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Eureka 5700-5739 Vacuum Cleaner User Manual

1. 6008623 Kolind eu MOO 49 Exmark Lazer Z and Lazer Z AS Turf Equipment 3 Year Limited Commercial Warranty 5 Year or 750 Hours Limited Consumer Warranty General Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Commercial Warranty Conditions This warranty applies to Exmark Lazer Z and Lazer Z AS turf equipment sold in the U S or Canada for a period of three years for commercial usage This warranty includes the cost of parts and labor for a period of two years and the cost of parts for one additional year This warranty does not cover pickup and delivery charges to and from any authorized Exmark Service Dealer Consumer Warranty Conditions This warranty applies to Exmark Lazer Z and
2. Av 38 1915 HOLNTO Old 8 gt 30010 SAL del av inr e 1 v S 9 8 LOL 6 8v av ps te z L E E E B B HYOLOANNOD IWOH3 CIMIIA SHOLOANNOD LON m IWE 2 HOLIMS ayvug XOVTE TONOS Tand 2 z E HOLIMS 3d HT imr 4 JONVEO 2 HOLIMS 3UNVEO Y Y AHOSS320V INTE 8 v2 962061 21696 E 8 9 6 S v4 v 4 26 l L oP HOLIMS LVIS 81 v HOLIMS NOLLINSI HOLIMS Old Y30N3S stitute LUVAS t 3NON 340 av SWNINYSL TVNINYAL 1 WNIWH3L 1 WNIWHAL 18915 VNIWH3L NOILINSI TVNIWH3L Ayav 8 055322 TVNINH3L SNOILO3NNOO 1 HOLIMS 47 Schematics Electrical Logic Schematic 5198009 45 SLIM M 1310lA7 A sig NVL L 35NVHO HO T um 3 3339 LHDSIT 89 A3HD AD In it 1 N33H9 ND gt 5
3. Vig adhe d 1 i w t mp TUN Ay m drm it ME mhi TETTE nara 1 G000503 55 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Engine Serial No E No Serial No 2009 Exmark Mfg Inc Part No 4500 471 Rev A Industrial Park Box 808 402 223 6300 Cle Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
4. 6008601 Figure 16 1 Deck foot pedal 3 Cut of height decal 2 Height adjustment pin 4 Transport lock control 5 Insert the height adjustment pin into the hole corresponding to the desired cutting height See the decal on the side of the deck lift plate for cut heights 6 Push the deck lift pedal release the transport lock and allow the deck to lower to the cutting height Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed 1 Stop the machine and move the motion control levers outward to the neutral lock position 2 Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 Adjust the anti scalp rollers by removing the bushing spring disc washer and bolt 6 Place the rollers in one of the positions shown Figure 17 Rollers will maintain 3 4 inch 19 mm clearance to the ground to minimize gouging and roller wear or damage 25 Operation m 1 2 2 0 51 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm Figure 17 For cutting heights above 3 5 inches 90 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller 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
5. 2 3 3 5 4 1 2 Total Accessory Score Total Accessory Score Required Weight Kit s 10 19 116 1173 Under toe board mount weight kit 20 and Higher Two 116 1173 Under toe board mount weight kits one 116 1173 Under toe board mount weight kit and one 116 1238 Front toe board mount weight kit 48 and 52 inch units that come with an under toe board weight as standard can add an additional toe board weight for primary accessory weighting scores 10 19 and front toe board weight kit for secondary accessory weighting scores 20 and higher Other units should install a first under toe board kit for primary accessory weighting scores 10 19 and a second under toe board kit for secondary accessory weighting scores 20 and higher 17 Product Overview 60 inch units which already have an under toe board P rod u ct Ove rv ew mount weight as standard requires 116 1238 front toe board top mount kit instead of 116 1173 Torque Requirements Blade Drive Sheave 90 110 ft lb 122 149 Mounting Nut Cutter Housing Spindle 160 185 ft lb Nut 217 251 N m Blade Mounting Bolt 55 60 ft lb 75 81 N m lubricate with anti seize Anti Scalp Roller Nyloc 30 35 ft lb 41 47 N m Nut See Figure 18 Anti Scalp Roller Hex 50 55 ft lb 68 75 N m Capscrew See Figure 18 Engine Mounting Bolts Figure 4 Kawasaki 23HP 15 19 ft lb 20 26 N m 1 Rollover Protection 5 Fuel cap Kohler 23 27HP 27 33 ft lb 37
6. Figure 35 RH Motion Control Shown 1 Screw 3 Motion control lever 2 Cover plate 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 36 42 1 1 G006131 Figure 36 Spring disc washers Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen around engine shrouding and exhaust system area 3 Wipe up any excessive grease or oil around the engine and exhaust system area Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 100 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove cooling shroud clean out covers Kohler ot cooling shrouds Kawasaki from engine and cle
7. Service Air Cleaner Service Interval Every 200 hours Service the air cleaner 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 Loosen retaining clips and remove air cleaner compartment cover 3 Remove paper element Check the condition of the paper element Replace if dirty bent or damaged 31 Maintenance 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 Do Not wash or use pressurized air to clean paper element or inner element 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 under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Drain oil while engine is warm from operation The oil drain hose is located on right hand side of engine at the rear Place pan under machine to catch oil Remove plug from end of drain hose Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft lb Replace the oil fil
8. Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as equivalent to the parts supplied as original equipment A 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 Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engi
9. jacks for support Use adequate jack stands or equivalent support Deck Leveling 1 Position the mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check the tire pressure in the drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Position the transport lock in the latching position 5 Push the foot pedal all the way forward and the deck will latch at the 5 1 2 inch 14 cm transport position Figure 25 36 Maintenance 1 G008615 Figure 25 Foot lever 3 Transport lock 2 Cut of height pin Insert the height adjustment pin into the 3 inch 7 6 cm cutting height location Release the transport lock and allow the deck to lower to the cutting height Raise the discharge deflector On both sides of the deck measure from the level surface to the front tip of the blade The measurement should read 3 inches 7 6 mm Note In most conditions the back blade tip should be adjusted 1 4 inch 6 4 mm higher than the front I A N 6 Figure 26 3 1 4 inches 8 3 cm Back blade tip Front blade tip 3 inches 7 6 cm 5 Level surface 6 Rear of machine 7 Front of machine 10 Loosen the jam nuts on the top of each deck link Fine tune the adjuster on the front deck lift assembly by turning it to get 3 inch 7 6 mm height see Figure 27 To i
10. 10 11 12 13 14 15 39 Note the order of the standard nut and lock nut no nut on the cable anchor side of the swivel Release hold on the caliper lever and cable The wheel hub should turn by hand in both directions relative to the caliper some friction resistance is acceptable If there is no movement between the hub rotor and the caliper then back off the standard nut one turn from the swivel and repeat step 10 drive release valves must be in the released position on the hydros If the hub rotor moves very freely relative to the caliper then tighten the standard nut one turn against the swivel and repeat step 10 Once step 10 is achieved hold the threaded rod end with a tool and tighten the lock nut against the standard nut Do Not allow the cable to turn when the nuts are tightened Rotate the drive wheel release handle to the operating position Refer to the Drive Wheel Release Valves section in Operation Repeat on the opposite side of machine Maintenance 16 Install the rear tires and torque lug nuts to 90 95 ft lb 122 129 N m 17 Remove jack stands Electric Clutch Adjustment No adjustment necessary Motion Control Linkage Adjustment Located on either side of the fuel tank below the seat are the pump control linkages Rotating the pump linkage with a 1 2 inch wrench allows fine tuning adjustments so that the machine does not move in neutral Any adjustment
11. 28 Recommended Maintenance Schedule s 28 Periodic Maintenance ioo ee Ne ERR 29 Check Engine Oil Level autera 29 Check Mower Blades sois 30 Check Safety Interlock System eene 30 Check Rollover Protections Systems Roll IO DS eon 31 Check Seat 31 Check for Loose Hardware 31 Service Air Cleaner 31 Change Ereine sse 32 Check Hydraulic Oil Level 32 Check Tite LC SSUES ron teen tine Tes 32 Check Condition Of 33 Lubricate Grease as eto desde 33 Lubricate Brake Handle Pivot 34 Lubricate Deck Lift Pivot o nece tic aes 34 Gheck Spark Plugs uscite 34 Change Hydraulic System Filter and 34 Wheel Hub Slotted Nut Torque SPSCHICAHON eene eae dies 35 Check Spark Arrester if equipped 35 Thread Locking 36 Copper Based Anti seize 36 Dielectric Greaser 36 uos adita ee et obvio eds 36 Teens 36 Deck Removal 38 Pump Drive Belt Tension enis rts 39 Deck Belt Tension cus 39 Adjusting the Parking Brake 39 Electric Clutch 40 Motion Control Linkage Adjustment 40 Motion Control Damper Adjustment 40
12. Carefully clean area around the filters It is important that no dirt or contamination enter the hydraulic system 6 Using a socket unscrew filters to remove and allow oil to drain Maintenance 7 Before installing the new filters apply a thin coat of Exmark Premium Hydro oil on the surface of the two rubber seals 8 Install the new filters and torque to 14 ft lb 19 N m 9 Fill the hydraulic system as stated in Check Hydraulic Oil Level section Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours 10 Remove the catch pan and properly dispose of hydro oil and filter according to local codes 11 Re install the pump drive belt 12 Start engine and move throttle control ahead to full throttle position Move the speed control levers to the full speed and run for one minute Shut down the machine allow the hydros to cool and recheck oil level 13 Remove the jack stands Note Do Not change the hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated ot been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminants into the system Wheel Hub Slotted Nut Torque Specification Service Interval After the first 100 hours Every 500 hours thereafter Wh
13. Lazer Z AS turf equipment sold in the U S or Canada for a period of five years or 750 hours whichever occurs first for residential usage Residential usage means use of the product on the same lot as your home Use at more than one location is considered commercial use and the commercial use warranty detailed above would apply This warranty only includes the cost of parts and labor For the first warrantable service repair Exmark will cover up to 45 for associated pick up and delivery charges to and from any authorized Exmark Service Dealer Additional transportation charges may apply contact your Dealer for details Warranty Exceptions Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine 2 years The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet Items and Conditions Not Covered This warranty does not cover the following Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoli
14. eyes and skin Never siphon by mouth Safety Never operate the mower with damaged guards A CAUTION E shields or covers Always have safety shields tank is located inside thetoll guards switches and other devices in place and in bar tube Removing or modifying the roll proper working condition bar could result in fuel leakage and violate Never mow with the discharge deflector raised emissions regulations removed or altered unless there is a grass collection system or mulch kit in place and Do Not remove roll bar P working properly Do Not weld drill or modify roll bar in Do Not change the engine governor setting or any way overspeed the engine Stop engine wait for all moving parts to stop e Check that the operator s presence controls key atid engage packing brake safety switches and shields are attached and functioning properly Do Not operate unless they Before checking cleaning or working on the are functioning properly MOWER After striking a foreign object or abnormal Operation vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower A WARNING Operating engine parts especially the Whenever you leave the mower muffler become extremely hot Severe burns can occur contact and debris such as leaves grass brush etc can catch fire Before clearing block
15. fins and air passages for the engine are plugged 5 Dirt in fuel filter 6 Dirt watet or stale fuel is in the fuel system 1 Drive release handle not in operating position 2 Drive or pump belt is worn loose or broken 3 Drive or pump belt is off a pulley 4 Broken or missing idler spring 5 Hydraulic fluid level is low or too hot 1 Blade s not sharp 2 Cutting blade s is are bent 3 Mowet deck is not level 4 Underside of mower is dirty 5 Tire pressure in drive tires not correct 6 Blade spindle bent 7 Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness 1 Cutting blade s is are bent or unbalanced 2 Blade mounting bolt is loose 3 Engine mounting bolts are loose 4 Loose engine pulley idler pulley or blade pulley 5 Engine pulley is damaged 6 Blade spindle is bent 1 Drive belt is worn loose ot broken 2 Deck belt is worn loose or broken 3 Deck belt is off pulley 4 Broken or missing idler spring 5 Drive belt not routed correctly 46 1 Reduce the ground speed 2 Clean or teplace the air cleaner element 3 Add oil to the crankcase 4 Remove the obstructions from the cooling fins and air passages 5 Replace the fuel filter 6 Contact an Authorized Service Dealer 1 Tire pressure in drive tires not correct 1 Adjust tire pressure in the drive tir
16. front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and 33 pump with grease until it oozes out around top beating Remove grease zerk and thread plug back in Place cap back on 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 23 1 Seal guard 2 Spacer nut with wrench flats Remove caster 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 bearings for wear or damage and replace if necessary Pack the bearings with a NGLI grade 1 multi purpose grease Insert one bearing 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 removed or broken loose apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do Not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut Maintenance 9 Insert the assembled nut and axle int
17. 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 Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank Check 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 Maintenance second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown after one second has elapsed if the handles are in The delay will be 1 2 second if the handles are out 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 el
18. 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 as Loctite 242 Fel Pro Pro Lock Nut Type are used on the following fasteners e ROPS spring pin housing Hydro pump control arm linkage bolt and attachment bolt Hydro cooling fan screw Hydro park brake cable anchor mounting bolt Sheave and clutch retaining bolt in the end of engine crankshaft Thread locking adhesives are required for some hardware on engines see the Engine manual 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 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 A 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
19. when transporting Ignition Switch Located on right console see Figure 6 The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Allow the key to return to the on position immediately after the engine starts 1 57 ax 071 Figure 8 3 Start 2 3 6008610 Note Brake must be engaged motion control levers out neutral lock position and PTO switch disengaged to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right console in the message display see Figure 6 and Figure 9 The hour meter records the number of hours that the engine has run 9008612 Figure 9 LCD Indicators Low fuel indicator light Fuel level bar display Low voltage indicator light Hour Voltage display gt O N Hours are recorded when the key is on and the engine is running battery voltage is 12 8V or higher or when the key is on and the operator is in the seat The hour meter is recording when the decimal point is flashing in Hour Voltage display Hours are displayed when the key is off and when the machine is running Note If the i
20. 45 N m System ROPS Kawasaki 29HP 27 33 ft lb 37 45 N m 2 Engine Controls right 6 Height of cut adjustment Kawasaki 34HP 17 21 ft lb 23 28 N m console 3 Seat belt 7 Parking brake 4 Motion control levers Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Motor Mounting 72 77 ft lb 98 104 N m Bolts Wheel Hub Slotted Nut minimum 200 ft lb 271 N m Rollover Protection 75 80 ft lb 102 108 N m System Roll Bar 1 2 inch Mounting Bolts Clutch Retaining Bolt 55 60 ft lb 75 81 N m secured with threadlocker Hydro Park Brake Cable 67 89 ft lb 91 121 N m Anchor 1 2 inch Mounting Bolt secured with threadlocker 18 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of the machine Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position into the T slot locks them in the neutral position Figure 5 When the motion control levers in the neutral position the LCD indicator appears in the message display on the RH console see Figure 9 q G008593 Figure 5 1 Neutral lock position 4 Forward h
21. 70 5 inches 179 1 cm 46 8 inches 118 9 cm 16 Specifications Tread Width Center to Center of Tires Widthwise inch Deck 52 inch Deck Drive Wheels 36 2 inches 36 2 inches 91 9 cm 91 9 cm Caster Wheels 32 8 inches 32 8 inches 83 3 cm 83 3 cm 60 inch Deck 172 inch Deck Drive Wheels 41 6 inches 43 6 inches 105 7 cm 110 7 cm Caster Wheels 39 5 inches 47 1 inches 100 3 cm 119 6 cm Wheel Base Center of Caster Tire to Center of Drive Tire 48 inch 52 inch 60 inch 72 inch Deck Deck Deck Deck 48 0 inches 48 0 inches 50 6 inches 53 6 inches 121 9 cm 121 9 cm 128 5 cm 136 1 cm Curb Weight 48 inch 52 inch 60 inch 72 inch Deck Deck Deck Deck 23HP 1108 Ib Kawasaki 1125 lb 1116 Ib 1116 Ib 506 1260 Ib Kawasaki 572 ke 1292 Ib 586 kg Accessory Weight Table Worksheet Use the table below to determine if extra weight is required for the unit Identify the accessories and correct deck size and place the corresponding values in the Accessory Score column If the Total Accessory Score meets the following add the recommended weight kit Note The 72 inch deck does not require a weight kit 48 inch 52 inch 60 inch Accessory Deck Deck Deck Score Light Kit Michigan 11 Seat CRSS 7 Bagger 2 Pneumatic Caster Tires Mulch Kit Striper Kit OCD02 Hitch Kit Sunshade Kit 5
22. 8 5 r ama 5 5 5 E 9 AAA 2 5 5 DORMIT 202 F ab cae v Na ne 8 s Q 3 vse uz INS DH Md ualuvis ANH ov Yanan gt ofa ng NS i b ms 4 ov na ZMS e D EN HO LIMS T lc i uon ov 1415 Si B SS bL ms b l fefe fe ANN NOILINDI b SMS A 9 1 1 NIML l e t i Fg an et etc AE on ae 4 ano 5199 LYVLS NO 1 sauossaoov suonoouuoo ou 440 7 NY 4 Od H uo yoeq uoniuBI 5 1 v 5 2 v IMS 48 Schematics Hydraulic Diagram h p 22082 0 2 ssed g Jeeupioous Jeieu lt ssed g 2 19115 Sa
23. ECK 1 633922 KEEP HANDS and FEET AWAY 1 633922 1 403005 A DANGER THIS UNIT WHEN COVER 1 NOT IN PLACE 98 5954 CAUTION HOT SURFACE ey 103 2076 103 2076 Safety A WARNING TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked position and use seat belt THERE IS NO ROLL OVER PROTECTION WHEN THE ROLL BAR IS DOWN 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 Read and follow Slope operation instructions and warnings 107 2102 107 2102 A WARNING Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning avoid loss of control and possibility of rollover NOT operate near drop offs or near water NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes There is no rollover protection when the roll bar is down Always keep roll bar the raised and locked position and use seat belt Read and follow rollover protection instructions and warning SS B rcd than 15 Lubricate Blade Bolt threads with copper ba
24. LAZER Z MODELS 5 gt E 2 2 o For Serial Nos 790 000 amp Higher Part No 4500 471 Rev A AWARNING 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 When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 002 Ce 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 improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibil
25. LT DRIVE Can cause serious injury Stop engine and wait until all moving parts have stopped before reaching underneath 116 0205 12 Safety 116 0211 SERVICE AID Every 50 hours 1 Check hydraulic oil Only use recommended hydro oil 2 Check tire pressure in pneumatic tires 13 psi Yearly 3 Grease belt idlers 4 Grease front caster pivots See operator s manual for additional details Fuel Empty 116 0752 Latch 2 Unlatch Full 1 2 3 Half 4 5 Battery Message Display 6 Hour meter 7 PTO 8 Parking brake 9 Neutral 10 Operator presence switch 1 PTO disengage PTO Switch Symbols 2 WARNING To avoid serious injury or death Read and understand the operator s Do NOT operate without shields guards manual before using this machine and safety devices in place and working Do NOT operate unless trained to safely Check the function of the operator use this machine Do NOT operate under the influence of alcohol or drugs Hearing protection is recommended presence controls OPC safety system daily Do NOT defeat the OPC system Stop engine and remove key before adjusting servicing or cleaning machine and attachments DANGER To avoid serious injury or death Avoid blades unless engine and blades are stopped 109 7069 109 7069 WARNING To avoid serious injury or de
26. Motion Control Neutral Lock Pivot PAST 41 Motion Control Handle Adjustment 41 Motion Control Full Forward Tracking Foral rin iari 41 Caster Pivot Bearings Pre Load 42 run M 43 Clean Engine and Exhaust System ERR UH te cR TE 43 Remove Engine Shrouds and Clean Cooling RM T ER MES 43 Clean Hydro Fan Cooling Guards 43 Clean Debris From 43 Clean Grass Build Up Under Deck 43 Waste Disposal vitet e iei e 44 Troubl shooting c sesto estu 45 Schematics 2727 ER UAR 47 Safety Safety Safety Alert Symbol 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 1 Safety alert symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION 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
27. ages Stop engine wait for all moving parts to stop and engage parking brake Before refueling Allow engine parts especially the muffler Bef ing th her to cool belore touching efore dumping the grass catcher A 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 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 Do Not operate the machine without guards shields and safety devices in place and working properly A WARNING Keep hands feet hair jewelry or clothing Engine exhaust contains carbon monoxide away from rotating parts which is an odorless deadly poison that can kill you NEVER carry passengers DO NOT operate Do Not run engine indoors or in a small the mower when people especially children or confined area where dangerous carbon pets are in the area monoxide fumes can collect Be alert slow down and use caution when making turns Look behind and to the side before Operate only in daylight or good artificial light changing directions keeping away from holes and hidden hazards Stop the blades slow down and use caution when crossing surfaces other than grass and when t
28. aintenance A 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 3 Clean out any grass build up from underside of deck and in discharge deflector 44 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 A 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 Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified ba
29. an cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause inadequate cooling Make sure cooling shroud clean out covers ot cooling shrouds are reinstalled Operating the engine without cooling shroud clean out covers ot cooling shrouds will cause engine damage due to overheating Clean Hydro Fan Cooling Guards Service Interval Before each use or daily Removing debris from the hydro fan cooling guards will allow the hydro system to run cooler and improve the life of the hydro system 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Slide seat all the way back then lift the seat to access the LH and RH hydro drive area 3 Remove accumulated debris from the hydro fan cooling guards 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 2 Raise deck to the transport 5 1 2 inch 14 cm cutting height position Lift the front of unit and support unit using jack stands or equivalent support 43 M
30. andles out 2 Neutral operate position handles in 3 Front of Unit 5 Neutral operate 6 Reverse Choke Control Located on right console black lever see Figure 6 The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the reat to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the ON position G009389 Figure 6 Right Console Fuses Message display Ignition switch PTO engagement switch Throttle Choke oA PWNS Throttle Control Located on right console red lever see Figure 6 The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle Brake Lever Located on right side of unit just to the front of the RH motion control lever The brake lever engages a parking brake on the drive wheels Operation Note The LCD indicator appears in the message display on the RH console when the park brake is engaged see Figure 9 Pull the lever up and rearward to engage the brake Depress the release button and push downward to disengage the brake 6008607 Figure 7 1 Release button 2 Park brake The unit must be tied down and brake engaged
31. apsed 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 Knobs Service Interval Before each use or daily Check that both the mounting hardware and the knobs are in good working condition Make sure the knobs are fully engaged with the ROPS in the raised position The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged 6008619 Figure 21 1 Engaged 2 Partially engaged Do Not operate with ROPS in this 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 to stop and remove key Engage parking brake Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating
32. ath Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit If individual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward Having a full width ramp provides a 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 or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the traile
33. ath Pick up objects that could be Before leaving the operator s thrown by the blades position Disengage PTO Move drive levers out to neutral lock position Engage park brake Stop engine Do NOT mow when people and pets are in the area Do NOT carry passengers Look behind and to the side before changing directions 13 Specifications Specifications Model Numbers Serial Nos 790 000 and Higher LZZ23KC486 LZZ23K A526 LZZ23KC526 LZZ27KC526 LZZ27KC606 LZZ29K A606 LZZ34K A606 LZZ34K A726 Systems Engine Engine Specifications See your Engine Owner s Manual RPM Full Speed 3750 50 RPM PTO not engaged Idle 1500 RPM Fuel System Capacity 12 0 gal 45 4 L Type of Fuel Regular unleaded gasoline 87 octane or higher Fuel Filter Kohler Kohler P N 24 050 13 Kawasaki Kawasaki P N 49019 7001 Fuel Shut Off Valve All Units 1 4 turn increments OFF Fuel level eight segment display right hand control panel Low fuel indicator light Electrical System Charging System Flywheel Alternator Charging Capacity Kohler and Kawasaki 15 amps Battery Type BCI Group U1 Recommended Minimum Battery CCA 34HP Kawasaki 340 CCA Allother engines 260 CCA Battery Voltage 12 Volt Low Voltage Light RH control panel Polarity Negative Ground Fuses 14 All units 25 amp main fuse 25amp charging system f
34. d wait for all moving parts to stop Make sure unit is on a level surface Check with engine cold Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick according to the engine manufacturer s recommendations Remove the dipstick and read the oil level If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval As required CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter or with the message display If the ignition key is turned to the position f
35. e engine is off and the key switch is turned to the ON position 21 Operation 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 Transport Lock Located on the height of cut adjustment plates to the right of the parking brake Position in the transport latching position to automatically latch the cutting deck when raised to the transport position see item 1 in Figure 11 In the non latching position the deck will automatically return to the cutting height when the pedal is lowered see item 3 in Figure 11 G008608 Figure 11 1 Latching position 2 Transport lock control 3 Non latching position Pre Start Fill fuel tank For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Do Not add oil to gasoline Do Not overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 inch 13 mm below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 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 Operating Instructions Raise the Rollov
36. e 3 G000963 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 e Avoid sudden starts when mowing uphill because the mower may tip backwards Be aware that operating on wet grass across steep slopes or downhill may cause the mower to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights ot 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 bar is installed on the unit Safety A WARNING There is no rollover protection when the roll bar is down Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or dr
37. e Interval Every 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check tire pressure in drive tires Inflate drive tires to 13 psi 90 kPa 4 Semi pneumatic caster tires Do Not need to be inflated Note Do Not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty 32 Maintenance Check Condition Of Belts Service Interval Every 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt 3 Check under machine to inspect the pump drive belt Note No adjustments are required for belt tension Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 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 Deck and Pump Idler Pivots See step 3 for special lubrication instructions on the front caster pivots 6008599 Lubricate
38. e operate raised position Ensure that the rear part of the seat is secured with the seat latch Open the Fuel Shut Off Valve The fuel shut off valve is located behind and below the seat Rotate the valve and align with the fuel line to open Starting the Engine 1 Move the motion control levers out to the neutral lock position Pull up and back on the parking brake lever to engage the parking brake Push down on the PTO switch to the disengage position Note It is not necessary for the operator to be in the seat to start the engine Place the throttle midway between the SLOW and FAST positions On a cold engine push the choke lever forward into the ON position On a warm engine leave the choke the OFF position Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the ON position gradually return choke to the OFF position as the engine warms up Engaging the PTO A DANGER The rotating blades under the mower deck ate 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 engag
39. each 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 of ignition until fuel vapors have dissipated Do Not operate without entire exhaust system in place and in proper working condition Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete A WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from
40. ed A DANGER An uncovered discharge opening will allow objects to be thrown in an operatot 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 mower 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 2 Pull the PTO switch outward to engage the blades 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle midway between the SLOW and FAST positions 2 Push the PTO switch in to disengage the blades 23 Operation Stopping the Engine 1 Bring the unit to a full stop 2 Disengage the PTO 3 Move the motion control levers out to the neutral lock position 4 Engage the parking brake 5 Place the throttle midway between the SLOW and FAST positions 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 person
41. en tightening the slotted nut on the wheel motor tapered shaft 1 Remove and discard the cotter pin 2 Torque the slotted nut to 200 ft lb 271 N m 3 Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 inch or less should be showing G008603 Figure 24 2 No more than two threads 0 1 inch max should be showing here 1 0 1 inch max 4 If more than two threads 0 1 inch are showing remove nut and install washer P N 1 523157 between hub and nut 5 Torque the slotted nut to 200 ft Ib 271 N m 6 Then tighten nut until the next set of slots line up with the cross hole in shaft Do Not loosen nut to align the slot If required tighten to the next set of slots 7 Install new cotter pin P N 1 806800 Note Do Not use anti seize on wheel hub Check Spark Arrester if equipped Service Interval Every 50 hours A WARNING Hot exhaust system components may ignite gasoline vapors even after the engine is stopped Hot particles exhausted during engine operation may ignite flammable materials Fire may result in personal injury or property damage Do Not refuel or run engine unless spark arrester is installed 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Wait for muffler to cool Maintenance 3 If any breaks in the screen or welds are observed replace arrester If plugging of the screen is
42. er Protection System ROPS Important The roll bar is an integral and effective safety device Keep the roll bar in the raised and locked position when operating the mower Lower the roll bar temporarily only when absolutely necessary 1 The knob must be completely latched with the tabs interlocking as shown in Figure 12 to lock the roll bar in the raised operate position 2 Apply forward pressure to the upper hoop of the roll bar 3 Pull the knob and rotate 90 to hold in the unlatched position to lower the roll bar 4 To return to the operate position raise the roll bar and then rotate knobs 90 so that the tabs interlock partially Apply forward pressure to the roll bar upper hoop and observe that the knobs return to the completely latched position 5 G008592 Figure 12 Roll bar upper hoop Knob in latched position Pull knob to unlatch Rotate 90 to hold unlatched Knob in unlatched position 5 Make sure the knobs are fully engaged with the roll bar in the raised position The upper hoop of Operation the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged see Figure 13 6008619 Figure 13 1 Engaged 2 Partially engaged Do Not operate with ROPS in this condition Important Always use the seat belt with the roll bar in th
43. es 1 Position handle in operating position see Drive Wheel Release Valves section in Operation 2 Change the belt 3 Change the belt 4 Replace the spring 5 Add hydraulic fluid to reservoir or let it cool down 1 Sharpen the blade s 2 Install new cutting blade s 3 Level mower deck from side to side and front to reat 4 Clean the underside of the mower 5 Adjust tire pressure in the drive tires 6 Contact an Authorized Service Dealer 7 Replace blades spindles and or check for damage to mower deck 1 Install new cutting blade s 2 Tighten the blade mounting bolt 3 Tighten the engine mounting bolts 4 Tighten the appropriate pulley 5 Contact an Authorized Service Dealer 6 Contact an Authorized Service Dealer 1 Check the belt tension 2 Install new deck belt 3 Install belt on clutch and deck pulleys idlers and tensioning idler per routing decal on deck 4 Replace the spring 5 Refer to belt routing decal on deck Schematics Schematics o Electrical Diagram 39018 3874
44. ether performed by a dealer or by you is at 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 conse
45. evel he mower blades he safety interlock system the rollover protections systems roll bar knobs heck the seat belt heck for loose hardware ean the engine and exhaust system area ean the hydro fan cooling guards ean the grass and debris build up from the machine and cutting deck ean the grass build up from under the cutting deck Before each use or daily K K K K K K heck the hydraulic oil level heck the tire pressures heck the condition of the belts heck spark arrester if equipped Every 50 hours OOO OOO OO O O O O hange the engine oil May need more often under severe conditions Every 100 hours Lubricate the deck lift pivots Remove the engine shrouds and clean the cooling fins Service the air cleaner May need more often under severe conditions See the Engine Owner s Manual for additional information Lubricate the brake handle pivot Check the spark plugs Every 200 hours 28 Maintenance Maintenance Service 2 Maintenance Procedure Interval Change the hydraulic filter and fluid Check the wheel hub slotted nut torque specifications Every 500 hours Check the wheel lug nuts Check the park brake adjustment Grease the deck and pump idler pivots Yearly 2 Grease the front caster pivots Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine an
46. gnition key is turned to the ON position for a few seconds before cranking the engine the battery voltage will display in the area where the hours are normally displayed Note The LCD indicators appear when each control meets the safe to start mode e g the indicator turns on when the operator is in the seat 20 Operation Fuel Shut Off Valve Located behind and below the seat The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Align valve handle with the fuel line to open Rotate 90 to close Fuel Gauge Located on the right console in the message display see Figure 6 and Figure 9 The fuel level is shown on a bar display The indicator light appears when the fuel level is low approximately one gallon remaining in the tank Drive Wheel Release Valves A WARNING Hands may become entangled in the rotating drive components below the engine deck which could result in serious injury or death Stop engine remove key allow all the moving parts to stop before accessing the drive wheel release valves A WARNING The engine and hydraulic drive units can become very hot Touching a hot engine or hydraulic drive units can cause severe burns Allow the engine and hydraulic drive units to cool completely before accessing the drive wheel release valves Located on t
47. ground Do Not adjust the rollers to support the deck 7 Be sure the roller bolts ate installed with the spring disc washer between the head of the bolt and the mounting bracket Figure 18 8 Torque the 3 8 24 x 2 Gr 8 hex capscrew to 50 55 ft lb 68 75 N m Figure 18 Figure 18 1 Spring disc washer 3 3 8 nyloc torque to 30 35 cone towards bolt head ft lb 41 47 N m 2 Front right anti scalp 4 3 8 24 x 2 GR8 torque to bracket shown 50 55 ft lb 68 75 N m Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain CAUTION This unit does not have proper turn signals lights reflective markings 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 dtive a unit on a public street or roadway Operation A WARNING Loading a unit on a trailer or truck increases the possibility of backward tip over Backward could cause serious injury or de
48. he back of the unitized hydraulic drive units below the engine deck During normal operating conditions the drive wheel release valves are positioned horizontally If the machine has to be pushed by hand the valves must be in the released position see Figure 10 Figure 10 1 Handle in released position Handle in operating position To release the drive system see item 1 in Figure 10 rotate the handle 1 4 turn to the vertical position until it hits against the stop To reset the drive system see item 2 in Figure 10 rotate the handle 1 4 turn to the horizontal position until it hits against the stop Note The handle must be horizontal and against the stop for operation Do Not tow machine PTO Engagement Switch Located on tight console see Figure 6 Switch must be pulled out up to engage the blades Switch 1s pushed in to disengage the blades The LCD indicator will appear when the PTO switch is disengaged see Figure 9 Low Voltage Indicator Located on the right console in the message display see Figure 6 and Figure 9 A low voltage condition less than 12 3 volts exists when the LCD indicator appears on the message display while the engine is running If the ignition key is turned to the ON position for a few seconds before cranking the engine the battery voltage will display in the area where the hours are normally displayed Note The indicator normally appears when th
49. he transport position Unlatching position Deck does not latch at the transport position Seat Type Standard seat with high back extra wide foam padded seat cushion with internal suspension thick bolstering two tone cover armrests integral safety switch and seat vibration isolation system Optional seat accessories for units with standard seats Custom ride suspension system to enhance Standard Seat Adds approximately 3 inches 7 6 cm to seat height Deluxe suspension seat with high back low profile foam in place cushion dampened adjustable spring suspension armrests and integral safety switch Seat height remains the same Seat Isolation System for reduced vibration to enhance ride of standard seat standard seat with Custom Ride Seat Suspension or Deluxe Suspension Seat Adds approximately 1 inch 2 5 cm to seat height Seat Isolation System is standard on all units Mounting Hinged seat frame to tilt up seat Held in tilted position with prop rod Adjustable fore and aft on seat tracks Armtests Standard seat foam padded adjustable flip up armrests Suspension seat molded adjustable flip up armrests Seat Safety Switch Integrated seat switch Time delay seat switch eliminates rough ground cut outs Hydrostatic Ground Drive System e Two unitized hydrostatic transmissions 48 and 52 inch decks 12 Parker axial piston pump 240cc Parker geroler m
50. ield 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 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 the space provided 1 G008590 Figure 1 Model and serial number location Model No Serial No Contents eer erent rT 3 Mov dp 5 Safety Alert 5 Safe Operating Practices 5 Safety and Instructional Decals 10 denos 14 Model Num ade orae p a 14 DVSUGITIS 14 16 Torque Requirements 18 Product Overview arwi 18 19 19 t medio Ro m p Mas 22 Operating Inste retlonis s scu ocn evi 22 MAUS POMS 26
51. ity for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2009 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PS 0 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 or 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 yout authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the f
52. 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 the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate service the equipment Local regulations may restrict the age of the operator 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 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 part
53. n the T slot the drive system is in the neutral lock position Figure 14 Note The N LCD indicator appears when both levers are in the neutral lock position When the motion control levers are moved directly inward together the drive system is in the neutral operate position 24 the neutral operate position Operation 6008595 Figure 15 Front of Unit 3 Neutral 2 Forward 4 Reverse Driving in Reverse 1 Move the motion control levers inward to the neutral operate position To move rearward in a straight line move both levers rearward with equal pressure To turn left or right release pressure on the motion control lever toward the desired turn direction 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 1 2 inches 2 5 cm to 14 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position Disengage the PTO 3 Position the transport lock in the latching position Raise and lock the deck to the 5 1 2 inch 14 cm transport position Figure 16 The deck is raised by pushing the foot operated deck lift pedal forward The pedal is located at the front right corner of the floor pan Note When changing the cutting height positions always come to a complete stop and disengage the PTO
54. ncrease the height turn the adjuster clockwise to decrease turn counterclockwise 6008617 Figure 27 3 Adjuster Adjuster link Jam nut 11 12 13 14 37 The back tip of the blade should measure 3 1 4 inches 8 3 cm Fine tune rear adjusters as required Re measure until all four sides are the correct height Tighten all the jam nuts on the deck lift arm assemblies Lower discharge deflector If the four deck links do not have enough adjustment to achieve accurate cut height with the desired rake the single point adjustment can be utilized to gain more adjustment see Figure 28 Maintenance 1 2 3 e 2 Ji 9 Ales lt Q 4 2 2 Figure 28 Single point height adjustment bolt Front height of cut plate mounting bolt Rear height of cut plate mounting bolt 15 16 17 18 To adjust the single point system first loosen the front and rear height of cut plate mounting bolts If the deck is too low tighten the single point adjustment bolt by rotating it clockwise If the deck is too high loosen the single point adjustment bolt by rotating it counterclockwise Note Loosen or tighten the single point adjustment bolt enough to move the height of cut plate mounting bolts at least 1 3 the length of the available travel in their slots This will regain some up and down adjustment on each of the four deck links Re tighten fro
55. ne oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All 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 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 The Exmark Lazer Z or Lazer Z AS equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance wh
56. ne before performing any work on the hydraulic system Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease New safety signs may be obtained from dirt and debris from safety signs and instructional your authorized Exmark equipment dealer or labels distributor or from Exmark Mfg Co Inc Replace all worn damaged or missing safety e Safety signs may be affixed by peeling off the signs backing to expose the adhesive surface Apply When replacement components are installed be only to a clean dry surface Smooth to remove sure that current safety signs are affixed to the any air bubbles replaced components Familiarize yourself with the following safety signs fan attachment or accessory has been installed and instruction labels They are critical to the safe make sure current safety signs are visible operation of your Exmark commercial mower ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm GROUND CLEARANCE WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 CUTTING HEIGHT INCHES mm 1 FOR MAXIMUM FLOTATION ROLLERS MAY POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS TO SUPPORT THE MOWER D
57. nsion Self tensioning No adjustment necessary Deck Belt Tension Self tensioning No adjustment necessary Adjusting the Parking Brake Service Interval After the first 100 hours Every 500 hours thereafter Check to make sure brake is adjusted properly 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 5 Remove the rear tires from the machine 6 Remove any debris from the brake area 7 Rotate the drive wheel release handle to the released position Refer to the Drive Wheel Release Valves section in Operation 8 Disengage the park brake 9 Using hands and fingers only push the caliper lever arm to engage the brake pads on the rotor until the lever stops While holding the lever at the stopped position use the other hand or fingers to pull the cable threaded end tight through the swivel Spin the standard nut against the swivel see Figure 30 Io G009965 Figure 30 Left Hand Brake Shown Cable anchor 6 Lock nut Threaded rod 7 Pull cable threaded rod this direction Hold threaded rod here Swivel pivot head Push lever this direction Caliper lever arm Standard nut shown against swivel 8 9
58. nt and rear height of cut plate mounting bolts Important Torque the front and rear height of cut plate mounting bolts to 27 33 ft lb 37 45 N m Repeat steps 9 through 13 Deck Removal Before servicing or removing the deck the spring loaded deck arms must be locked out A WARNING Deck lift arm assemblies have stored energy Removing the deck with out releasing the stored energy can cause serious injury or death Do Not attempt to disassemble the deck from the front frame without locking out the stored energy PONS Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove the height adjustment pin and lower the deck to the ground Place the height adjustment pin in the 3 inch 7 6 cm cutting height location This locks the deck lift arms in the lowest position when the deck is removed Remove the floorpan and belt shields Insert 1 2 inch socket driver into the square hole on the idler bracket and carefully rotate the deck idler counterclockwise to remove the belt Remove and retain the hardware on both sides of the deck as shown in Figure 29 Figure 29 Panhard rod right side only Deck strut Rear deck lift attachment shoulder bolt and nut Front deck lift attachment shoulder bolt and nut 38 Maintenance 7 Raise the front of the machine and slide the deck left or right to remove 8 Lower the front of the machine Pump Drive Belt Te
59. o 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 around 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 13 Torque the nut to 75 80 in Ib 8 9 N m loosen then re torque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut 14 Reinstall the seal guards over the wheel hub and insert wheel into caster fork Reinstall caster bolt and tighten nut fully Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 200 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate brake handle pivot with a spray type lubricant or light oil Lubricate Deck Lift Pivot Service Interval Every 100 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate deck lift pivot with a spray type lubricant or light oil Check Spa
60. ollers provide maximum turf protection Deck design allows for bagging mulching or side discharge 48 inch Deck 3 anti scalp rollers 52 inch Deck 3 anti scalp rollers 60 inch Deck 4 anti scalp rollers 72 inch Deck 4 anti scalp rollers Deck Depth 48 inch Deck 5 5 inches 14 cm 52 inch Deck 5 5 inches 14 cm 60 inch Deck 5 5 inches 14 cm 72 inch Deck 5 5 inches 14 Cutting Height Adjustment Foot activated lever is used to adjust the cutting height from 1 inch 2 5 cm to 5 1 2 inches 14 cm in 1 4 inch 6 4 mm increments Mulching Kit Optional Dimensions Overall Width 48inchDeck 52 inch Deck Without Deck 45 7 inches 45 7 inches 116 1 cm 116 1 cm Deflector Up 51 8 inches 56 3 inches 131 6 cm 143 0 cm Deflector Down 59 6 inches 64 8 inches 151 4 cm 164 6 cm 60 inch Deck 172 inch Deck Without Deck 53 0 inches 59 1 inches 134 6 cm 150 1 cm Deflector Up 62 5 inches 73 5 inches 158 8 cm 186 7 cm Deflector Down 72 8 inches 84 9 inches 184 9 cm 215 6 cm Overall Length 48 inch Deck 52 inch Deck Roll Bar Up 79 2 inches 79 2 inches 201 2 cm 201 2 cm Roll Bar Down 80 9 inches 80 9 inches 205 5 cm 205 5 cm 0 inch Deck 172 inch Deck Roll Bar Up 83 1 inches 86 1 inches 211 1 cm 218 7 cm Roll Bar Down 84 8 inches 87 8 inches 215 4 cm 223 0 cm Overall Height Roll Bar Up Roll Bar Down
61. or a few seconds the battery voltage will be displayed in the area where the hours are normally displayed Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Voltage Reading 12 6 100 greater 12 4 12 6 75 100 16 volts 7 30 Minutes amps Maximum Charging Charger Settings 16 volts 7 amps 12 2 12 4 50 75 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 or amps More 29 Maintenance 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 section 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 6006780 Figure 19 1 Install bushing in blade prior to installing b
62. otor 60 and 72 inch decks 16cc Parker axial piston pump 9 280 Ross motor Hydraulic Oil Type Exmark Premium Hydro oil Hydraulic Oil Capacity 52 oz 1 5 1 per side Hydraulic Filter P N 116 0164 Speeds 12cc 0 10 mph 16 1 km hr forward 0 5 5 mph 8 9 km hr reverse 16 0 11 5 mph 18 5 km hr forward 0 6 mph 9 7 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 Tread Multi Trac Smooth C S Size 60 amp 72 24 x 12 00 12 13 x 6 50 6 Decks Size 48 amp 52 24 x 9 50 12 13 x 5 00 6 Decks 15 Specifications Cutting Deck Cutting Width 48 inch Deck 121 9 cm 52 inch Deck 132 1 cm 60 inch Deck 152 4 cm 72 inch Deck 182 9 cm Discharge Side Blade Size 3 48 inch Deck 16 25 inches 41 3 cm 52 inch Deck 18 00 inches 45 7 cm 60inch Deck 20 50 inches 52 1 cm 72 inch Deck 24 50 inches 62 2 cm Blade Spindles Solid steel spindles with 1 18 inch 30 mm I D bearings Deck Drive Electric clutch Shaft diameter 1 125 inches 2 86 cm 48 and 52 inch Decks B Section belt with self tensioning idler 60 and 72 inch Decks 5V Section belt with self tensioning idler Deck floating deck is attached to out front support frame Anti scalp r
63. owning 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 or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excessive grease ot oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and Do Not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs
64. p in reverse Figure 31 Move the motion control levers to the reverse position and while applying slight pressure to the lever allow the reverse indicator springs to bring the levers back to neutral The wheels must stop turning or slightly creep in reverse G008621 Figure 31 1 Double nuts Shut off unit Remove jumper wire from wire harness and plug connector into seat switch Remove the jack stands Raise the deck and re install the height of cut pin Check that the machine does not creep in neutral with the park brakes disengaged Motion Control Damper Adjustment The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance See Figure 32 for mounting options 40 Maintenance We 6008620 Figure 32 RH Motion Control Shown 1 Torque nyloc nut to 200 in Ib 16 7 ft lb Bolt must protrude past end of nyloc nut after torque A T 40 Torx bit will be necessary to hold the stud from turning Most resistance firmest feel Damper Medium resistance medium feel Least resistance softest feel ak WN Motion Control Neutral Lock Pivot Adjustment The flanged nut can be adjusted to obtain a more desired motion control lever resistance Figure 33 G008621 Figure 33 1 Flanged nut 2 Jam nut 1 Loosen the jam nut 2 Tighten or loosen the flanged nut to the desired feel For more resistance tighten the flanged nut For less re
65. quential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 434 50 Notes 51 Notes 52 Service Record Date Description of Work Done Service Done By 53 PREMIUM HYDRO OIL BENEFITS Designed amp manufactured with superior anti wear protection Superior thermal stability Consistent hydro performance Superior shear resistance under heavy loads Field tested amp proven performance Twice the shear stability of SPECIALLY FORMULATED amp competing oils MANUFACTURED FOR SUPERIOR P CR CORMANCE IN ALL EXMARK Enhanced control performance DRAULIC DRIVE SYSTEMS Specially formulated for any 1 US Quart 946 ML 32 FL oz Exmark hydraulic system NOW AVAILABLE FOR PURCHASE Part No 109 9828 54 This is a5 slope No Slope Example Compare slope with a tree building fence post pole etc Align this edge with a vertical surface it 1 1 i y 1 1 ii D RE
66. r 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 27 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A WARNING A WARNING While maintenance or adjustments are being The engine can become very hot Touching made someone could start the engine a hot engine can cause severe burns Accidental starting of the engine could seriously injure you other bystanders Allow the engine to cool completely before service or making repairs around the engine Remove the key from the ignition switch area engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil ck he he wheel hub slotted nut torque specifications After the first 100 hours heck the wheel lug nuts heck the park brake adjustment the engine oil l
67. ransporting the mower to and from the area to be mowed Be sure all drives are in neutral and parking brake is engaged before starting engine Use seat belts with the roll bar in the raised and locked position Safety Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Slope Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes A DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed 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 mowed Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figur
68. rk Plugs Service Interval Every 200 hours Remove spark plugs check condition and reset gaps replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filter is installed between the fuel tank and the engine Replace when necessaty Kohler P N 24 050 13 Kawasaki P N 49019 7001 Replacement Filters Kohler Kawasaki Note It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage Change Hydraulic System Filter and Fluid Service Interval Every 500 hours Note Only use Exmark Hydro Filter Part No 116 0164 for summer or winter 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely A 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 may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 3 Remove the pump drive belt Place a catch pan under the hydro 5
69. s 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 machine e Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety A DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or drain the machine indoors inside an enclosed trailer Do Not fill the fuel tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 inch 6 13 mm below the bottom of the filler neck This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the r
70. s from starting engine 8 Close the fuel shut off valve located behind and below the seat when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine A CAUTION Figure 14 Neutral lock position 4 Forward handles out Neutral operate position 5 handles in Front of Unit Neutral operate 6 Reverse 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 1 or injury 2 Use caution when making turns Slow the machine down before making 3 sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop Driving Forward Release the parking brake Move the motion control levers inward to the center to the neutral position To move forward in a straight line move both levers forward with equal pressure To turn left or right pull the motion control lever back toward neutral in the desired turn direction The machine will move faster the farther the motion control levers are moved from the neutral position 4 stop position both motion control levers in When the motion control levers are positioned fully outward apart i
71. s should be made for neutral positioning only A 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 1 Prior to starting the engine push the deck lift pedal and remove the height of cut pin Lower deck to the ground Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely Remove the electrical connection from the seat safety switch located under the bottom cushion of the seat The switch is a part of the seat assembly Temporarily install a jumper wire across the terminals in the connector of the main witing harness 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 Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature Note The motion control lever needs to be in neutral while making any necessary adjustments Bring the motion control levers into the neutral position Adjust pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly cree
72. sed antiseize or grease and torque to 55 60 ft lbs 75 81 N m 109 3148 109 3148 2 Slow MOTION CONTROL 109 7232 109 7232 Fast 3 Neutral 4 Reverse 25 10 25 13 MAIN PTO CHARGE fe 109 7330 109 7330 107 2112 RELEASE 109 7929 Safety Engage and disengage at 1 2 throttle 109 8483 1 Throttle fast 3 Choke on 2 Throttle slow 4 Choke off A CAUTION FUEL MAY LEAK Fuel tank vent located inside roll bar tube Removing or modifying roll bar could result in fuel leakage and violate emissions regulations e Do Not remove roll bar Do Not weld drill or modify roll bar 116 0090 116 0090 109 8070 48 109 4994 52 109 8073 60 109 9023 72 109 9361 109 9361 Deck Drive Belt Routing 116 0157 1 See Operator s manual 0165 116 Torque Wheel Lug Nuts to 90 95 ft Ibs 122 129 N m Check after first Torque Wheel Hub Slotted Nut to 200 ft Ibs 271 N m min 100 hrs then every 2 0 See Operator s Manual for more details 500 hrs thereafter 116 0165 WARNING SPRING LOADED DECK LIFT ARMS Can cause serious injury Before servicing or removing deck Lower deck to lowest position Insert height of cut pin at 3 0 to lock out deck lift arms See operator s manual for disassembly procedure 109 9477 AWARNING 116 0205 ROTATING BE
73. sistance loosen the flanged nut 3 Tighten jam nut Motion Control Handle Adjustment Adjusting the height The motion control levers can be adjusted higher or lower for maximum operator comfort 1 Remove the two bolts holding the control lever to the control arm shaft Figure 34 G008631 Figure 34 1 Bolts 2 Control lever 3 Control arm shaft 4 Nuts 5 Slotted holes 2 Move the control lever to the next set of holes Secure the lever with the two bolts 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion conttol levers can be tilted fore or aft for maximum operator comfort 1 Loosen the upper bolt holding the control lever to the control arm shaft 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 34 Tighten both bolts to secure the control in the new position 3 Repeat the adjustment for the opposite control lever Motion Control Full Forward Tracking Adjustment If the machine travels or pulls to one side when the motion control levers are in the full forward position adjust the cover plates 1 Loosen the screws on a cover plate see Figure 35 41 Maintenance 2 Slide the cover plate backward or forward to adjust the travel of the lever and tighten the screws 3 Drive the machine and check the full forward tracking 4 Repeat steps 1 through 3 until desired tracking is obtained 2 9010015
74. t connected Faulty module 45 Disengage the PTO Set the parking brake Ensure the drive levers are in the neutral lock position Charge the battery 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 Replace module 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 and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the seat switch indicator Replace seat 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 Clean adjust or replace spark plug Check the spark plug wire connection Replace module Troubleshooting Engine loses power Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate 1 Engine load is excessive 2 cleaner is dirty 3 Oil level in the crankcase is low 4 Cooling
75. ter every other oil change Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Every 50 hours 1 Stop engine and wait for all moving parts to stop Engage parking brake Wait until the unit cools before checking the hydraulic oil Slide the seat all the way back then lift the seat to access the caps on the LH and RH hydro drives Clean the area around hydraulic reservoir cap and remove cap Wipe the dipstick clean and re insert the cap back into the hydro Lightly tighten the cap Remove the cap again and check the level of the oil on the dipstick See Figure 22 for oil levels 6008606 Figure 22 1 Full 2 Add Note The oil level on the dipstick will be incorrect if the oil is checked when the unit is hot If the dipstick oil level is at the mark add Exmark Premium Hydro oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Check Tire Pressures Servic
76. ttery reseller Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running 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 ate corroded loose faulty Fuse is blown Relay or switch is defective Faulty module Fuel tank is empty Fuel shutoff valve is closed Oil level in the crankcase is low The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Air cleaner is dirty Seat switch is not functioning properly Electrical connections are corroded loose faulty Relay or switch is defective Faulty spark plug Spark plug wire is no
77. use 10 amp PTO fuse 15 amp accessory fuse Safety Interlock System LCD indicators appear for the PTO park brake drive levers and operator presence in the message display on the RH control panel 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 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 Steering is controlled by varying the position of the levers relative to each other Moving motion control levers outward in slots locks the drive system in neutral PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades Parking Brake Lever Engages parking brake Parking Brake Release Button Releases parking brake Specifications Deck Height Adjustment Lever Sets cutting height to desired position Deck Lift Pedal Foot pedal that lifts deck Transport Lock Latching position Automatically latches at t
78. ushing spindle B Install bushing blade assembly into spindle Make sure the splines on the bushing are engaged in the spindle before tightening the bolt 2 74 6008629 Figure 20 1 Use wrench here for blade installation This nut has been torqued to 140 145 ft Ib 190 197 N m 2 Torque to 55 60 ft Ib 75 81 N m Apply lubricant to threads as needed to prevent seizing Copper based anti seize preferable Grease acceptable substitute 30 C Apply lubricant to threads of blade bolt to prevent seizing Copper based anti seize preferable Grease acceptable substitute Install blade bolt finger tight Place wrench on the top spindle nut then torque the blade bolts to 55 60 ft Ib 75 81 N m A WARNING Incorrect installation of the blade or components used to retain the blade can be dangerous Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death 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 M 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

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