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Exmark eXmark Lazer Z DS-Series LZDS User's Manual

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3. IMOTISA a quu 5 ipio mE om esse VONIWHL HOLIMS amaya o ET 30435 S TWNIWYAL 3181 S po wav 9 az 3NOL1Vna E yovisiionisa 4 vs mm 8 183 ama xa A X V 1 8 3NON 3301 5 4 3unssaud 10 E i nome i Ae Tro pl M men o 1 OVI H NI Old ii 8 53 2 gt BOR 222 2 gg E 8 8 Cae 83525 88 Piin 8858 FS gg 8866 m 5 md ue 8 55 P AVTaY bara HOLWINN X vw N Old and i r1l EES Eta 3 4 8 5552 1001 HOLIMS L unos 7and 55558 Elm vas NazuopIovIE ANVLNAWOW 037 AV3S NI agen NMOHS A30 135 031710 aovno HOLIMS Old NI a3ovoNasia Old NMOHS 54 Exmark Commercial Turf Equipment 2 Year Limited Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant o
4. coer cen cn DR DN EE SE RAE 20 20 Mt de Fe M EA ne 22 Operating INStrUCHONS acie erret 23 uad gatum 27 AEE so aoi ep 29 Recommended Maintenance Schedule s 29 Periodic Maintenance eoo e eg ERN 30 Check Engine 30 Cheek Battery Chataes oisi He do natio s 30 Check Mower Blades easet ee es 32 Check Safety Interlock System 33 Check Rollover Protections Systems Roll nea 33 Check Seat Beltine 33 Check for Loose Haridwar divs ence 33 Service ir Clearer Geta ipe meatier edu 33 Chance Enotne 34 Check Hydraulic Oil Level eerte net 34 Check Tire Pressures ood v p 34 Check Condition Of Belts uite deser 35 Lubricate Grease d ie 35 Wheel Hub Slotted Nut Torque Specification eie uos eee Pe 36 Lubricate Brake Handle Pivot 36 Lubricate Brake Rod Bushings 36 Lubricate Motion Control Bronze 37 Drain Fuel Filter Water 37 Change Fuel Filter Water Separator 37 Change Hydraulic System Filter 37 Check Engine Coolant cetus 38 Change Engine Coolant coser etuer 38 Check Spark Arrester if equipped 39 Thread
5. Coolant level is low Debris on or atound radiator Water pump or alternator belt is worn loose broken Tracking needs adjustment Tire pressure in drive tires not correct Reverse indicator and motion control linkage need adjustment By pass valve is not closed tight Drive or pump belt is worn loose broken Drive or pump belt is off a pulley Broken or missing idler spring Hydraulic fluid level is low or too hot Blade s not sharp Cutting blade s is are bent Mower deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Cutting blade s is are bent or unbalanced Blade mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Belt is damaged Drive belt is worn loose or broken Drive belt is off pulley Deck belt is worn loose or broken Deck belt is off pulley Broken or missing idler spring Clutch has disengaged 51 Reduce the ground speed Add oil to the crankcase Clean or replace the air cleaner element Add coolant Remove debris see Clean the Radiator section in Maintenance Contact an Authorized Service Dealer Adjust the tracking Adjust tire pressur
6. 1090 NO NEED 50 F 10 C to 23 F 5 C Approximately 5 seconds Below 23 F 5 C Approximately 10 seconds 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 Move the throttle to the SLOW if in MIDWAY and let the engine warm up few minutes before moving the throttle to the FAST position Engaging the PTO DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged 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 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 The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mo
7. Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure that PTO 15 disengaged Torque the 3 8 24 x 2 Gr 8 hex capscrew to 50 55 ft lb 68 75 N m Figure 12 G006119 Figure 12 1 Spring disc washer 3 cone towards bolt head Front right anti scalp bracket shown 3 8 nyloc torque to 30 35 ft lb 41 47 N m 3 8 24 x 2 8 torque to 50 55 ft Ib 68 75 N m 4 9 If the 3 8 nyloc nut has been removed re install and torque to 30 35 ft lb 41 47 N m Figure 12 Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable ot 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 Do Not drive a unit on a public street roadway A WARNING Loading a unit on a trailer or truck increases the possibility of backward tip
8. away from the belt with bolt end of guide near end of slot Figure 21 4 Ifadjustment is necessary loosen the bolt securing the belt guide and make proper adjustment Tighten hardware 1 8 inch G006125 Figure 21 1 End of slot 2 Belt guide Parking Brake Adjustment Service Interval After the first 100 hours Every 500 hours thereafter Check to make sure brake is adjusted properly This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced 1 Drive the machine onto a level surface 2 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine wait for all moving parts to stop and remove the key 4 Raise the back of the machine up and support the machine with jack stands Maintenance 9o c ow on CAUTION Raising the mower deck for service or maintenance relying solely on mechanical 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 Remove the rear tires from the machine Remove any debris from the brake area Engage the parking brake lever up Loosen the jam nut item 9 in Figure 22 just above the
9. implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 589 C Notes 56 Service Record Date Description of Work Done Service Done By 57 MAXIMIZE THE PERFORMANCE OF YOUR 4 CYCLE PREMIUM ENGINE OIL PREMIUM HYDRO OIL Part No 116 3373 Part No 109 9828 Both SAE 30 and SAE 10W 30 in one Commercial quality for tough high bottle heat conditions Contains increased levels of zinc and Designed specifically for zero turn phosphorus for better lubricity mower hydraulic systems No Viscosity Index Improvers that tend Superior shear resistance under to shear down in high heat heavy loads Synthetic formulation Gas amp Diesel compatible Anti corrosion additives API SL and JASO rated with wet clutch compatibility for other machines EXMARK MAINTENANCE Available from your local Exmark dealer Find your closest dealer at exmark com 58 6011841 Figure 32 This page may be copied for personal use The maximum slope you can safely operate the machine on is 15 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope Align this edge with a vertical surfac
10. Locking Adhesives enit 39 Mobil HTS Grease Or Food Grade rs co 40 Copper Based Anti seize 40 Dielectric deese bang OR pM UE 40 euo 40 Decl deut 40 Pump Drive Bele 41 Deck Belt Tension 41 Mule Drive Belt Tension Adjustment 41 Alternator Belt eicere 42 Belt Guide Adjastment ueteres 42 Parking Brake Adjustment trm 42 Electric Clutch Adjustment 44 Reverse Indicator Adjustment 45 Motion Control Linkage Adjustment 45 Motion Control Damper Adjustment 47 Caster Pivot Bearings Pre Load ER ME Pug dO onan e 47 COATING T 48 Clean Engine Cooling System 48 Clean Engine and Exhaust System Aene e diruit p o aes 48 Clean the wicca aera 48 Clean Debris From Machine uus 49 Clean Grass Build Up Under Deck 49 Waste Disposal a niet bete cn ecards 49 sols ba spelunca depo 50 See mates acea oue rRNA a inen dire 53 Safety Safety Safety Alert Symbol This lawn mower meets or exceeds the B71 4 specifications of the American National Standards Institute in effect at the time of production Exmark designed and tested this lawn mower to offer reasonably s
11. moving parts to stop and remove key Engage parking brake 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 Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt 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 Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval 1 Front 2 Yearly Caster wheel Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval ae Drive Belt Idler Arm 5 Brake 1 2 200 Hours Brackets 6 Mule Drive Belt Idler Arm 7 Pump Drive Belt 1 1 Yearly Idler Arm 8 Deck 1 2 40 Hours Reat Struts 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 Cl Y Nn ga F G006148 C 5 83 A4 312 Numb
12. or distributor Exmark parts manuals are available online at http www exmark com All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and ate equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 Model and serial number location Model No Serial No Contents etre NM RM 3 MP RN 5 Safety Alert Symboli oid 5 Safe Operating PEACUCOS 5 Safety and Instructional Decals 11 ONS nanara EN dentes 17 Model Numbers jis ades t ora p i vee RE 17 e E PR o deed 17 ERS 19 Torque Requirements att nd essi 19 Product Overview ipte cios Dd ue et d rad 20
13. 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 Do exceed 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers ot 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 reat 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 sutface for the frame members to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck Do Not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer 27 Operation truck Steeper angles may also ca
14. remove the two roll bar pins Figure 6 Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins Figure 6 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 G006159 Figure 6 1 Roll bar 2 Raised position 3 Pin 4 Hairpin cotter pin 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 2 Pull up and back on the parking brake lever to engage the parking brake 3 Push down on the PTO switch to the disengage position Note It is not necessaty for the operator to be in the seat to start the engine 4 Place the throttle midway between the SLOW and FAST positions 5 On a warm engine place the throttle in the SLOW position 6 cold engine below 14 F 10 C place the throttle in the MIDWAY position Note Do Not use fuel left over from summer 23 Operation Turn ignition switch to the 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 Hold Glow Plugs On Above 50 F
15. sound if the engine overheats Refer to Check Engine Coolant Level in Maintenance Cooling System Fan Electric with continuous operation with engine running e Coolant Liquid 50 50 mix of DexCool extended life antifreeze and water e Coolant Capacity 4 quarts Operator Controls Steering and Motion Control Note Motion control levers are adjustable to two heights Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steeting 1s controlled by varying the position of the levers relative to each other 17 Specifications Moving motion control levers outwatd in slots locks the drive system in neutral PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades e Parking Brake Lever Engages parking brake Deck Height Adjustment Lever Sets cutting height to desired position Deck Lift Assist Pedal Foot pedal that assists in raising the deck Seat Type Deluxe suspension seat high back low profile foam in place cushion dampened adjustable spring suspension and armrests adjustable back angle 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 e Armrests Molded adjustable flip up armrests e Seat Safety Switch Integrated seat switch Time delay seat
16. 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 Fasten deck belt spans together with mechanics wire tie wrap to prevent oil from draining onto belt 4 Place pan under machine to catch oil Remove the oil drain plug Allow oil to drain and replace oil drain plug Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of Exmark 4 Cycle Premium Engine Oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 full turn Unlatch radiator and lift it up to access oil fill Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in the Check Engine Oil Level section Do Not overfill Start the engine and check for leaks 7 Remove wire or tie wrap from belt spans 9 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 Check for leaks including around the oil filter 10 Wipe up any spilled oil Check Hydraulic Oil Level Service Interval Every 40 hours 1 Stop engine and wait for all moving
17. with stored energy e Disconnect battery before making any repairs Disconnect the negative terminal first and the Safety positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s ot weat gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Charge batteties 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 4 DANGER Charging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery e Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid e Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediat
18. your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are limited to the duration of the express warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an
19. 0 ft lb 41 N m cm cm Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Motor Mounting 72 77 ft lb 98 104 N m Overall Height Pot Wheel Hub Slotted Nut 211 260 ft lb Roll Bar Up Roll Bar Down 286 352 N m 72 7 inches 184 7 cm 53 8 inches 136 7 cm Rollover Protection System 30 35 ft lb 41 47 N m Roll Bar Mounting Bolts Tread Width Center to Center of Deck Drive Jackshaft Nut 75 80 ft lb 102 108 N m Tires Widthwise 60 inch Deck 72 inch Deck Drive Wheels 41 9 inches 106 4 45 9 inches 116 6 cm cm Caster Wheels 37 3 inches 94 7 47 3 inches 120 1 cm cm Wheel Base Center of Caster Tire to Center of Drive Tire 72 inch Deck 60 2 inches 152 9 cm Clutch Retaining Bolt 55 60 ft lb 75 81 N m secured with threadlocker Exhaust Muffler Nuts and 228 26 N m Mounting Bolts 60 inch Deck 56 0 inches 142 2 cm Curb Weight 60 inch Deck 72 inch Deck 1545 Ib 701 kg 1645 Ib 746 kg 19 Operation Product Overview Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of the machine Moving the levers forward or backward turns the wheel on the same side forward reverse respectively Wheel speed is proportional to the amount the lever is moved Moving the levers outward fr
20. 3d X TWNINYL t i v 5 5 9 XOVT8 MO TI3A 8 H 2 t ILH z HOLWTNA 1 z LU 1 epee wowla 7 5555 g 88 5 BS 5 HOLIMS Old GAH YILIN A 5 RS 8 m 10 vas 188 davis Lz 9 8v az vc ai vi 6 8 9 S Z1 Y 12 2 8 V HOLIMS Old GAH YD IL bou 2 2 a i 8 Da Y D Y gc pes NY aa 6 8 t TOHLNOD TINIO avo Av Tad LVS Old AVTAG 1 35 LVS SNOL23NNO2 1v35 HINI HOLIMS 01 1 0 HOLIMS 30194340 XOV I8 NId OL NI HOLIMS 095012 SI HOLINS 53 Electrical Schematic Schematics
21. 5 16 volts 7 1 Hour amps 12 0 12 2 25 50 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours amps More Recommended Jump Starting Procedure Service Interval As required 1 Check the weak battery for terminal corrosion white green or blue snow it must be cleaned off ptior to jump starting Clean and tighten connections as necessaty CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use 31 properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded ot labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries Note The following instructi
22. 7 Socket head adjusting screw 8 Jam nut 12 Raise deck lift lever to the 5 inch 12 7 cm cutting height position Figure 10 Adjust spring compression until proper distance 15 obtained between the two latge washers Figure 18 Adjustment is made by turning the nut at the front of each spring clockwise will shorten the spring counterclockwise will lengthen the spring Lock in position with jam nuts Note When above adjustments have been made the front of the deck will be slightly lower than the reat of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary Deck 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 Check to make sure the center of the bolt head in the center of the spring loaded pulley on left side engine deck support is positioned between the centers of the two alignment holes in the left support plate Figure 19 and Figure 20 It is necessary to adjust the belt tension when the center of the bolt head is at or below the center of the bottom alignment hole 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
23. Contact Authorized Service Dealer loose or broken Warning buzzer emits intermittent beep Oil level is low Check oil level Oil leaking from engine Contact Authorized Service Dealer Clutch will not engage Fuse is blown Replace fuse Check coil resistance battery charge charging system and witing connections and replace if necessary Low voltage supply at the clutch Check coil resistance battery charge charging system and wiring connections and replace if necessary Damaged coil 3 Replace clutch Inadequate current supply 4 Repair or replace clutch lead wire or electrical system Clean connector contacts Rotor armatute airgap is too large Remove shim or replace clutch Engine has overheated Determine cause of overheat see Engine overheats 52 Schematics Schematics Electrical Diagram Wa NO19 105 90 3105 Tani MOL93NNOO HOLVNUALTV z 8 5 dial HOLIMS WAL HOLIMS 53
24. IDnUDW BER DIU FEDT NZ 3 M gt o v 0 N 3 N 312 000 000 amp Higher Lazer Z LZDS Units Part No 4501 041 Rev For Serial Nos Rs T Yi ui e N T 5 A WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancet birth defects or other reproductive harm Important The engine in this product is not equipped with a spark arrester muffler It is a violation of California Public Resource Code CPRC Section 4442 to use or operate this engine on any forest covered brush covered or grass covered land as defined in CPRC 4126 Other states or federal areas may have similar laws To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with the Canadian standard ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add impr
25. N Engine coolant is toxic Swallowing coolant can cause poisoning Do Not swallow Keep out of reach of children and pets 3 Drain coolant when engine is cool Coolant may be drained from the radiator by removing the drain plug in the right rear corner The engine block may be drained by removing the rear radiator hose and or by opening the drain cock on the right hand side of the engine block see Figure 17 Maintenance 6006168 Figure 17 Oil dipstick 2 Drain cock Reinstall all drain plugs and hoses and tighten drain cock 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 WARNING Engine compartment contains open belt drives fans and other rotating components that can cause injury Fingers hands loose clothing or jewelry can get caught by the rotating fan and drive shaft Do Not operate machine without the covets in place Keep fingers hands and clothing clear of rotating components Shut off engine wait for moving parts to stop engage parking brake and remove key before performing maintenance With the cap off the radiator tilt hood closed and put the seat down Start t
26. PTO push PTO switch in to the disengaged position and then pull out to engage Refer to the Engine overheats in the Troubleshooting section Coolant Temperature Gauge Located at the front of 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 An alatm will sound and the PTO will disengage Refer to the Warning Buzzer in the Troubleshooting section Note If the engine coolant level is below the indicator line on the overflow bottle when the engine is cold the coolant temperature gauge may not register correctly during operation Refer to Check Engine Coolant Level in Maintenance Voltmeter Located next to the Coolant Temperature Gauge at the front of the left fuel tank The voltmeter measure the voltage output of the alternator Both high and low voltages will potentially damage the battery 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 Low Oil Pressure Light Located on the right fuel tank Light will come on when engine oil pressure is low ot lost Warning Buzzer Located behind the seat under the air deflector on the electrical panel The buzzer is a warning signal that the en
27. TION Raising the mower deck for service or maintenance relying solely on mechanical hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support 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 Deck Leveling 1 Position mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check tire pressure in drive tires Proper inflation pressure for tires is 10 psi 69 kPa Adjust if necessary Set anti scalp rollers to top holes or remove them completely for this adjustment 5 Raise the deck to the 5 inch 12 7 cm height position also transport position and take all force off of the two large deck lift springs by loosening the nuts at the front of each spring Figure 18 6 Lower the deck to the 1 inch 2 54 cm height position Force the left rear deck support arm downward about 1 4 inch 6 4 mm to get the deck to rest at the 1 inch height position Place locking pliers between the rear swivel and spring stop to hold the deck in this position Figure 18 7 Place a 3 4 inch 19 mm thick block of wood under each of the two rear anti scalp roller brackets and place one under one of the front center anti scalp roller brackets 8 Loosen the two top chain bolts in slots in the rear deck
28. afe service however failure to comply with the following instructions may result in personal injury This Safety Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 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 DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention 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 th
29. ar peaks and valleys it is sometimes difficult to measure the true gap G011733 Figure 25 Feeler gauge Maintenance Figure 26 1 Feeler gauge If the gap is less than 0 010 inch then reinstall the shim and reference the Troubleshooting section If the gap is sufficient proceed to the safety check in step F Perform the following safety check a Siton the seat and statt 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 Engage and disengage the PTO switch ten consecutive times to ensure the clutch is functioning properly If the clutch does not engage properly reference the Troubleshooting section 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 to put pressure on spring Figure 27 Check where lever is relative to notch in console should be centered allowing lever to pivot outward to the neutral lock position If adjustment is needed loosen the nut against the yoke a
30. as Loctite 242 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 Sheave retaining bolt in the end of engine crankshaft e Caster wheel spacer nuts Maintenance e 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 are used on the following Fuel tank studs where studs are inserted into tank Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations Between the cutter housing spindle and bearings Between the cutter housing spindle and sheave Under top cutter housing bearing guard Between the jackshaft and bearings and the jackshaft and sheaves Copper Based Anti seize Copper based anti seize is used in the following location On threads of Blade Bolts See Check Mower Blades section Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Dielectric grease should not be applied to sealed connectors 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 CAU
31. at start the engine and release the park brake WARNING Engine must be running and drive wheels must be turning so adjustments can be performed Contact with moving parts hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces Increase the throttle to high idle Bring both drive levers out of neutral and push them into full forward position Pull the park brake lever up until the engine rpm starts to drop Hold the park brake lever in this position for 15 seconds E Release the brake lever Move the drive levers into the full reverse position Repeat steps E and Move the drive levers back to the neutral lock position I Return the throttle to low idle and stop the engine J Allow the brake bands and drums to cool Repeat steps 7 through 11 Install the tires and torque the lug nuts to 90 95 ft lb 122 129 N m Remove the jack stands Maintenance Electric Clutch Adjustment No adjustment necessary However when the clutch brake has worn to the point where the clutch no longer engages consistently the shim can be removed to extend the clutch life Figure 23 1 Armature 5 2 Field shell 6 Re gap shim 3 Rotor 7 Brake pole 4 Brake mounting bolt Removing the Shim 1 Stop engine wait for all moving patts to stop and
32. ator section 6 Inspect seals in engine cover and replace if necessary Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions A CAUTION Excessive debris around engine and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove air deflector panel from behind seat 3 Clean around flywheel cylinder head injectors and injector pump 4 Clean all debris from the exhaust system area 5 Wipe up any excessive grease or oil around the engine and exhaust area 6 Reinstall the air deflector panel Important Do Not use water to clean engine Use low pressure compressed air See Engine Owner s Manual Clean the Radiator Service Interval Every 50 hours May be required more often in dry 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 4 While holding fan up remove the four screws attaching the fan to the shroud Disconnect and remove the fan 5 Using compressed air blow out debris stuck between the fins of the entire radiator both from the top down and from the bottom up 6 If debr
33. contribute toward longer life of the pump components 22 Operation Important Do Not use kerosene or gasoline instead of diesel fuel Failure to observe this caution will damage the engine Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows the fuel to expand Overfilling may result in fuel leakage or damage to the engine or emission system If possible fill the fuel tank after each use This will minimize possible buildup of condensation inside the fuel tank Biodiesel Ready This machine can also use a biodiesel blended fuel of up to B20 20 biodiesel 80 petrodiesel The petrodiesel portion should be low or ultra low sulfur Observe the following precautions The biodiesel portion of the fuel meets specification ASTM D6751 or EN14214 The blended fuel composition should meet ASTM D975 or EN590 e Painted surfaces may be damaged by biodiesel blends Use B5 biodiesel content of 5 or lesser blend in cold weather Monitor seals hoses gaskets in contact with fuel as they may degrade over time Fuel filter plugging maybe expected for a time after converting to biodiesel blends Contact your distributor if you wish for more information on biodiesel Operating Instructions Raise the Rollover Protection System ROPS Important Lower the roll bar only when absolutely necessary 1 Remove the hairpin cotter pins and
34. ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Keep the roll bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely necessary Do Not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Check carefully for overhead clearances i e branches doorways and electrical wires before driving under any objects and Do Not contact them In the event of a rollover take the unit to an Authorized Service Dealer to have the ROPS inspected Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excessive grease ot oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Letengine cool before storing and Do Not store near flame 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 e Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required e Carefully release pressure from components
35. ds away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system WARNING Fuel system components are under high pressure The use of improper components can result in system failure fuel leakage and possible explosion Use only approved fuel lines and fuel filters for high pressure systems 10 Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible 4 WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 KEEP HANDS and FEET AWAY 1 403005 STEP Iu 1 51 3742 1 513742 A CAUTION DO NOT OPERATE WITHOUT GUARD IN PLACE 1 513748 1 513748 11 New safety signs may be obtained from your authoriz
36. e a tree building fence pole etc Example of how to compare slope with folded edge 59 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM 12V POWER PORT MICRO MULCH SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB WALK BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO MULCH SYSTEM TURF STRIPER STANDON Place Model No and Serial No Date Purchased Label Here Included in the Literature Pack or Fill in Below Engine Model No and Spec No Model No Engine Serial No E No Serial No 2011 Exmark Mfg Co Inc Part No 4501 041 Rev A Industrial Park Box 808 402 223 6300 Cf Beatrice NE 68310 Fax 402 223 5489 8 Rights Reserved Printed in the USA www exmark com
37. e equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users e Never let children or untrained people operate service the equipment Local regulations may restrict the age of the operator Only adults and mature teenagers should operate mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Manual and recognizes the risks involved 2 is sufficiently mature to use caution and 3 is of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks e The owner uset can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation 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 e 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 A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machi
38. e recharge batteries in storage when the open circuit voltage drops to 12 4 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 Note To prevent damage due to freezing battery and read the oil level should be fully charged before putting away for winter storage volts 5 If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL Check the voltage of the battery with a digital mark on the dipstick Exmark 4 Cycle Premium voltmeter Locate the voltage reading of the battery in Engine Oil is recommended refer to the Engine the table and charge the battery for the recommended Owner s manual for an acceptable alternative Do time interval to bring the charge up to a full charge Not overfill of 12 6 volts or greater Important Do Not operate the engine with the Important Make sure the negative battery cable oil level below the LOW or ADD mark on is disconnected and the battery charger used for the dipstick or over the FULL mark charging the battery has an output of 16 volts and 30 Maintenance 7 amps or less to avoid damaging the battery see chart for recommended charger settings 12 6 or greater Percent Charge Maximum Charging No Charging Required 12 4 12 6 75 100 16 volts 7 30 Minutes amps 100 16 volts 7 amps 12 2 12 4 50 7
39. e in the drive tires Adjust the reverse indicator and the motion control linkage Tighten the by pass valve Change the belt Change the belt Replace the spring Add hydraulic fluid to reservoir or let it cool down Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to tear Clean the underside of the mower Adjust tite pressure in the drive tires Contact an Authorized Service Dealer Replace blades spindles and or check for damage to mower deck Install new cutting blade s Tighten the blade mounting bolt Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Contact an Authorized Service Dealer Install new belt Check the belt tension Check belt for damage replace if necessary Install drive belt and check belt guide for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Replace the spring Engine has overheated determine cause of overheat see Engine overheats Troubleshooting Warning buzzer emits continuous beep See Temperature is increasing on coolant Turn unit off and allow engine and engine also Engine overheats temperature gauge components to cool Coolant level is low 2 Add coolant Debris on or atound radiator 3 Remove debris Water pump or alternator belt is worn 4
40. e in this position Note Brake must be engaged motion control levers out neutral lock position and PTO switch OFF to start engine Itis not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right fuel tank 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 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 The valve has three positions each position made in 1 4 turn increments Valve Handle Position Fuel Flow Right Tank Left Tank Fuel Gauge Located on the left fuel tank 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 Located on the top right front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine t
41. eat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Read and follow slope operation instructions and warnings 107 2102 107 2102 Safety BAFFLE ADJUSTMENT CUTTING HEIGHT INCHES mm 4 5 114 and Higher 3 Visible Holes 3 5 89 4 25 108 2 Visible Holes 1 0 25 3 25 83 1 Visible Hole 109 0872 109 0872 RELEASE 5 WARNING To avoid serious injury death Read and understand the operator s manual before using this machine Do NOT operate unless trained to safely use this machine Do NOT operate under the influence of alcohol or drugs Do NOT operate without shields guards and safety devices in place and working Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system ENGAGE Stop engine and remove key before adjusting servicing or cleaning machine and attachments Hearing protection is recommended 109 1214 109 1214 Avoid blades unless engine and blade avoid serious injury or death are stopped CUTTING WARNING d To avoid serious injury or death l Pickup objects that could be thrown by the blades Do NOT mow when people and pets are in the area Do NOT carry passengers Look behind and to the side before changing directions 109 1215 Before leaving the operator s positio
42. ed e Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figure 3 6000963 Figure 3 1 Safe Zone Use the mower here on slopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water Remove or matk obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwards Beaware that operating on wet grass across steep slopes ot downhill may cause the mowet to lose traction Loss of traction to the drive wheels may result in sliding and loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturet s recommendations for wheel weights or counter weights to improve stability Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Using the Rollover Protection System ROPS A Rollover Protection System roll bat is installed on the unit WARNING There is no rollover protection when the roll bar is down Wheels dropping over edges
43. ed Exmark equipment dealer distributor ot from Exmark Mfg Co Inc e 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 e Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower 1 633706 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 Safety This cooling system protected by Shell DEX COOL Extended Life Antifreeze Coolant Top off only with Shell DEX COOL Extended Life Antifreeze Coolant Suggested change interval is at 4 years or 4 000 hours of service Do not mix with conventional coolants Shell DEX COOL Extended Life Antifreeze Coolant is available at your local aut rts stor DexCoolis General Motors Corp Another Product Innovation From 103 0223 103 0261 103 1798 103 1798 12 SURFACE 103 2076 ROTATING FAN BLADES 9 Can cause serious injury QN DO NOT operate without guards in place v Stop engine before removing guards 103 7218 103 7218 AWARNING TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked position and use seat belt BAR IS DOWN Lower the roll bar only when absolutely necessary Do not wear s
44. elements May need more often under severe conditions See the Every 600 hours 3 i SL Engine Owner s Manual for additional information Every 500 hours Every 4 000 hours e Change engine coolant Dex CoolO extended life coolant orange color Change the engine oil if operated less than 100 hours Grease the front caster wheel hubs Grease front caster pivots Grease the deck drive belt idler arm Grease the mule drive belt idler arm Grease the pump drive belt idler arm Yearly Periodic Maintenance Check Battery Charge Service Interval Monthly Check Engine Oil Level Service Interval Before each use or daily A WARNING 1 Stop engine and wait for all moving parts to stop CALIFORNIA Make sure unit is on a level surface Proposition 65 Warning Check with engine cold Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of A CAUTION California to cause cancer and reproductive harm Wash hands after handling If the radiator prop rod is not securely positioned in the notch the radiator may fall Falling radiator could cause serious injury Raise radiator to gain access to dipstick Allowing batteries to stand for an extended period of time without recharging them will result in reduced Be sure the prop rod is engaged securely in performance and service life To preserve optimum the notch at the far right side of the slot battery performance and lif
45. ely CAUTION If the ignition is in the ON position there is potential for sparks and engagement of components Sparks could cause an explosion ot moving parts could accidentally engage causing personal injuty Be sure ignition switch is in the OFF position before charging the battery Keep all guards shields and all safety devices in place and in safe working condition e Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard WARNING Removing standard original equipment parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Making unauthorized changes to the engine fuel or venting system may violate EPA and CARB regulations Replace all parts including but not limited to tires belts blades and fuel system components with original Exmark parts Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and han
46. er 6 Mule Drive Belt Idler Arm Located Under Engine Frame Number 7 Pump Dtive Belt Idler Arm Located Under Engine Frame Lubticate 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 35 Maintenance Wheel Hub Slotted Nut Torque Specification Service Interval After the first 100 hours Every 500 hours thereafter Torque the slotted nut to 211 260 ft Ib 286 352 N m Note Do Not use anti seize on wheel hub Lubricate Caster Wheel Hubs Service Interval As required 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake G006115 Figure 16 1 Seal guard 2 Spacer nut with wrench flats Remove castet wheel from caster forks Remove seal guards from the wheel hub 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 Pry out seals and inspect beatings for wear or damage and replace if necessaty Pack the bearings with NGLI grade 1 multi purpose grease Insert one beating one new seal into the wheel Note Seals Exmark P N 103 0063 must be replaced If the axle assembly has had both spacer nuts re
47. erse order of connection the engine block black connection is the first to disconnect 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 3 Inspect blades and sharpen or replace as required 4 Reinstall the blades if they were removed in the following order A Install bushing through blade with bushing flange on bottom grass side of blade 32 6006111 1 Figure 14 Install bushing in blade prior to installing bushing in spindle B Install bushing blade assembly into spindle 9006112 Figure 15 Use wrench here for 2 Torque to 55 60 ft Ib blade installation This 75 81 N m Apply nut has been torqued to lubricant to threads 90 110 ft Ib 122 149 as needed to prevent N m seizing Copper based anti seize preferable Grease acceptable substitute 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 Maintenance 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 s
48. etro diesel Fuel Filter In line 113 Micron Exmatk P N 112 7836 Fuel Shut Off Valve 1 4 tutn increments OFF right tank left tank Fuelgauge in left hand fuel tank Electrical System Charging System External Alternator Charging Capacity 60 amps e Battery Type BCI Group 26 Recommended Minimum Battery CCA 540 CCA Battery Voltage 12 Volt Polarity Negative Ground e Fuses 20 amp blade type One 30 amp blade type Safety Interlock System e 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 Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Engine Overheat Protection System PTO will disengage an alarm will sound and the coolant temperature gauge will be in the red area when the engine temperature reaches an overheat condition The PTO will not re engage until the engine has cooled and the PTO switch is manually shut off and re engaged Note If the engine coolant level is below the indicator line on the overflow bottle when the engine is cold the coolant temperature gauge may not register correctly during operation and or the warning buzzer may not
49. gine Use seat belts with the roll bar in the raised and locked position Never operate the mower with damaged guards shields or covers Always have safety shields Safety guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Park machine on level ground Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mowet After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mowet Stop engine wait for all moving parts to stop and engage patking brake Before refueling Before dumping the grass catcher 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 Do Not operate the machine without guatds shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts NEVER catry passengers DO NOT operate the mower when people espec
50. gine is overheating or the oil pressure is low See the Troubleshooting section Note If the engine coolant level is below the indicator line on the overflow bottle when the engine is cold the warning buzzer may not sound if the engine overheats Refer to Check Engine Coolant Level in Maintenance Deck Lift Pedal Located at the right front corner of the floor pan Push the pedal forward with your foot to raise the cutting deck Allow the pedal to move rearward to lower the cutting deck to the cut height that has been set Pre Start Fill fuel tank on level ground Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps 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 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 Use of summer grade diesel fuel above 20 F 7 C will
51. gure 28 Move the motion control levet 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 Bring the LH motion control lever into the neutral position Adjust the LH pump control rod length by rotating the tracking adjustment knob in the appropriate direction until the wheels slightly creep in reverse Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral The wheel must stop turning or slightly creep in reverse Figure 29 6006156 1 Figure 29 Left Hand Side of Unit 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 Maintenance Motion Control Damper Adjustment The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance See Figure 30 for mounting options 1 G006131 Figure 31 1 Spring disc washers Figure 30 Motion control bracket Least resistance softest feel Medium resi
52. haust system in place and in proper working condition WARNING Diesel fuel is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness e Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth e 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 A WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors in a small confined area where dangerous carbon monoxide fumes can collect e Operate only in daylight or good artificial light keeping away from holes and hidden hazards e Be sure all drives are in neutral and parking brake is engaged before starting en
53. he engine as stated in the Operating Instructions Section Return the seat up and hood forward to the open position Operate engine until the engine thermostat opens and coolant is circulating through the radiator 39 core As air is purged from the engine block and the coolant level drops add additional coolant to the radiator 8 When the radiator is completely full and no additional coolant can be added continue running and install the radiator cap Make sure that the cap is completely seated by pressing down firmly while turning until the cap stops Once the cap is installed the engine may be stopped Check Spark Arrester if equipped Service Interval Every 50 hours WARNING Hot exhaust system components may ignite fuel vapors even after the engine is stopped Hot particles exhausted during engine operation may ignite flammable materials Fire may result in personal injury property damage Do Not refuel or run engine unless spark arrester is installed 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Wait for muffler to cool 3 If any breaks in the screen or welds are observed replace arrester If plugging of the screen is observed remove arrester and shake loose particles out of the arrester and clean screen with a wire brush soak in solvent if necessary Reinstall arrester on exhaust outlet Thread Locking Adhesives Thread locking adhesives such
54. hown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death Always install the original Exmark blades blade bushings and blade bolts as shown Check Safety Interlock System Service Interval Before each use or daily Note To prevent engine cut outs on rough terrain the seat kill switch has a 1 2 second delay 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank 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 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 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 Run engine at one thi
55. ially children pets in the area Be alert slow down and use caution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Slope Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes DANGER Operating on wet grass ot 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 Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution on slopes e Avoid sudden turns or rapid speed changes Keep the roll bar in the raised and locked position and use seat belt See inside the back cover to determine the approximate slope angle of the area to be mow
56. is remains it may be necessary to use water from a low pressure hose If the radiator is clean proceed to step 8 7 Cover the engine with a piece of cardboard or a plastic sheet Squirt water down through the fins Blow through with low pressure air from both directions If debris remains repeat until clean 8 Re assemble the fan to the radiator Reconnect the fan 9 Start the engine to ensure the fan is functioning properly 48 Maintenance Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 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 Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 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 maintenance relying solely on mechanical ot 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 suppor
57. k Depth 60 inch Deck 6 0 inches 15 2 cm 72 inch Deck 6 0 inches 15 2 cm Cutting Height Adjustment 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 e Mulching Kit Optional 18 Specifications Dimensions Torque Requirements Overall Width Blade Drive Sheave 90 110 ft lb 122 149 N m 60 inch Deck 72 inch Deck Mounting Nut Without Deck 53 5 inches 135 9 61 5 inches 156 2 Cutter Housing Spindle 160 185 ft lb 217 251 cm m Nut N m Blade Mounting Bolt 55 60 ft lb 75 81 N m lubricate with anti seize Engine Deck Front Frame 30 35 ft lb 41 47 N m Mount Bolts cm Deflector Up 61 4 inches 156 0 74 3 inches 188 7 cm cm Deflector Down 72 8 inches 184 9 85 8 inches 217 9 cm cm Anti Scalp Roller Nyloc 30 35 ft lb 41 47 N m Nut See Figure 12 Overall Length Anti Scalp Roller Hex 50 55 ft lb 68 75 N m 60inchDeck 72 Deck Capscrew See Figure 12 Roll Bar Up 81 9 inches 208 0 85 8 inches 217 9 Engine Mounting Bolts cm cm 1 2 13 inch screws 67 83 ft lb 99 113 N m Roll Bar Down 92 5 inches 235 0 96 4 inches 244 9 screws 3
58. levets are in the neutral lock position Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Fill the fuel tank Open the fuel shutoff valve Add oil to the crankcase Be sure the throttle control is midway between the SLOW and FAST positions Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the seat switch indicator Replace scat if needed Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mower pulls left or right with levers fully forwatd Machine does not drive Uneven cutting height Abnotmal vibration Blades do not rotate Engine load is excessive Oil level in the crankcase is low Dirty air filter
59. lift arms Loosen jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose Turn the socket head adjusting screws in until slack is taken out of each chain Tighten the jam nuts Tighten 40 Maintenance the chain bolts in the deck lift arms making sure they don t move while tightening 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 1s tight and all slack is removed from linkage Do Not lift front of deck off 3 4 inch 19 mm block Secure front swivel using locking nut in front of swivel Repeat for right side 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 11 1 2 4 3 o INC 8 6 6006122 5 7 Figure 18 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 6 Front of unit
60. lover protections systems roll bar pins heck the seat belt Before each use or daily heck for loose hardware heck engine coolant level ean the engine cooling system ean the engine and exhaust system area ean the grass and debris build up from the machine and cutting deck ean the grass build up from under the cutting deck heck the hydraulic oil level heck the tire pressures tents heck the condition of the belts Grease height adjustment shaft bearings Grease the rear deck struts 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 Every EOS Check spark arrester if equipped Clean the engine cooling system Every 100 hours Change the engine oil May need more often under severe conditions Lubricate the brake handle pivot Every 160 Lubricate the brake rod bushings Lubricate the motion control bronze bushings Every 200 hours Grease the brake brackets Every 400 hours Replace the fuel filter water separator more often in dirty or dusty conditions 29 Maintenance Maintenance Service Maintenance Procedure Interval Check the wheel hub slotted nut totque specifications Check the wheel lug nuts Change the hydraulic filter Every 250 hours yearly if using Mobil 1 15W50 Check the park brake adjustment Replace the air cleaner
61. ment forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop When the motion control levers are positioned fully outward apart in the T slot the drive system is in the neutral lock position Figure 7 When the motion control levers are moved directly inward together the drive system is in the neutral operate position G006147 Figure 7 1 Neutral lock position 5 Neutral operate handles out 2 Neutral operate position 6 Reverse handles in 3 Front of Unit 7 Neutral lock 4 Forward Driving Forward 1 Release the parking brake 2 Move the motion conttol levets inward to the center to the neutral position 3 To move forwatd in a straight line move both levers forward with equal pressure 77 o 6016947 Figure 8 To turn left or right pull the motion control levet back toward neutral in the desired turn direction The machine will move faster the farther the motion control levers are moved from the neutral position 4 stop position both motion control levers in the neutral operate position Driving in Reverse 1 Move the motion control levers inward to the neutral operate position 2 To move rearward in a straight line move both levers rearward with equal pressure A d QD vy Fig
62. moved or broken loose apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do 36 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 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 With the open end of the wheel facing up fill the atea inside the wheel atound the axle full of NGLI grade 1 multi purpose grease 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 Torque the nut to 75 80 in lb 8 9 N m loosen then re totque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut 13 14 Reinstall the seal guards over the wheel hub and insert wheel into caster fork Reinstall caster bolt and tighten nut fully Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 160 hours 1 Stop engine wait for all mo
63. n Disengage PTO Move drive levers out to neutral lock position Engage park brake Stop engine 109 1215 13 ANTI SCALP ROLLER ADJUSTMENT For normal operating conditions place rollers in positions shown for proper ground clearance CUTTING HEIGHT INCHES mm 1 0 25 2 0 51 3 0 76 4 0 102 FOR MAXIMUM FLOTATION rollers may be positioned lower but must maintain a minimum of 1 4 6 4 mm ground clearance Never position the rollers to support the mower deck 109 1399 109 1399 BELT ROUTING BELT 1 633127 60 109 5018 66 1 643052 72 109 2219 109 2219 CAUTION PINCH POINT May cause serious injury Place radiator prop securely 109 2263 Safety ANA ROTATING MECHANICAL DEVICES Can cause serious injury DO NOT operate without guards in place Stop engine before opening cover or removing guards 109 2264 109 2264 Engine RPM 3850 50 load 109 2478 109 2478 CHARGE RELAY 109 2951 Lubricate Blade Bolt threads with copper based antiseize grease and torque to 55 60 ft Ibs 75 81 109 3148 109 3148 Safety PUMP BELT ROUTING BELT 109 7582 116 0127 116 0127 ONLY USE EXMARK HYDRO OIL FILL TO TOP OF BAFFLE 4 CAUTION HOT SURFACE 116 0404 Ee ee 116 0404 Oha ORO SERVICE AID Eve
64. n the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark commercial turf equipment sold in the U S or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery Year Prorated Engine The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following Pickup and delivery charges to and from any authorized Exmark Service Dealer Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubrica
65. nd 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 Repeat on opposite side of unit 2 G006127 Figure 27 4 Yoke 5 Loosen here 6 Reverse indicator 1 Turn bolt here Lever centered in notch End of slot 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 45 Maintenance CAUTION Raising the mower deck for service or maintenance relying solely on mechanical 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 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
66. ne Safety Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystandets DANGER In certain conditions diesel fuel is extremely flammable and vapors are explosive fire or explosion from diesel fuel can burn you others and cause property damage Fill the fuel tank outdoors on level ground in an open area when the engine is cold Wipe up any diesel fuel that spills Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer Do Not fill the fuel tank completely full Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows diesel fuel to expand Overfilling may result in fuel leakage or damage to the engine or emission system Never smoke when handling diesel fuel and stay away from an open flame or where diesel fuel fumes may be ignited by spark 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 If fuel is spilled Do Not attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do Not operate without entire ex
67. nts incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 55 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at
68. o 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 Tracking Adjustment Knob Located under the seat on the LH pump control link Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position 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 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 21 Operation PTO Engagement Switch Located on right fuel tank Switch must be pulled out up to engage the blades Switch is pushed in to disengage the blades Note If the engine overheats the PTO will automatically disengage The PTO cannot be engaged until the engine has cooled down To re engage the
69. om the center position into the T slot locks them in the neutral position Figure 5 2 Figure 4 1 7l 1 Motion control levers 5 Engine Controls right console 2 Parking brake 6 Seat belt 3 Height of cut adjustment 7 Rollover Protection System ROPS 4 Fuel cap both sides Figure 5 1 Neutral lock position 5 Neutral operate handles out 2 Neutral operate position 6 Reverse handles in 3 Front of Unit 7 Neutral lock 4 Forward Throttle Control Located on right fuel tank The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed 20 Operation 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 15 used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the position Rotate clockwise to the next position to engage the starter key must be held against spring pressur
70. ons are adapted from the SAE J1494 Rev Dec 2001 Battery Booster Cables Surface Vehicle Recommended Practice SAE Society of Automotive Engineers WARNING Batteries contain acid and produce explosive gases Shield the eyes and face from the batteries at all times Do Notlean over the batteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems ate off and at the same rated system voltage These instructions are for negative ground systems only Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 13 Maintenance G012785 Figure 13 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block 4 Connect the other end of the positive cable to the positive terminal of the booster battery 5 Connect the black negative cable to the other terminal negative of the booster battery 6 MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK 7 Statt the vehicle and remove the cables in the rev
71. ovements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2011 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet 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 If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer
72. own 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 15 disengaged 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 outwatd to the neutral locked position 2 Disengage the PTO 3 Engage the patk brake 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 washet 6 Place the rollers in one of the positions shown Figure 11 Rollers will maintain 3 4 inch 19 mm clearance to the ground to minimize gouging and roller weat or damage 1 p 2 1 0 inch 25mm 2 0 inch 51mm 3 0 inch 76mm 4 0 inch 102mm OOOO Figure 11 For cutting heights above 4 0 inches 102 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller 2 Cutting height mounting bracket 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 26 Operation Be sure the roller bolts are installed with the spring disc washer between the head of the bolt and the mounting bracket
73. parts to stop Engage parking brake 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 Note The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the 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 Tf the oil is at room temperature about 75 F 24 C fill only to the COLD level Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Maintenance Check tire pressure in drive tires Inflate drive tires to 10 psi 69 kPa seges pe 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 Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all
74. rd throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown after one second has elapsed if the handles are in The delay will be 1 2 second if the handles are out 33 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 Again run engine at one third throttle brake engaged and move left motion control lever in engine must initiate shutdown after 1 2 second has elapsed Repeat again moving the right lever in then moving both levers in engine must initiate shutdown after 1 2 second has elapsed whether operator is on seat or not Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check Rollover Protections Systems Roll Bar Pins Service Interval Before each use or daily Make sure latch pin and hair pin are fully installed and lanyard is in good condition Check Seat Belt Service Interval Before each use or daily Visually inspect seat belt for wear cuts and proper operation of retractor and buckle Replace before operating if damaged Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts
75. remove key Engage parking brake Allow the machine to cool completely before starting these instructions 2 Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers 3 Check the condition of the wire harness leads connectors and terminals Clean or repair as necessary 4 Verify that 12V is present at the clutch connector when the PTO switch is engaged 5 Measure the gap between the rotor and armature If the gap is greater than 04 inch 1 mm proceed with the following steps A Loosen both brake mounting bolts one half to one full turn see Figure 24 Note Do Not remove the brake pole from the field shell armature The brake pole has worn to match the armature and needs to continue to match after the shim is removed to ensure proper brake torque 44 1 E 6011734 Figure 24 Brake mounting bolt 2 Shim 1 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 Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers Re torque each bolt M6 x 1 to 10 ft lb 13 N m 0 5 ft lb 0 7 N m Using 0 010 inch thick feeler gauge verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown Due to the way the rotor and armature faces we
76. rnative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours 37 Maintenance 6 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 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 Note Do Not change hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Check Engine Coolant Level Service Interval Before each use or daily Note If the engine coolant level is below the indicator line on the overflow bottle when the engine is cold the coolant temperature gauge may not register correctly during operation and or the warning buzzer may not sound if the engine overheats 1 Stop engine and wait for all moving parts to stop Make sure unit is on a level surface 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 If the coolant level is low open hood raise radiator remove the cap to the overflow bottle and fill
77. rotection instructions and warnings LESS THAN 15 116 3303 116 5074 CN a O disengage PTO at 1 2 throttle If engine overheats PTO will disengage GLOW PLUGS See operator s manual 116 5185 116 5185 PTO engage 2 PTO disengage CALIFORNIA SPARK ARRESTER WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrester may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements 117 2718 117 2718 Safety _ CAUTION CAUTION A solution of 50 antifreeeze and D h 50 water must be used in this engine o not ether Freezing point about 34 F Do not starting fluid use 100 antifreeze or severe damage Severe engine dam age 19420 87801 will occur 19426 87881 19320787903 19426 87903 MOTION MOTION 107 9866 1 Fast 3 Neutral 2 Slow 4 Reverse Specifications Specifications Model Numbers Serial Nos 312 000 000 and Higher LZDS902K605 LZDS902K725 Systems Engine Engine Specifications See your Engine Owner s Manual Engine Oil Type Exmark 4 Premium Engine Oil RPM Full Speed 3850 50 RPM PTO not engaged Idle 1400 100 RPM Fuel System e Capacity 15 5 gal 58 6 L Type of Fuel Diesel fuel 40 cetane or higher or biodiesel up to B20 20 biodiesel 80 p
78. ry 8 hours 1 Check engine oil Every 40 hours 2 Check hydraulic oil Only use recommended hydro oil 3 Check tire pressure 10 psi 4 Grease deck pivots 5 Grease deck strui 6 Grease deck lift pivot Every 200 hours 7 Grease brake brackets Yearly 8 Grease front caster pivots 9 Grease front caster wheel bearings 10 Grease belt idlers See operator s manual for additional details 116 0997 116 0997 Torque Wheel Hub Slotted Nut to 211 260 ft Ibs 100 hrs then every 3 286 352 N m See Operator s Manual for more details 500 hrs thereafter 116 2643 Torque Wheel Lug Nuts to 90 95 ft Ibs 122 129 N m Check after first 2643 116 15 A WARNING Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers Going up or backing down steep slopes or ramps can result in backward rollovers avoid loss of control and possibility of rollover resulting in serious injury or death Do not operate near drop offs or water Do not operate on slopes or ramps greater than 15 Do not use split ramps use full width ramps to load a unit for transport Reduce speed and use extreme caution on slopes or ramps Avoid sudden turns and rapid speed changes There is no rollover protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover p
79. s could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running Engine loses power PTO is engaged Parking brake is not engaged Drive levers are not in neutral lock position Battery does not have a full charge Electrical connections are corroded loose faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed Oil level in the crankcase is low The throttle is not in the correct position Dirt in fuel filter Dirt watet stale fuel is in the fuel system Air cleaner is dirty Seat switch is not functioning properly Electrical connections are corroded loose ot faulty Relay or switch is defective Engine load is excessive Air cleaner is dirty Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt watet or stale fuel is in the fuel system 50 Disengage the PTO Set the parking brake Ensure the dtive
80. spring a 1 2 inch drive breaker bar and 9 16 inch socket works best Reposition the adjusting pulley to the bottom of the slot Note When installing a new belt it is necessaty 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 41 Maintenance 9010225 Figure 19 1 Front of unit 2 Alignment holes 6010226 Figure 20 3 Right side idler pulley adjustable 1 Spring idler pulley 2 Front of unit Alternator Belt Tension Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt seat and remove air deflector panel To tighten alternator belt loosen both upper and lower alternator mounting bolts Rotate alternator out away from engine and retighten hardware to secure in place 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 be 1 8 inch 3 2 mm
81. stance medium feel Most resistance firmest feel Torque nyloc nut to 200 in Ib 16 7 ft Ib Bolt must protrude past end of nyloc nut after torque Damper 7 Damper must move freely on bolt afk ONS D Caster Pivot Bearings Pre Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1 4 of a turn to properly set the pre load on the bearings If disassembled make sure the spring disc washers are reinstalled as shown in Figure 31 47 Maintenance Cleaning Clean Engine Cooling System Service Interval Before each use or daily May be required more often in dry or dirty conditions CAUTION Excessive debris around the engine cooling ait 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 Clean all debris from inside of pump drive belt compartment daily Clean debris from radiator screen and core daily 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 3 Wipe debtis from screen in engine covet Rotate engine cover forward and wipe debris from radiator core as required 5 Clean debris from radiator fins with compressed air Important If debris or air can not be blown through the radiator see Cleaning of the Radi
82. switch eliminates rough ground cut outs Hydrostatic Ground Drive System e Hydrostatic Pumps Two Hydro Gear PW variable displacement piston pumps Wheel Motors Two Parker Ross with 1 1 4 inch tapered shafts 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 0 12 0 mph 19 3 km hr forward 0 8 0 mph 12 9 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running Tires amp Wheels Pneumatic Semi Pneumatic Air Filled mes 26 x 12 00 12 13 x 6 50 6 wu Cutting Deck Cutting Width 60 inch 152 4 cm 72 inch 182 9 cm Discharge Side e Blade Size 3 ea 60inch Deck 20 75 inches 52 7 cm 72inch Deck 24 75 inches 62 9 cm Blade Spindles Solid steel spindles with 1 18 inch 30 mm I D bearings Deck Drive Electric clutch mounted on horizontal engine shaft B Section belt with self tensioning idler from electric clutch to transfer shaft mounted on deck Blades are driven by one Section belt w self tensioning idler from transfer shaft on deck to blade spindles 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 Dec
83. t Use adequate jack stands or equivalent support Clean out any grass build up from underside of deck and in discharge deflector Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 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 In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the gatbage Management and disposal practices must be within relevant federal state ot local laws If a battery 15 being replaced or if the unit containing the battery 15 no longer operating and 15 being scrapped take the battery to a local certified recycling center If no local recycling is available return the battety to any certified battery reseller 49 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 problem
84. to stop and remove key Engage parking brake Visually inspect machine for any loose hardware ot any other possible problem Tighten hardware ot correct the problem before operating Service Air Cleaner Service Interval Every 50 hours Service the air cleaner May need more often under severe conditions See Maintenance the Engine Owner s Manual for additional information Every 600 hours Replace the air cleaner elements May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Unhook two air filter canister latches to gain access to the air cleaner element 3 Remove air cleaner canister cover and remove outer element 4 Check the condition of the paper element Replace if dirty bent or damaged 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 6 Do Not wash or use pressurized air to clean 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 Change Engine Oil Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first May need more often
85. 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 WARNING Engine coolant is hot and pressurized and radiator and surrounding parts are hot Spray or steam from hot pressurized liquid in the engine cooling system and touching a hot radiator may cause severe burns Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system 38 A CAUTION Engine coolant is toxic Swallowing coolant can cause poisoning Do Not swallow Keep out of reach of children and pets Change Engine Coolant Service Interval Every 4 000 hours Every 4 years whichever comes first Dex Cool extended life coolant orange color 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Machine must be positioned on level surface 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 WARNING Engine coolant is hot and pressurized and radiator and surrounding parts are hot Spray or steam from hot pressurized liquid in the engine cooling system and touching a hot radiator may cause severe burns Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system CAUTIO
86. trunnion roller 2 3 turns 8 4 6016452 5 7 3 Figure 22 Lever down 6 Remove pin to adjust disengaged rod length for additional brake adjustment Lever up engaged 7 Trunnion roller Nyloc nut below trunnion 8 Spring retainer bracket roller Jam nut above trunnion roller Nyloc nut below spring 9 1 8 to 3 16 inch 3 2 to 4 8 mm 9 Tighten the bottom nyloc nut item 3 in Figure 22 until the brake spring is completely compressed then loosen one half turn 10 Tighten the jam nut against the trunnion roller 11 Check the cleatance between the bottom of the brake bracket and the nyloc nut just under the 12 13 14 15 43 spring Clearance should measure 1 8 to 3 16 inch 3 2 4 8 mm If necessary adjust the nyloc nut accotdingly If the correct gap can no longer be achieved because there is no clearance between the nyloc nut below the spring and the jam nut or there are no threads left in the bottom nyloc nut the length of the brake 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 If a brake component has been removed or replaced see the steps below otherwise proceed to step 14 Burnishing the Brake Procedure Clear the area of any flammable material before starting the burnishing process B While sitting in the operator s se
87. ure 9 Operation To turn right release pressure on the RH motion conttol levet and the reat of the machine will move towards the rear and to the right To turn left release pressure on the LH motion conttol levet and the reat of the machine will move towatds the rear and to the left 3 To stop position both motion control levers in the neutral operate 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 outwatd 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 position Figure 10 The deck can be raised by pulling the deck lever up and or by pushing down on the foot operated deck lift assist lever located at the front right corner of the floor pan Note When changing the cutting height positions always come to a complete stop and disengage the PTO G006118 Figure 10 1 Lever in transport and 5 inch 12 7 cm cutting height position 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 5 Move the deck height lever out of the transport position or 5 inch 12 7 cm cutting height and d
88. use the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 28 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position WARNING A WARNING While maintenance or adjustments are being The engine can become very hot Touching a hot made someone could start the engine engine can cause severe burns Accidental starting of the engine could seriously injure you or other bystanders 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 After the first 5 hours Change the engine oil Che ck the wheel hub slotted nut totque specifications heck the wheel lug nuts heck the park brake adjustment k the engine oil level k the mower blades k the safety interlock system heck the rol
89. ving parts to stop and remove key Engage parking brake Lubticate bronze bushings on brake handle pivot with a spray type lubricant or light oil Lubricate Brake Rod Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Unhook seat latch and tilt seat up 3 Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil Maintenance bushings are located to the inside of the flange bearings Lubricate Motion Control Bronze Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Unhook seat latch and tilt seat up 3 Lubricate bronze bushings on flange bearings securing the motion control arm shafts with a light oil ot a spray type lubricant Drain Fuel Filter Water Separator Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Place a drain pan under the fuel filter and loosen the drain plug approximately 1 turn 3 Water should drain 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 Change Fuel Filter Water Separator Service Interval Every 400 hours Yearly whichever comes first more often in dirt
90. wer deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle midway between the SLOW and FAST positions Pull the PTO switch outward to engage the blades 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle midway between the SLOW and FAST positions 2 Push the PTO switch in to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Move the motion control levers out to the neutral lock position 3 Engage the parking brake 4 Place the throttle midway between the SLOW and FAST positions 5 Disengage the PTO 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building 24 Operation 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 Use caution when making turns Slow the machine down before making sharp turns Important To begin move
91. wheels to rotate freely Unhook seat latch and tilt seat forward 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 Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature Loosen lock nuts from the ball joints at each end of the pump control linkage Figure 28 G006155 Figure 28 Right Hand Side of Unit Turn here to adjust 2 Loosen here right hand thread 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 The reverse indicator spring must be correct before the following adjustments can be made See the Reverse Indicator Adjustment section Note The motion control lever needs to be in neutral while making any necessary adjustments The left rod assembly controls the left wheel and the right rod assembly controls the right wheel Bring the motion control lever into the neutral position Adjust RH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse Fi
92. y or dusty conditions DANGER Use of improper components can result in system failure fuel leakage and possible explosion Ensure that an Authorized Service Dealer replace the fuel filter and any components for the fuel system Use only approved fuel lines hose clamps and fuel filters for high pressure systems Change Inline Fuel Filter Service Interval As required An inline fuel filter is installed between the fuel tank and the fuel pump Replace when necessary Replacement Filters Exmark P N 112 7836 Change Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 Note Use only Exmark P N 103 2146 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Raise seat Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system Unscrew filter to remove and allow oil to drain from reservoir 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 Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn Fill reservoir as stated in Check Hydraulic Oil Level section Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alte

Exmark eXmark Lazer Z DS-Series LZDS User's Manual

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