallowing coolant
can cause poisoning.
• Do Not swallow.
• Keep out of reach of children and pets.
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Maintenance
7. Operate engine until the engine thermostat opens
and coolant is circulating through the radiator
core. As air is purged from the engine block and
the coolant level drops, add additional coolant to
the radiator.
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.
Fuel Tank — Mounting
Hardware Specifications
Service Interval: As required
Figure 14
2. Drain cock
1. Oil dipstick
When installing the nuts on the fuel tank studs, fully
tighten the nyloc nut and back off 1/2 turn. This
allows for normal fuel tank expansion and contraction
with changes in temperature and fuel levels.
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.
Thread Locking Adhesives
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
• Pump drive sheave set screws.
• Square head setscrews on Hydro pump control
arms.
WARNING
• Sheave retaining bolt in the end of engine
crankshaft.
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.
• Caster wheel spacer nuts.
• Fuel tank bulkhead fitting nuts.
• 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:
• Do Not operate machine without the
covers in place.
• Keep fingers, hands, and clothing clear of
rotating components.
Fuel tank studs, where studs are inserted into tank.
• Shut off engine, wait for moving parts to
stop, engage parking brake and remove
key, before performing maintenance.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
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.
• Between the cutter housing spindle and bearings.
• Between the cutter housing spindle and sheave.
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Maintenance
• Under top cutter housing bearing guard.
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.
• Between the jackshaft and bearings and the
jackshaft and sheaves.
Copper-Based Anti-seize
Copper-based anti-seize is used in the following
locations:
Deck Leveling
1. Position mower on a flat surface.
On threads of Blade Bolts See Check Mower Blades
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
section.
3. Check tire pressure in drive tires. Proper inflation
pressure for tires is 10 psi (69 kPa). Adjust if
necessary.
Dielectric Grease
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
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
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
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
the chain bolts in the deck lift arms making sure
they don’t move while tightening.
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.
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
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Maintenance
front swivel using locking nut in front of swivel.
Repeat for right side.
side engine deck support, is positioned between
the centers of the two alignment holes in the
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.
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.
3. When adjustment is necessary, loosen the idler
pulley on the right-hand side so it can move up
and down in the slot.
Place a wrench on the 3/8 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).
Figure 15
Reposition the adjusting pulley to the bottom of
the slot.
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
5. Swivel
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.
6. Front of unit
7. Socket head adjusting screw
8. Jam nut
12. Raise deck lift lever to the 5 inch (12.7 cm)
compression until proper distance is obtained
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.
Figure 16
1. Front of unit
2. Alignment holes
Pump Drive Belt Tension
Self-tensioning - No adjustment necessary.
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.
2. Check to make sure the center of the bolt head
in the center of the spring loaded pulley, on left
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Maintenance
be 1/8 inch (3.2 mm) away from the belt, with
4. If adjustment is necessary, loosen the bolt securing
the belt guide and make proper adjustment.
Tighten hardware.
Figure 17
3. Right side idler pulley
1. Spring idler pulley
2. Front of unit
(adjustable)
Figure 18
1. End of slot
2. Belt guide
Deck Belt Tension
Self-tensioning - No adjustment necessary.
Brake Link Adjustment
Check to make sure brake is adjusted properly.
1. Disengage brake lever (lever down).
Alternator Belt Tension
Stop engine, wait for all moving parts to stop and
remove key. Engage parking brake.
2. Measure the length of the spring. Measurement
should be 2 13/16 inches (7.1 cm) between
3. If adjustment is necessary, adjust the nyloc nut
at the bottom of the spring to achieve 2 13/16
inches (7.1 cm).
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.
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.
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
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Maintenance
Electric Clutch Adjustment
No adjustment necessary.
Reverse Indicator
Adjustment
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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
Figure 19
6. Remove pin to adjust
4. Check where lever is relative to notch in console
(should be centered allowing lever to pivot
outward to the neutral lock position).
1. Lever down
(disengaged)
rod length for additional
brake adjustment
7. Trunnion roller
2. Lever up (engaged)
3. Nyloc nut below trunnion 8. Spring retainer bracket
roller
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.
4. Nyloc nut below spring
5. 1/8 to 3/16 inch (3.2 to 10. Jam nut above trunnion
4.8 mm)
roller
9. 2 13/16 inches (7.1 cm)
Brake Adjustment
1. Check for brake link 2 13/16 inches (7.1 cm)
measurement as described in the Brake Link
Adjustment section.
6. Repeat on opposite side of unit.
2. Engage the brake lever (lever up). The space
between the brake spring bracket and the nyloc
nut under the spring should measure 1/8 inch to
3/16 inch (3.2–4.8 mm).
3. If adjustment is necessary, loosen jam nut above
the trunnion roller. Adjust the nyloc nut under
the trunnion roller until distance listed above
exists between the spring retainer bracket and the
adjacent nyloc nut. Tighten the jam nut above
the trunnion roller.
4. 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 above
the trunnion or there are no threads left on 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 by
following steps 2 and 3.
Figure 20
1. Turn bolt here
2. Lever centered in notch 5. Loosen here
3. End of slot
6. Reverse indicator
4. Yoke
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Maintenance
Motion Control Linkage
Adjustment
WARNING
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.
Figure 21
Right-Hand Side of Unit
1. Turn here to adjust
2. Loosen here (right-hand
thread)
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.
6. Start engine. Brake must be engaged and
motion control levers out to start engine.
Operator does not have to be in the seat
because of the jumper wire being used. Run
engine at full throttle and release brake.
7. The reverse indicator spring must be correct
before the following adjustments can be made.
See the Reverse Indicator Adjustment section.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Note: The motion control lever needs to be in
neutral while making any necessary adjustments.
The left rod assembly controls the left wheel and
the right rod assembly controls the right wheel.
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.
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
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.
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.
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.
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
5. Loosen lock nuts from the ball joints at each end
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Maintenance
wheel must stop turning or slightly creep in
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 washers are
Figure 22
Left-Hand Side of Unit
1. Turn LH tracking adjustment knob. (Do Not loosen any
nuts on LH side)
10. Shut off unit. Remove jumper wire from wire
harness connector and plug connector into seat
switch.
Motion Control Damper
Adjustment
Figure 24
The top damper mounting bolt can be adjusted to
obtain a more desired motion control lever resistance.
1. Spring disc washers
Clutch Shim
Some later model year units have been built with
clutches that contain a brake shim. 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 23
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.
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Maintenance
A. Loosen both brake mounting bolts one-half
to one full turn as shown below.
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.
Figure 25
5. Brake spacer
1. Armature
2. Field shell
3. Rotor
6. Re-gap shim
7. Brake pole
4. Brake mounting bolt
Figure 27
Removing the Shim:
1. Brake mounting bolt
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.
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).
2. Using a pneumatic line, blow out any debris
from under the brake pole and around the brake
spacers.
Figure 28
Figure 26
1. Shim
C. 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.
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13
N-m) +/-0.5 ft-lb (0.7 N-m).
4. Verify that 12V is present at the clutch connector
when the PTO switch is engaged.
5. Measure the gap between the rotor and armature.
If the gap is greater than .04 inch (1 mm), proceed
with the following steps:
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
44
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Maintenance
as shown. (Due to the way the rotor and
armature faces wear (peaks and valleys) it is
sometimes difficult to measure the true gap.)
does not engage properly, reference the
Troubleshooting section.
Figure 29
1. Feeler gauge
Figure 30
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.
If the clutch does not disengage,
reinstall the shim and reference the
Troubleshooting section.
c. Engage and disengage the PTO switch
ten consecutive times to ensure the clutch
is functioning properly. If the clutch
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Maintenance
2. Remove air deflector panel from behind seat.
Cleaning
3. Clean around flywheel, cylinder head, injectors,
and injector pump.
Clean Engine Cooling
System
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
4. Reinstall the air deflector panel.
Important: Do Not use water to clean engine.
Use low pressure compressed air. See Engine
Owner’s Manual.
conditions.)
Cleaning of the Radiator
Service Interval: Every 50 hours (May be
required more often in dry
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.
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. Rotate seat and engine cover forward.
• Clean all debris from inside of pump drive
belt compartment daily.
4. While holding fan up, remove the four screws
attaching the fan to the shroud. Disconnect and
remove the fan.
• Clean debris from radiator screen and
core daily.
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.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Clean all debris from inside of pump drive belt
compartment.
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.
3. Wipe debris from screen in engine cover.
4. Rotate engine cover forward and wipe debris
from radiator core as required.
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.
5. Clean debris from radiator fins with compressed
air.
8. Re-assemble the fan to the radiator. Reconnect
the fan.
Important: If debris or air can not be blown
through the radiator, see Cleaning of the
Radiator section.
9. Start the engine to ensure the fan is functioning
properly.
6. Inspect seals in engine cover and replace if
necessary.
Clean Debris From Machine
Service Interval: Before each use or daily
Remove Accumulated Debris
from Engine
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Service Interval: Before each use or daily
Engine parts should be kept clean to reduce the risk
of overheating and ignition of accumulated debris.
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.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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Maintenance
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.
Clean Grass Build-Up Under
Deck
Service Interval: Before each use or daily
If a battery is being replaced or if the unit containing
the battery is no longer operating and is being
scrapped, take the battery to a local certified recycling
center. If no local recycling is available return the
battery to any certified battery reseller.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Raise deck to the transport (5 inch (12.7 cm)
cutting height) position. Lift the front of unit
and support unit using jack stands or equivalent
support.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
3. Clean out any grass build-up from underside of
deck and in discharge chute.
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.
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.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• Do Not swallow electrolyte.
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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 adjustments 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 set.
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.
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. Electrical connections are corroded, loose 8. Check the electrical connections for
or faulty.
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
9. Relay or switch is defective.
1. Engine load is excessive.
9. 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.
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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.
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.
5. Replace the spring.
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.
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Troubleshooting
Problem
Possible Cause
1. Oil level is low.
Corrective Action
1. Check oil level.
Warning buzzer emits intermittent beep.
2. Oil leaking from engine.
1. Fuse is blown.
2. Contact Authorized Service Dealer.
Clutch will not engage.
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.
5. Rotor/armature airgap is too large.
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Schematics
Schematics
Electrical Diagram
K C A
K C A
W O N R / B B L
W O N R / B B L
K C A
P I N K / B L
C A K B L
C A K B L
O R A N G E
R E D
K C A B L
K C A
W O N R / B B L
K C A W O / B L Y E L L
K C A W O / B L Y E L L
O R A N G E
K C A B L
D E R / W O Y E L L
K C A B L
K C A B L
K C A
P I N K / B L
E T I H W / K C A B L
K C A
K C A
W O N R / B B L
O R A N G E / B L
P I N K
. G R D E K E N
. G R D E K E N
K C A
K C A
O R A N G E / B L
O R A N G E / B L
C A K B L
Y A G R
C A K B L
W O Y E L L
. G R D E K E N
. G R D E K E N
V I O L E T
Y A G R
O R A N G E
E U L B . T L
E U L B . T L
E U L B . T L
O R A N G E
V I O L E T
O R A N G E
O R A N G E
Y A G R
Y A G R
. G R D E K E N
N E E R G . T L
Y A G R
K C A B L
. G T L R E E N
E U L B . T L
A T N
N W O R B
N W O R B
R E D
R E D
K C A W O / B L Y E L L
K C A W O / B L Y E L L
E U L B . T L
E U L B . T L
K C A B L
P I N K
K C A B L
K C A W O / B L Y E L L
A T N
A T N
C A K B L
C A K B L
R E D
G010235
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Schematics
Electrical Logic Schematic
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Schematics
Hydraulic Diagram
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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
The Exmark turf equipment, including any defective part,
must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to turf
equipment operated under normal conditions. You must 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
2 years*
• 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.
G4500-425
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Notes:
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Notes:
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Service Record
Date:
Description of Work Done:
Service Done By:
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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.
© 2009 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
Part No. 4500-501 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
All Rights Reserved
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