Exmark Lawn Mower 0 User Guide

LAZER Z® X-SERIES  
For Serial Nos.  
312,000,000 & Higher  
Lazer Z (LZX) Units  
Part No. 4501-196 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
Figure 1  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
If additional information is needed, or should  
you require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Motion Control Damper Adjustment..............45  
Contents  
Torque Requirements .....................................20  
Periodic Maintenance ........................................31  
4
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Safety  
Safe Operating Practices  
Safety  
Safety Alert Symbol  
This lawn mower meets or exceeds the B71.4  
specifications of the American National Standards  
Institute in effect at the time of production.  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
1. has read and understands the Operator's  
Manual and recognizes the risks involved;  
2. is sufficiently mature to use caution; and  
Figure 2  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
Safety Alert Symbol  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
Preparation  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
CAUTION  
This machine produces sound levels in excess  
of 85 dBA at the operator’s ear and can cause  
hearing loss through extended periods of  
exposure.  
Wear hearing protection when operating this  
machine.  
5
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Safety  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
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.  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• 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.  
• Fill the fuel tank outdoors on level ground,  
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 or inside an enclosed  
trailer.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Do Not fill the fuel tank completely full.  
Fill the fuel tank to the bottom of the filler  
neck. The empty space in the tank allows  
gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine  
or emission system.  
• 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.  
• 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 reach of children.  
WARNING  
• 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.  
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.  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
6
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Safety  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
CAUTION  
Fuel tank vent is located inside the roll  
bar tube. Removing or modifying the roll  
bar could result in fuel leakage and violate  
emissions regulations.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Do Not remove roll bar.  
• Park machine on level ground. Stop engine, wait  
for all moving parts to stop, remove key and  
engage parking brake:  
• Do Not weld, drill, or modify roll bar in  
any way.  
• Check that the operator's presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
– Before checking, cleaning or working on the  
mower.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
Operation  
WARNING  
– Before clearing blockages.  
– Whenever you leave the mower.  
Operating engine parts, especially the muffler,  
become extremely hot. Severe burns can occur  
on contact and debris, such as leaves, grass,  
brush, etc. can catch fire.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
• Allow engine parts, especially the muffler, to  
cool before touching.  
– Before dumping the grass catcher.  
• Remove accumulated debris from muffler and  
engine area.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Do Not operate the machine without  
guards, shields, and safety devices in place  
and working properly.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can kill  
you.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
Do Not run engine indoors or in a small confined  
area where dangerous carbon monoxide fumes  
can collect.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
• Be alert, slow down and use caution when  
making turns. Look behind and to the side before  
changing directions.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine. Use seat belts  
with the roll bar in the raised and locked position.  
• Stop the blades, slow down, and use caution  
when crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
7
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Safety  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
Slope Operation  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
Figure 3  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
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.  
3. Water  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Do Not mow slopes greater than 15 degrees.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Reduce speed and use extreme caution on  
slopes.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Avoid sudden turns or rapid speed changes.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
• Keep 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.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
Using the Rollover Protection System  
(ROPS)  
A Rollover Protection System (roll bar) is installed  
on the unit.  
8
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Safety  
• Disconnect battery or remove spark plug wire  
WARNING  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
There is no rollover protection when the roll bar  
is down. Wheels dropping over edges, ditches,  
steep banks, or water can cause rollovers, which  
may result in serious injury, death or drowning.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Lower the roll bar only when absolutely  
necessary.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Do Not wear seat belt when the roll bar is  
down.  
• 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.  
• Drive slowly and carefully.  
• Raise the roll bar as soon as clearance  
permits.  
DANGER  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and Do Not contact  
them.  
Charging or jump starting the battery may  
produce explosive gases. Battery gases can  
explode causing serious injury.  
• Keep sparks, flames, or cigarettes away  
from battery.  
• In the event of a rollover, take the unit to an  
Authorized Service Dealer to have the ROPS  
inspected.  
• Ventilate when charging or using battery  
in an enclosed space.  
Maintenance and Storage  
• Make sure venting path of battery is  
always open once battery is filled with  
acid.  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
• Always shield eyes and face from battery.  
• Keep engine and engine area free from  
accumulation of grass, leaves, excessive grease  
or oil, and other debris which can accumulate  
in these areas. These materials can become  
combustible and may result in a fire.  
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.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Do Not swallow electrolyte.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• In the event of an accident, flush with  
water and call a doctor immediately.  
• Use jack stands to support components when  
required.  
• Carefully release pressure from components with  
stored energy.  
9
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Safety  
CAUTION  
WARNING  
If the ignition is in the “ON” position there  
is potential for sparks and engagement of  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
components. Sparks could cause an explosion accidentally injected into the skin must be  
or moving parts could accidentally engage  
causing personal injury.  
surgically removed within a few hours by a doctor  
familiar with this form of injury or gangrene may  
result.  
Be sure ignition switch is in the “OFF”  
position before charging the battery.  
• If equipped, make sure all hydraulic fluid  
hoses and lines are in good condition and all  
hydraulic connections and fittings are tight  
before applying pressure to hydraulic system.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• Use cardboard or paper, not your hands, to  
find hydraulic leaks.  
WARNING  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control levers  
in neutral and shutting off the engine before  
performing any work on the hydraulic system.  
Removing standard original equipment parts  
and accessories may alter the warranty, traction,  
and safety of the machine. Failure to use original  
Exmark parts could cause serious injury or  
death. Making unauthorized changes to the  
engine, fuel or venting system, may violate EPA  
and CARB regulations.  
For Kohler EFI (Electronic Fuel Injection) Units:  
WARNING  
Fuel system components are under high  
pressure. The use of improper components can  
result in system failure, gasoline leakage and  
possible explosion.  
Replace all parts including, but not limited to,  
tires, belts, blades, and fuel system components  
with original Exmark parts.  
Use only approved fuel lines and fuel filters for  
high pressure systems.  
10  
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
1-633922  
98-5954  
1-403005  
103-2076  
11  
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Safety  
109-7232  
3. Neutral  
1. Fast  
2. Slow  
4. Reverse  
109-7330  
107-2102  
109-3148  
109-8483  
All Units Except EFI  
1. Throttle–fast  
2. Throttle–slow  
3. Choke–on  
4. Choke–off  
12  
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Safety  
109-9361  
Deck Drive Belt Routing  
116-0205  
116-0211  
116-0090  
116-0157  
1. See Operator's Manual  
116-0752  
1. Latch  
2. Unlatch  
13  
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Safety  
117–2718  
116-1654  
116-2643  
116-5944  
Message Display  
1. Fuel  
6. Hour meter  
2. Empty  
7. PTO  
3. Half  
8. Parking brake  
9. Neutral  
10. Operator presence  
switch  
116-2844  
4. Full  
5. Battery  
EFI Units Only  
1. Throttle–fast  
2. Throttle–slow  
PTO Switch Symbols  
1. PTO–disengage  
2. PTO–engage  
116-3303  
14  
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Safety  
109-7069  
15  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 312,000,000 and Higher  
LZX680KC486; LZX740KC526; LZX740KC606; LZX740KC606CA; LZX749EKC606; LZX801KA606;  
LZX801KA606SS; LZX940KC606; LZX940KC726; LZX980KC606; LZX980KC726  
Systems  
– Kohler 940 & 980 engines: 340 CCA  
– All other engines: 260 CCA  
• Battery Voltage: 12 Volt  
• Low Voltage Light — RH control panel  
• Polarity: Negative Ground  
• Fuses:  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Engine Oil Type: Exmark 4–Cycle Premium  
Engine Oil  
• RPM: Full Speed: 3750 ±50 RPM (PTO not  
engaged) Idle: 1500 +100/-250 RPM  
All units:  
– 25 amp main fuse  
– 25 amp charging system fuse  
– 10 amp PTO fuse  
Fuel System  
• Capacity: 12.0 gal. (45.4 L)  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher; containing no more than 10%  
methanol or ethanol.  
– 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.  
• Fuel Filter:  
– Kohler:  
Kohler P/N 24 050 13  
– Kawasaki:  
• 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.)  
Kawasaki P/N 49019-7005  
– Kohler EFI:  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
Kohler P/N 25 050 42  
• Fuel Shut-Off Valve:  
All Units: 1/4 turn increments (“ON”, “OFF”).  
• Engine will stop if either the left, the right, or  
both levers are moved from neutral lock position  
while brake is engaged.  
• Fuel level eight segment display — right hand  
control panel.  
• Low fuel indicator light.  
Operator Controls  
• Steering and Motion Control:  
Electrical System  
Note: Motion control levers are adjustable to  
• Charging System: Flywheel Alternator  
two heights.  
• Charging Capacity:  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
Kohler and Kawasaki: 15 amps  
Kohler EFI: 20 amps  
• Battery Type: BCI Group U1  
• Recommended Minimum Battery CCA:  
– Steering is controlled by varying the position  
of the levers relative to each other.  
16  
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Specifications  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
• Armrests:  
– Standard seat: foam padded adjustable flip-up  
armrests.  
• PTO Engagement Switch: Engages electric clutch  
(to drive belt) which engages mower blades.  
– Suspension seat: molded adjustable flip-up  
armrests.  
• Parking Brake Lever: Engages/Disengages  
parking brake.  
• Seat Safety Switch:  
• Deck Height Adjustment Lever: Sets cutting  
height to desired position.  
Integrated seat switch. Time delay seat switch  
eliminates rough ground cut-outs.  
• Deck Lift Pedal: Foot pedal that lifts deck.  
• Transport Lock:  
Hydrostatic Ground Drive System  
• Two unitized hydrostatic transmissions:  
– 48 and 52 inch decks:  
Latching position: Automatically latches at  
the transport position.  
– Unlatching position: Deck does not latch at  
the transport position.  
◊ 12cc Parker axial piston pump  
◊ 240cc Parker geroler motor  
– 60 and 72 inch decks:  
Seat  
◊ 16cc Parker axial piston pump  
◊ 280cc Ross geroler motor  
• Hydraulic Oil Type: Exmark Premium Hydro Oil.  
• Hydraulic Oil Capacity: 52 oz (1.5 L) per side  
• Hydraulic Filter: P/N 116-0164  
• Speeds:  
• Type:  
– For all units except LZX801KA606SS,  
LZX940KC606, LZX940KC726,  
LZX980KC606, LZX980KC726: 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.  
– 12cc  
Optional seat accessories for units with  
standard seats:  
◊ 0-10 mph (16.1 km/hr) forward.  
◊ 0-5.5 mph (8.9 km/hr) reverse.  
– 16cc  
◊ Custom ride suspension system to enhance  
Standard Seat. Adds approximately 3  
inches (7.6 cm) to seat height.  
◊ 0-11.5 mph (18.5 km/hr) forward.  
◊ 0-6 mph (9.7 km/hr) reverse.  
◊ Deluxe suspension (adjustable spring  
suspension) seat with high back, armrests,  
and integral safety switch. Seat height  
remains the same.  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
– For LZX801KA606SS, LZX940KC606,  
LZX940KC726, LZX980KC606,  
LZX980KC726:  
Deluxe suspension (adjustable spring  
suspension) seat with high back, armrests, and  
integral safety switch. Seat height remains the  
same.  
• Mounting: Hinged seat frame to tilt up seat. Held  
in tilted position with prop rod. Adjustable fore  
and aft on seat tracks.  
17  
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Specifications  
– 72 inch Deck: 6 anti-scalp rollers  
• Deck Depth:  
Tires & Wheels  
Drive  
Front Caster  
– 48 inch Deck: 5.5 inches (14 cm)  
– 52 inch Deck: 5.5 inches (14 cm)  
– 60 inch Deck: 5.5 inches (14 cm)  
– 72 inch Deck: 5.5 inches (14 cm)  
• Cutting Height Adjustment:  
Pneumatic  
(Air-Filled)  
Semi-Pneumatic  
Quantity  
Tread  
2
2
Smooth  
13 x 6.50-6  
“Multi-Trac C/S”  
24 x 12.00-12  
Size (60 & 72  
Decks)  
Size (48 & 52  
Decks)  
24 x 9.50-12  
13 x 5.00-6  
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.  
Ply Rating  
Pressure  
4
• Mulching Kit: Optional.  
13 psi (90 kPa)  
Cutting Deck  
• Cutting Width:  
Dimensions  
Overall 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  
48 inch Deck  
52 inch Deck  
Without Deck  
Deflector Up  
45.7 inches  
(116.1 cm)  
48.0 inches  
(122.0 cm)  
51.8 inches  
(131.6 cm)  
56.3 inches  
(143.0 cm)  
• Blade Size: (3 ea.)  
Deflector Down 59.6 inches  
(151.4 cm)  
64.8 inches  
(164.6 cm)  
– 48 inch Deck: 16.25 inches (41.3 cm)  
– 52 inch Deck: 18.00 inches (45.7 cm)  
– 60 inch Deck: 20.50 inches (52.1 cm)  
– 72 inch Deck: 24.50 inches (62.2 cm)  
60 inch Deck  
72 inch Deck  
Without Deck  
Deflector Up  
53.0 inches  
(134.6 cm)  
59.1 inches  
(150.1 cm)  
• Blade Spindles: Solid steel spindles with 1.18 inch  
(30 mm) I.D. bearings.  
62.5 inches  
(158.8 cm)  
73.5 inches  
(186.7 cm)  
• Deck Drive:  
Deflector Down 72.8 inches  
(184.9 cm)  
84.9 inches  
(215.6 cm)  
Electric clutch. Shaft diameter 1.125 inches (2.86  
cm)  
– 48 and 52 inch Decks: “B” Section belt with  
self-tensioning idler.  
Overall Length:  
48 inch Deck  
52 inch Deck  
– 60 and 72 inch Decks: 5V Section belt with  
self-tensioning idler.  
Roll Bar - Up  
79.2 inches  
(201.2 cm)  
79.2 inches  
(201.2 cm)  
• Deck:  
Roll Bar - Down 80.9 inches  
(205.5 cm)  
80.9 inches  
(205.5 cm)  
Full floating deck is attached to out-front support  
frame. Anti-scalp rollers provide maximum turf  
protection. Deck design allows for bagging,  
mulching or side discharge.  
60 inch Deck  
72 inch Deck  
Roll Bar - Up  
83.1 inches  
(211.1 cm)  
86.1 inches  
(218.7 cm)  
– 48 inch Deck: 3 anti-scalp rollers  
– 52 inch Deck: 3 anti-scalp rollers  
– 60 inch Deck: 4 anti-scalp rollers  
Roll Bar - Down 84.8 inches  
(215.4 cm)  
87.8 inches  
(223.0 cm)  
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Specifications  
Overall Height:  
Accessory Weight Table Worksheet:  
Roll Bar - Up  
Roll Bar - Down  
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.  
70.5 inches (179.1 cm)  
46.8 inches (118.9 cm)  
Tread Width: (Center to Center of  
Tires, Widthwise)  
Note: The 72 inch deck does not require a weight kit.  
48 inch Deck  
52 inch Deck  
Drive Wheels  
Caster Wheels  
36.2 inches  
(91.9 cm)  
38.5 inches  
(97.8 cm)  
48 inch 52 inch 60 inch Accessory  
Deck  
Deck  
Deck Score  
32.8 inches  
(83.3 cm)  
32.8 inches  
(83.3 cm)  
2
3
2
3
Light Kit  
11  
12  
Michigan  
Seat/CRSS  
60 inch Deck  
72 inch Deck  
Bagger  
0
6
0
8
3
5
Drive Wheels  
Caster Wheels  
41.6 inches (105.7 43.6 inches (110.7  
cm) cm)  
Pneumatic  
Caster Tires  
39.5 inches (100.3 47.1 inches (119.6  
cm) cm)  
Mulch Kit  
Striper Kit  
OCD02  
-3  
-2  
-5  
1
-4  
0
-5  
0
-7  
2
-4  
1
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
Hitch Kit  
2
3
2
Sunshade  
Kit  
48 inch  
Deck  
52 inch  
Deck  
60 inch  
Deck  
72 inch  
Deck  
Total Accessory Score  
48.0 inches 48.0 inches 51.6 inches 53.6 inches  
(121.9 cm) (121.9 cm) (131.1 cm) (136.1 cm)  
Total Accessory Score  
0 – 9  
Required Weight Kit(s)  
None required  
Curb Weight:  
10 – 19  
*116-1173 Under toe board  
mount weight kit  
48 inch 52 inch 60 inch 72 inch  
Deck  
Deck  
Deck  
Deck  
20 and Higher  
*Two 116-1173 Under toe  
board mount weight kits or  
one 116-1173 Under toe  
board mount weight kit  
and one 116-1238 Front  
toe board mount weight kit  
Kohler  
1125 lb  
680 Units (510 kg)  
Kohler  
740 Units  
1116 lb  
(506 kg) (542 kg)  
1195 lb  
Kohler  
749 Units  
1195 lb  
(542 kg)  
*48 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).  
Kawasaki  
801 Units  
1212 lb  
(550 kg)  
Kohler  
940 Units  
1244 lb  
1276 lb  
(564 kg) (579 kg)  
1244 lb 1276 lb  
(564 kg) (579 kg)  
Kohler  
980 Units  
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Product Overview  
*60 inch units which already have an under toe board  
mount weight as standard requires 116-1238 front toe  
board top mount kit instead of 116-1173.  
Product Overview  
Torque Requirements  
Bolt Location  
Torque  
Blade Drive Sheave  
Mounting Nut  
90-110 ft-lb (122-149 N-m)  
Cutter Housing Spindle  
Nut  
160-185 ft-lb  
(217-251 N-m)  
Blade Mounting Bolt  
(lubricate with anti-seize)  
55-60 ft-lb (75-81 N-m)  
30-35 ft-lb (41-47 N-m)  
50-55 ft-lb (68-75 N-m)  
Anti-Scalp Roller Nyloc  
Nut See Figure 18  
Anti-Scalp Roller Hex  
Capscrew See Figure 18  
Figure 4  
Engine Mounting Bolts  
(Kohler 680 & 740)  
(Kohler 749)  
1. Rollover Protection  
System (ROPS)  
5. Fuel cap  
27-33 ft-lb (37-45 N-m)  
27-33 ft-lb (37-45 N-m)  
17-21 ft-lb (23-28 N-m)  
17-21 ft-lb (23-28 N-m)  
2. Engine Controls (right  
console)  
6. Height of cut adjustment  
7. Parking brake  
3. Seat belt  
(Kohler 940)  
4. Motion control levers  
(Kohler 980)  
27-33 ft-lb (37-45 N-m)  
90-95 ft-lb (122-129 N-m)  
(Kawasaki 801)  
Wheel Lug Nuts  
Wheel Motor Mounting  
Bolts  
72-77 ft-lb (98-104 N-m)  
Wheel Hub Slotted Nut  
211-260 ft-lb  
(286-352 N-m)  
Rollover Protection  
System (Roll Bar) 1/2  
inch Mounting Bolts  
75-80 ft-lb (102-108 N-m)  
Clutch Retaining Bolt  
(secured with threadlocker)  
55-60 ft-lb (75-81 N-m)  
67-89 ft-lb (91-121 N-m)  
Hydro Park Brake  
Cable Anchor 1/2 inch  
Mounting Bolt (secured  
with threadlocker)  
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Operation  
Choke Control (All Units Except  
Kohler EFI)  
Operation  
Note: Determine the left and right sides of the  
Located on right console (black lever) (see Figure 6).  
machine from the normal operating position.  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to the  
rear, to the detent, will put the choke in the “OFF”  
position. Do Not run a warm engine with choke in  
the “ON” position.  
Controls  
Motion Control Levers  
The motion control levers located on each side of  
the console control the forward and reverse motion  
of the machine.  
Moving the levers forward or backward turns  
the wheel on the same side forward or reverse  
respectively. Wheel speed is proportional to the  
amount the lever is moved.  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 5).  
When the motion control levers are in the neutral  
position, the LCD indicator appears in the message  
display on the RH console (see Figure 8).  
Figure 6  
Right Console  
1. Fuses  
4. PTO engagement switch  
5. Throttle  
2. Message display  
3. Ignition switch  
6. Choke  
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.  
Figure 5  
1. Neutral lock position  
(handles out)  
4. Forward  
Note: The LCD indicator appears in the message  
display on the RH console when the park brake is  
engaged (see Figure 8).  
2. Neutral operate position 5. Neutral (operate)  
(handles in)  
3. Front of Unit  
6. Reverse  
Pull the lever up and rearward to engage the brake.  
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Operation  
Push the lever forward and down to disengage the  
brake.  
The unit must be tied down and brake engaged when  
transporting.  
Ignition Switch  
Located on right 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.  
Figure 8  
1. LCD Indicators  
2. Low fuel indicator light  
3. Fuel level bar display  
4. Low voltage indicator light  
5. Hour/Voltage display  
The hour meter is recording when the decimal point  
is flashing in Hour/Voltage display.  
Hours are displayed when the key is off or when the  
machine is running.  
Note: If the ignition key is turned to the “ON”  
position for a few seconds before cranking the engine,  
the battery voltage will display in the area where the  
hours are normally displayed.  
Figure 7  
1. Off  
2. On  
3. Start  
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.)  
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.)  
Fuel Shut-Off Valve  
Located behind and below the seat.  
Hour Meter  
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.  
Located on the right console in the message display  
(see Figure 6 and Figure 8).  
The hour meter records the number of hours that  
the engine has run.  
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 8).  
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).  
22  
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Operation  
Drive Wheel Release Valves  
WARNING  
Note: The handle must be horizontal and against  
the stop for operation.  
Do Not tow machine.  
Hands may become entangled in the rotating  
drive components below the engine deck, which  
could result in serious injury or death.  
PTO Engagement Switch  
Located on right console (see Figure 6).  
Stop engine, remove key, allow all the moving  
parts to stop before accessing the drive wheel  
release valves.  
Switch must be pulled out (up) to engage the blades.  
Switch is pushed in to disengage the blades.  
The LCD indicator will appear when the PTO switch  
is disengaged (see Figure 8).  
WARNING  
The engine and hydraulic drive units can become  
very hot. Touching a hot engine or hydraulic  
drive units can cause severe burns.  
Low Voltage Indicator  
Located on the right console in the message display  
(see Figure 6 and Figure 8).  
Allow the engine and hydraulic drive units to  
cool completely before accessing the drive wheel  
release valves.  
A low voltage condition (less than 12.3 volts) exists  
when the LCD indicator appears on the message  
display while the engine is running.  
Located on the back of the unitized hydraulic drive  
units, below the engine deck.  
If the ignition key is turned to the “ON” position for  
a few seconds before cranking the engine, the battery  
voltage will display in the area where the hours are  
normally displayed.  
During normal operating conditions, the drive wheel  
release valves are positioned horizontally. If the  
machine has to be pushed by hand, the valves must  
be in the “released” position (see Figure 9).  
Note: The indicator normally appears when the  
engine is off and the key switch is turned to the  
“ON” position.  
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.  
Figure 9  
Transport Lock  
1. Handle in “released” position  
2. Handle in “operating” position  
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 10).  
To release the drive system (see item 1 in Figure 9),  
rotate the handle 1/4 turn to the vertical position  
until it hits against the stop.  
In the non-latching position, the deck will  
automatically return to the cutting height when the  
pedal is lowered (see item 3 in Figure 10).  
To reset the drive system (see item 2 in Figure 9),  
rotate the handle 1/4 turn to the horizontal position  
until it hits against the stop.  
23  
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Operation  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Operating Instructions  
Raise the Rollover 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.  
Figure 10  
3. Non-latching position  
1. Latching position  
2. Transport lock control  
1. The knob must be completely latched with the  
tabs interlocking as shown in Figure 11 to lock  
the roll bar in the raised, operate position.  
2. Apply forward pressure to the upper hoop of the  
roll bar.  
Electronic Control Unit Malfunction  
Indicator  
3. Pull the knob and rotate 90° to hold in the  
unlatched position to lower the roll bar.  
Kohler EFI Units Only:  
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.  
The electronic control unit (ECU) continuously  
monitors operation of the EFI system. If a problem  
or fault within the system is detected, the malfunction  
indicator light (MIL) is illuminated. The MIL is the  
light located in the right console panel to the right of  
the throttle control. Follow the troubleshooting steps  
outlined in the Kohler engine operator’s manual if the  
MIL is illuminated.  
Pre-Start  
Fill fuel tank on level ground. For best results use  
only clean, fresh regular grade unleaded gasoline with  
an octane rating of 87 or higher.  
Important: Never use methanol, gasoline  
containing methanol, gasohol containing more  
than 10% ethanol, premium gasoline, or white  
gas because the fuel system could be damaged.  
Figure 11  
Do Not add oil to gasoline.  
1. Roll bar upper hoop  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system.  
2. Knob in “latched” position  
3. Pull knob to unlatch  
4. Rotate 90° to hold unlatched  
5. Knob in “unlatched” position  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
5. Make sure the knobs are fully engaged with the  
roll bar in the raised position. The upper hoop of  
the roll bar may need to be pushed forward or  
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Operation  
pulled rearward to get both knobs fully engaged  
(see Figure 12).  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
Engaging the PTO  
DANGER  
The rotating blades under the mower deck are  
dangerous. Blade contact can cause serious  
injury or kill you.  
Figure 12  
1. Engaged  
2. Partially engaged — Do  
Not operate with ROPS  
in this condition.  
Do Not put hands or feet under the mower or  
mower deck when the blades are engaged.  
Important: Always use the seat belt with the  
roll bar in the operate (raised) position. Ensure  
that the rear part of the seat is secured with the  
seat latch.  
DANGER  
An uncovered discharge opening will allow  
objects to be thrown in an operator’s or  
bystander’s direction. Also, contact with the  
blade could occur. Thrown objects or blade  
contact can cause serious injury or death.  
Open the Fuel Shut-Off Valve  
Rotate the valve and align with the fuel line to open.  
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.  
Starting the Engine  
1. Move the motion control levers out to the neutral  
lock position.  
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.  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
3. Push down on the PTO switch to the “disengage”  
position.  
Important: Operator must be in seat before the  
PTO can be engaged.  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
1. Set the throttle midway between the “SLOW” and  
“FAST” positions.  
4. Place 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.  
5. On a cold engine, push the choke lever forward  
into the “ON” position (except Kohler EFI units).  
On a warm engine, leave the choke in the “OFF”  
position.  
Disengaging the PTO  
1. Set the throttle midway between the “SLOW” and  
“FAST” positions.  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
2. Push the PTO switch in to disengage the blades.  
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  
Stopping the Engine  
1. Bring the unit to a full stop.  
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Operation  
2. Move the motion control levers out to the neutral  
lock position.  
3. Engage the parking brake.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
5. Disengage the PTO.  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
Driving the Machine  
CAUTION  
Machine can spin very rapidly by positioning one  
lever too much ahead of the other. Operator may  
lose control of the machine, which may cause  
damage to the machine or injury.  
Figure 13  
1. Neutral lock position 4. Forward  
(handles out)  
2. Neutral operate position 5. Neutral (operate)  
(handles in)  
3. Front of Unit  
6. Reverse  
Driving Forward  
• Use caution when making turns.  
1. Release the parking brake.  
• Slow the machine down before making sharp  
turns.  
2. Move the motion control levers inward to the  
center to the neutral position.  
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.  
3. To move forward in a straight line, move both  
levers forward with equal pressure.  
When the motion control levers are positioned fully  
outward (apart) in the T-slot, the drive system is in  
the neutral lock position (Figure 13).  
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.  
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Operation  
To turn right, release pressure on the RH motion  
control lever and the rear of the machine will  
move towards the rear and to the right.  
To turn left, release pressure on the LH motion  
control lever and the rear of the machine will  
move towards the rear and to the left.  
3. To stop, position both motion control levers in  
the neutral operate position.  
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.  
Figure 14  
2. Disengage the PTO.  
3. Position the transport lock in the latching  
position.  
To turn left or right, pull the motion control lever  
back toward neutral in the desired turn direction.  
4. Raise and lock the deck to the 5 1/2 inch (14 cm)  
transport position (Figure 16).  
The machine will move faster the farther the  
motion control levers are moved from the neutral  
position.  
The deck is raised by pushing the foot operated  
deck lift pedal forward. The pedal is located at the  
front right corner of the floor pan.  
4. To stop, position both motion control levers in  
the neutral operate position.  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
Driving in Reverse  
1. Move the motion control levers inward to the  
neutral operate position.  
2. To move rearward in a straight line, move both  
levers rearward with equal pressure.  
Figure 16  
Figure 15  
1. Deck foot pedal  
3. Height of cut decal  
2. Height adjustment pin  
4. Transport lock control  
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Operation  
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.  
Figure 18  
2. Disengage the PTO.  
3. Engage the park brake.  
1. Spring disc washer  
3. 3/8 nyloc-torque to 30-35  
ft-lb (41-47 N-m)  
(cone towards bolt head)  
2. Front right anti-scalp  
bracket shown  
4. 3/8-24 x 2 GR8 torque to  
50-55 ft-lb (68-75 N-m)  
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.  
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, or a slow moving  
vehicle emblem. Driving on a street or roadway  
without such equipment is dangerous and  
can lead to accidents causing personal injury.  
Driving on a street or roadway without such  
equipment may also be a violation of State laws  
and the operator may be subject to traffic tickets  
and/or fines.  
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  
mounting bracket  
2. Cutting height  
For Maximum Deck Flotation, place the rollers  
one hole position lower. Rollers should maintain  
1/4 inch (6.4 mm) clearance to the ground. Do  
Not adjust the rollers to support the deck.  
Do Not drive a unit on a public street or roadway.  
7. Be sure the roller bolts are 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).  
28  
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Operation  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over. Backward  
tip-over could cause serious injury or death.  
• Use extreme caution when operating a unit  
on a ramp.  
• Use only a single, full width ramp; Do Not  
use individual ramps for each side of the unit.  
• If individual ramps must be used, use enough  
ramps to create an unbroken ramp surface  
wider than the unit.  
• 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 surface for the frame members to contact if the  
unit starts to tip backward. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck Do Not exceed 15°. A steeper  
angle may cause mower deck components to get  
caught as the unit moves from ramp to trailer or  
truck. Steeper angles may also cause the unit to tip  
backward. If loading on or near a slope, position  
the trailer or truck so it is on the down side of the  
slope and the ramp extends up the slope. This will  
minimize the ramp angle. The trailer or truck should  
be as level as possible.  
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.  
29  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could seriously  
injure you or other bystanders.  
The engine can become very hot. Touching a hot  
engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine area.  
Remove the key from the ignition switch, 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  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
• Check the park brake adjustment.  
• Change the hydraulic filter and fluid.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check the rollover protections systems (roll bar) knobs.  
• Check the seat belt.  
• Check for loose hardware.  
Before each use or daily  
• Clean the engine and exhaust system area.  
• Clean the hydro fan cooling guards.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the cutting deck.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Check spark arrester (if equipped).  
Every 50 hours  
• Change the engine oil. (May need more often under severe conditions.)  
• Lubricate the deck lift pivots.  
• Remove the engine shrouds and clean the cooling fins.  
Every 100 hours  
Every 200 hours  
Every 250 hours  
• Check the spark plugs.  
• Replace the primary air cleaner element — check secondary air cleaner element; replace if  
dirty. (May need more often under severe conditions. See the Engine Owner's Manual for  
additional information.)  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Replace the secondary air cleaner element (May need more often under severe conditions.  
See the Engine Owner's Manual for additional information.)  
• Change the hydraulic filter and fluid. (May need more often under severe conditions.)  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
Every 500 hours  
Yearly  
• Check the park brake adjustment.  
• Grease the deck and pump idler pivots.  
• Grease the front caster pivots.  
Periodic Maintenance  
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.  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick  
and wipe oil off. Reinsert the dipstick according  
to the engine manufacturer's recommendations.  
Remove the dipstick and read the oil level.  
Check the voltage of the battery with a digital  
voltmeter or with the message display. If the ignition  
key is turned to the “on” position for a few seconds,  
the battery voltage will be displayed in the area where  
the hours are normally displayed. Locate the voltage  
reading of the battery in the table and charge the  
battery for the recommended time interval to bring  
the charge up to a full charge of 12.6 volts or greater.  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Exmark 4-Cycle Premium  
Engine Oil is recommended; refer to the Engine  
Owner's manual for an acceptable alternative. Do  
Not overfill.  
Important: Make sure the negative battery cable  
is disconnected and the battery charger used for  
charging the battery should have an output of  
16 volts and 7 amps or less to avoid damaging  
the battery (see chart for recommended charger  
settings). This is especially important on Kohler  
EFI (Electronic Fuel Injection) units. Failure to  
do so may damage the ECU (Electronic Control  
Unit).  
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  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
WARNING  
CALIFORNIA  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
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.  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
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Maintenance  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
CAUTION  
Charger  
Settings  
Interval  
2 Hours  
3 Hours  
Connecting the jumper cables incorrectly  
(wrong polarity) can immediately damage the  
electrical and/or EFI system.  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
14.4 volts/4  
amps  
Be certain of battery terminal polarity and  
jumper cable polarity when hooking up  
batteries.  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
Note: The following instructions are adapted  
from the SAE J1494 Rev. Dec. 2001 – Battery  
Booster Cables – Surface Vehicle Recommended  
Practice (SAE – Society of Automotive  
Engineers).  
Important: For Kohler EFI units: Unplug the  
harness from the ECU before performing any  
welding on the equipment.  
Recommended Jump  
Starting Procedure  
Service Interval: As required  
WARNING  
Batteries contain acid and produce explosive  
gases.  
• Shield the eyes and face from the batteries  
at all times.  
1. Check the weak battery for terminal corrosion  
(white, green, or blue “snow”), it must be cleaned  
off prior to jump starting. Clean and tighten  
connections as necessary.  
• Do Not lean over the batteries.  
Note: Be sure the vent caps are tight and level.  
Place a damp cloth, if available, over any vent  
caps on both batteries. Be sure the vehicles do  
not touch and that both electrical systems are  
off and at the same rated system voltage. These  
instructions are for negative ground systems only.  
CAUTION  
Corrosion or loose connections can cause  
unwanted electrical voltage spikes at anytime  
during the jump starting procedure.  
Do Not attempt to jump start with loose or  
corroded battery terminals or damage to the  
engine or EFI may occur.  
3. Connect the positive (+) cable to the positive (+)  
terminal of the discharged battery that is wired to  
the starter or solenoid as shown in Figure 19.  
DANGER  
Jump starting a weak battery that is cracked,  
frozen, has low electrolyte level, or an  
open/shorted battery cell, can cause an  
explosion resulting in serious personal injury.  
Do Not jump start a weak battery if these  
conditions exist.  
2. Make sure the booster is a good and fully charged  
lead acid battery at 12.6 volts or greater. Use  
properly sized jumper cables (4 to 6 AWG) with  
short lengths to reduce voltage drop between  
systems. Make sure the cables are color coded or  
labeled for the correct polarity.  
32  
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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:  
Figure 19  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
1. Positive (+) cable on discharged battery  
2. Positive (+) cable on booster battery  
3. Negative (–) cable on the booster battery  
4. Negative (–) cable on the engine block  
5. Booster battery  
6. Discharged battery  
7. Engine block  
4. Connect the other end of the positive cable to the  
positive terminal of the booster battery.  
Figure 21  
5. Connect the black negative (–) cable to the other  
terminal (negative) of the booster battery.  
1. Install bushing in blade prior to installing bushing in  
spindle.  
6. MAKE THE FINAL CONNECTION ON  
THE ENGINE BLOCK OF THE STALLED  
VEHICLE (NOT TO THE NEGATIVE POST)  
AWAY FROM THE BATTERY. STAND BACK  
(see Figure 20).  
B. Install bushing/blade assembly into spindle.  
Make sure the splines on the bushing are  
engaged in the spindle before tightening the  
bolt.  
Figure 20  
Figure 22  
1. Engine block  
2. Negative (–) cable  
1. Use wrench here for blade installation. This nut has  
been torqued to 90-110 ft-lb (122-149 N-m)  
2. Torque to 55-60 ft-lb (75-81 N-m) Apply lubricant to  
threads as needed to prevent seizing. Copper-based  
anti-seize preferable. Grease acceptable substitute.  
7. Start the vehicle and remove the cables in the  
reverse order of connection (the engine block  
(black) connection is the first to disconnect).  
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Maintenance  
C. Apply lubricant to threads of blade bolt to  
prevent seizing. Copper-based anti-seize  
preferable. Grease acceptable substitute.  
Install blade bolt finger tight. Place wrench  
on the top spindle nut then torque the blade  
bolts to 55-60 ft-lb (75-81 N-m).  
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.  
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.  
Again, run engine at one-third throttle, brake  
engaged, and move left motion control lever  
in - engine must initiate shutdown after 1/2  
second has elapsed.  
Repeat again moving the right lever in, then  
moving both levers in - engine must initiate  
shutdown after 1/2 second has elapsed whether  
operator is on seat or not.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
motion control levers moved out in the neutral  
lock position. The operator does not need to be  
in the seat to start the engine.  
Check Rollover Protections  
Systems (Roll Bar) Knobs  
Service Interval: Before each use or daily  
Try to start with operator in seat, parking brake  
disengaged, PTO disengaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Check that both the mounting hardware and the  
knobs are in good working condition. Make sure the  
knobs are fully engaged with the ROPS in the raised  
position. The upper hoop of the roll bar may need  
to be pushed forward or pulled rearward to get both  
knobs fully engaged.  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Try to start with operator in seat, parking  
brake engaged, PTO disengaged, and the left  
motion control lever in, starter must not crank,  
repeat again with the right lever in, then with  
both levers in - starter must not crank.  
2. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
34  
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Maintenance  
Engine Owner's Manual  
for additional information.)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. See the Engine Owner's Manual for maintenance  
instructions.  
Check Air Filter Assembly (if  
equipped)  
Figure 23  
2. Partially engaged — Do  
Service Interval: As required  
1. Engaged  
Not operate with ROPS  
in this condition.  
Important: To prevent engine damage, always  
operate the engine with both air filters and cover  
installed.  
1. When checking or replacing the air filter element,  
make sure the air filter assembly is installed in the  
brackets.  
Check Seat Belt  
Service Interval: Before each use or daily  
2. Position the air cleaner cover so that the  
breather valve does not interfere with the throttle  
mechanism.  
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.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
Service Air Cleaner  
Service Interval: Every 250 hours—Replace  
the primary air cleaner  
element — check  
secondary air cleaner  
element; replace if dirty.  
(May need more often  
under severe conditions.  
See the Engine Owner's  
Manual for additional  
information.)  
Figure 24  
1. Air cleaner cover  
2. Throttle mechanism  
3. Breather valve  
3. Secure the cover with latches.  
Every 500 hours—Replace  
the secondary air cleaner  
element (May need more  
often under severe  
Change Engine Oil  
Service Interval: After the first 5 hours  
Every 100 hours/Yearly  
(whichever comes first)  
conditions. See the  
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Maintenance  
(May need more often  
under severe conditions.)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Drain oil while engine is warm from operation.  
3. The oil drain hose is located on right hand side  
of engine at the rear. Place pan under machine  
to catch oil. Remove plug from end of drain  
hose. Allow oil to drain and replace oil drain plug.  
Torque plug to 20-24 ft-lb.  
4. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of Exmark 4–Cycle Premium Engine oil on the  
surface of the rubber seal. Turn filter clockwise  
until rubber seal contacts the filter adapter then  
tighten filter an additional 1/2 to 3/4 turn.  
Figure 25  
2. Add  
1. Full  
Note: The oil level on the dipstick will be  
incorrect if the oil is checked when the unit is hot.  
7. If the dipstick oil level is at the “add” mark add  
Exmark Premium Hydro Oil.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
8. Replace hydraulic reservoir cap and tighten until  
6. Use oil recommended in the Check Engine Oil  
Level section. Do Not overfill. Start the engine  
and check for leaks.  
snug. Do Not overtighten.  
Check Tire Pressures  
Service Interval: Every 50 hours  
7. Wipe up any spilled oil from engine deck  
mounting surfaces.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Check Hydraulic Oil Level  
Service Interval: Every 50 hours  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 13 psi (90 kPa).  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
4. Semi-pneumatic caster tires Do Not need to be  
inflated.  
2. Wait until the unit cools before checking the  
hydraulic oil.  
Note: Do Not add any type of tire liner or foam  
fill material to the tires. Excessive loads created by  
foam filled tires may cause failures to the hydro drive  
system, frame, and other components. Foam filling  
tires will void the warranty.  
3. Slide the seat all the way back, then lift the seat to  
access the caps on the LH and RH hydro drives.  
4. Clean the area around hydraulic reservoir cap and  
remove cap.  
5. Wipe the dipstick clean and re-insert the cap back  
into the hydro. Lightly tighten the cap.  
Check Condition Of Belts  
Service Interval: Every 50 hours  
6. Remove the cap again and check the level of the  
oil on the dipstick. See Figure 25 for oil levels.  
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.  
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Maintenance  
Note: No adjustments are required for belt  
tension.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Figure 26  
1. Seal guard  
2. Spacer nut with wrench  
flats  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Lubrication Chart  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with the  
other spacer nut still assembled to it) from the  
wheel assembly.  
1
2
1. Deck and  
Pump Idler  
Pivots  
Yearly  
2. Front  
Caster  
*0  
2
*Yearly  
Pivots  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
* See step 3 for special lubrication instructions on  
the front caster pivots.  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
11. Insert the second bearing and new seal into the  
wheel.  
Lubricate Caster Wheel Hubs  
Service Interval: As required  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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Maintenance  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
Replacement Filters  
Kohler  
Kohler P/N 24 050 13  
Kawasaki  
Kawasaki  
P/N 49019-7005  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
Kohler EFI  
Kohler P/N 25 050 42  
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.  
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  
Lubricate Deck Lift Pivot  
Service Interval: Every 100 hours  
Service Interval: After the first 250 hours  
Every 500 hours thereafter  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Note: Only use Exmark Hydro Filter–Part No.  
116-0164 for summer or winter.  
2. Lubricate deck lift pivot with a spray type  
lubricant or light oil.  
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.  
Check Spark Plugs  
Service Interval: Every 200 hours  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner's  
Manual.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Change Fuel Filter  
Service Interval: As required  
A fuel filter is installed between the fuel tank and the  
engine. Replace when necessary.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
For Kohler EFI Units:  
3. Remove the pump drive belt.  
WARNING  
4. Place a catch pan under the hydro.  
Fuel system components are under high  
pressure. The use of improper components can  
result in system failure, gasoline leakage and  
possible explosion.  
5. 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.  
Use only approved fuel lines and fuel filters for  
high pressure systems.  
7. Before installing the new filters, apply a thin coat  
of Exmark Premium Hydro Oil on the surface  
of the two rubber seals.  
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Maintenance  
8. Install the new filters and torque to 14 ft-lb (19  
N-m).  
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.  
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:  
Do Not refuel or run engine unless spark arrester  
is installed.  
Hydro Oil  
Service Interval  
Exmark Premium Hydro  
Oil (Preferred)  
After first 250 hours  
*Every 500 hours  
thereafter  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Mobil 1 15W50  
After first 250 hours  
*Every 250 hours  
thereafter  
2. Wait for muffler to cool.  
3. If any breaks in the screen or welds are observed,  
replace arrester.  
*May need more often under severe conditions.  
4. If plugging of the screen is observed, remove  
arrester and shake loose particles out of the  
arrester and clean screen with a wire brush (soak  
in solvent if necessary). Reinstall arrester on  
exhaust outlet.  
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.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
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 or been  
extremely hot.  
• ROPS spring pin housing.  
• Hydro pump control arm, linkage bolt, and  
attachment bolt.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminants into the system.  
• Hydro cooling fan screw.  
• Hydro park brake cable anchor mounting bolt  
• Sheave and clutch retaining bolt in the end of  
engine crankshaft.  
Wheel Hub - Slotted Nut  
Torque Specification  
Thread locking adhesives are required for some  
hardware on engines — see the Engine manual.  
Service Interval: After the first 100 hours  
Every 500 hours thereafter  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
Torque the slotted nut to 211-260 ft-lb (286-352  
N-m).  
Note: Do Not use anti-seize on wheel hub.  
• Between the jackshaft and bearings.  
Check Spark Arrester  
(if equipped)  
• Between the jackshaft and sheaves, spindles, and  
bearings.  
Service Interval: Every 50 hours  
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Maintenance  
• Between the spindles and sheaves.  
Adjustments  
• Under top cutter housing bearing guard.  
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.  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
location:  
CAUTION  
On threads of Blade Bolts. See Check Mower  
Blades section.  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be enough  
support or may malfunction allowing the unit to  
fall, which could cause injury.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
Dielectric grease should not be applied to sealed  
connectors.  
Do Not rely solely on mechanical or hydraulic  
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.  
4. 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 27).  
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Maintenance  
Figure 28  
1. 3 1/4 inches (8.3 cm) 4. 3 inches (7.6 cm)  
5. Level surface  
Figure 27  
3. Transport lock  
2. Back blade tip  
3. Front blade tip  
1. Foot lever  
2. Height of cut pin  
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 cm)  
height (see Figure 29).  
6. Insert the height adjustment pin into the 3 inch  
(7.6 cm) cutting height location.  
7. Release the transport lock and allow the deck to  
lower to the cutting height.  
To increase the height, turn the adjuster clockwise;  
to decrease, turn counterclockwise.  
8. Raise the discharge deflector.  
9. Measure from the level surface to the front tip of  
the center blade. The measurement should read  
3 inches (7.6 cm).  
Note: In most conditions, the back blade tip  
should be adjusted 1/4 inch (6.4 mm) higher than  
the front.  
Figure 29  
1. Adjuster link  
2. Jam nut  
3. Adjuster  
11. The back tip of the blade should measure 3  
1/4 inches (8.3 cm). Fine tune rear adjusters as  
required.  
41  
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Maintenance  
12. Re-measure until all four sides are the correct  
height. Tighten all the jam nuts on the deck lift  
arm assemblies.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
13. Lower discharge deflector.  
Deck Belt Tension  
14. If the four deck links do not have enough  
adjustment to achieve accurate cut height with the  
desired rake, the single point adjustment can be  
utilized to gain more adjustment (see Figure 30).  
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. This  
procedure must be followed after the first 100 hours  
or when a brake component has been removed or  
replaced.  
1. Drive the machine onto a level surface.  
2. Disengage the blade control switch (PTO), move  
the motion control levers to the neutral locked  
position and set the parking brake.  
3. Stop the engine, wait for all moving parts to stop,  
and remove the key.  
4. Raise the back of the machine up and support the  
machine with jack stands.  
Figure 30  
CAUTION  
1. Single point height adjustment bolt  
2. Front height-of-cut plate mounting bolt  
3. Rear height-of-cut plate mounting bolt  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
15. To adjust the single point system, first loosen the  
front and rear height-of-cut plate mounting bolts.  
16. If the deck is too low, tighten the single point  
adjustment bolt by rotating it clockwise. If  
the deck is too high, loosen the single point  
adjustment bolt by rotating it counterclockwise.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
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. Measure the overall length of the compression  
spring. The correct length should be between  
1 1/2–1 9/16 inches (3.8–4.0 cm). If the spring  
length is within this range, no adjustment is  
needed. If it is not, proceed to step 9.  
9. Hold the threaded rod end with a tool and adjust  
the lock nut until the spring length is between  
1 1/2–1 9/16 inches (3.8–4.0 cm) see Figure 31).  
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.  
17. Re-tighten front and rear height-of-cut plate  
mounting bolts.  
Important: Torque the front and rear  
height-of-cut plate mounting bolts to 27-33  
ft-lb (37-45 N-m).  
18. Repeat steps 9 through 13.  
42  
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Maintenance  
Do Not allow the cable to turn when the nuts are  
being loosened.  
Electric Clutch Adjustment  
No adjustment necessary. However when the clutch  
brake has worn to the point where the clutch no  
longer engages consistently, the shim can be removed  
to extend the clutch life.  
Figure 32  
1. Armature  
5. Brake spacer  
6. Re-gap shim  
7. Brake pole  
Figure 31  
2. Field shell  
3. Rotor  
Left Hand Brake Shown  
1. Cable anchor  
5. Caliper  
4. Brake mounting bolt  
2. Hold threaded rod here  
6. Compression spring  
3. Measure  
4. Lock nut  
7. Threaded rod  
8. Hub  
Removing the Shim:  
1. Stop engine, wait for all moving parts to stop,  
and remove key. Engage parking brake. Allow  
the machine to cool completely before starting  
these instructions.  
10. Disengage the park brake. Turn the wheel hub  
by hand in both directions relative to the caliper;  
no drag of the caliper pad on the wheel hub is  
desired.  
2. Using a pneumatic line, blow out any debris  
from under the brake pole and around the brake  
spacers.  
11. If there is no movement between the hub and the  
caliper then repeat the adjustment (drive release  
valves must be in the “released” position on the  
hydros).  
3. Check the condition of the wire harness leads,  
connectors, and terminals. Clean or repair as  
necessary.  
12. After adjusting the brakes on both sides of the  
mower, cycle the brake handle a minimum of six  
times to allow the cable to seat into the sheath  
and mounting tabs.  
4. Verify that 12V is present at the clutch connector  
when the PTO switch is engaged.  
5. Measure the gap between the rotor and armature.  
If the gap is greater than .04 inch (1 mm), proceed  
with the following steps:  
13. Recheck the spring length; engage the park brake  
and repeat steps 8 through 11 if the length is not  
in the correct range.  
A. Loosen both brake mounting bolts one-half  
to one full turn (see Figure 33).  
14. Rotate the drive wheel release handle to the  
“operating” position. Refer to the Drive Wheel  
Release Valves section in Operation.  
Note: Do Not remove the brake pole from  
the field shell/armature. The brake pole has  
worn to match the armature and needs to  
continue to match after the shim is removed  
to ensure proper brake torque.  
15. Install the rear tires and torque lug nuts to 90-95  
ft-lb (122-129 N-m).  
16. Remove jack stands.  
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Maintenance  
Figure 35  
Figure 33  
2. Shim  
1. Feeler gauge  
1. Brake mounting bolt  
• If the gap is less than 0.010 inch, then  
reinstall the shim and reference the  
Troubleshooting section.  
B. Using needle nose pliers, or by hand, take  
hold of the tab and remove the shim (Do Not  
discard the shim until proper clutch function  
has been confirmed).  
• If the gap is sufficient, proceed to the  
safety check in step F.  
C. Using a pneumatic line, blow out any debris  
from under the brake pole and around the  
brake spacers.  
F. Perform the following safety check:  
a. Sit on the seat and start the engine.  
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13  
N-m) +/-0.5 ft-lb (0.7 N-m).  
b. Make sure the blades Do Not engage with  
the PTO switch “off ” and the clutch  
disengaged.  
E. Using a 0.010 inch thick feeler gauge, verify  
that a gap is present between the rotor and  
armature face on both sides of the brake pole  
as shown. (Due to the way the rotor and  
armature faces wear (peaks and valleys) it is  
sometimes difficult to measure the true gap.)  
If the clutch does not disengage,  
reinstall the shim and reference the  
Troubleshooting section.  
c. Engage and disengage the PTO switch  
ten consecutive times to ensure the clutch  
is functioning properly. If the clutch  
does not engage properly, reference the  
Troubleshooting section.  
G011733  
Motion Control Linkage  
Adjustment  
1
Figure 34  
Located on either side of the fuel tank, below the seat  
are the pump control linkages. Rotating the pump  
linkage with a 1/2 inch wrench allows fine tuning  
adjustments so that the machine does not move in  
neutral. Any adjustments should be made for neutral  
positioning only.  
1. Feeler gauge  
44  
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Maintenance  
WARNING  
Engine must be running and drive wheels must  
be turning so adjustments can be performed.  
Contact with moving parts or hot surfaces may  
cause personal injury.  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
1. Prior to starting the engine, push the deck lift  
pedal and remove the height of cut pin. Lower  
deck to the ground.  
Figure 36  
1. Double nuts  
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.  
8. Shut off unit. Remove jumper wire from wire  
harness and plug connector into seat switch.  
3. Remove the electrical connection from the seat  
safety switch, located under the bottom cushion  
of the seat. The switch is a part of the seat  
assembly.  
9. Remove the jack stands.  
10. Raise the deck and re-install the height of cut pin.  
11. Check that the machine does not creep in neutral  
with the park brakes disengaged.  
4. Temporarily install a jumper wire across the  
terminals in the connector of the main wiring  
harness.  
Motion Control Damper  
Adjustment  
The top damper mounting bolt can be adjusted to  
obtain a more desired motion control lever resistance.  
See Figure 37 for mounting options.  
5. Start engine. Brake must be engaged and  
motion control levers out to start engine.  
Operator does not have to be in the seat  
because of the jumper wire being used. Run  
engine at full throttle and release brake.  
6. Run the unit at least 5 minutes with the drive  
levers at full forward speed to bring hydraulic oil  
up to operating temperature.  
Note: The motion control lever needs to be in  
neutral while making any necessary adjustments.  
7. Bring the motion control levers into the neutral  
position. Adjust pump control rod lengths  
by rotating the double nuts on the rod in the  
appropriate direction until the wheels slightly  
creep in reverse (Figure 36). 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.  
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Maintenance  
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 39).  
Figure 37  
RH Motion Control Shown  
1. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt must  
protrude past end of nyloc nut after torque. A T-40 Torx  
bit will be necessary to hold the stud from turning.  
2. Most resistance (firmest feel)  
3. Damper  
4. Medium resistance (medium feel)  
5. Least resistance (softest feel)  
Figure 39  
1. Bolts  
4. Nuts  
2. Control lever  
3. Control arm shaft  
5. Slotted holes  
Motion Control Neutral Lock  
Pivot Adjustment  
The flanged nut can be adjusted to obtain a more  
desired motion control lever resistance (Figure 38).  
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 control levers can be tilted fore or aft for  
maximum operator comfort.  
1. Loosen the upper bolt holding the control lever  
to the control arm shaft.  
2. Loosen the lower bolt just enough to pivot the  
control lever fore or aft Figure 39. Tighten both  
bolts to secure the control in the new position.  
Figure 38  
3. Repeat the adjustment for the opposite control  
lever.  
1. Flanged nut  
2. Jam nut  
1. Loosen the jam nut.  
Motion Control Full Forward  
Tracking Adjustment  
2. Tighten or loosen the flanged nut to the desired  
feel.  
If the machine travels or pulls to one side when the  
motion control levers are in the full forward position,  
adjust the cover plates.  
For more resistance, tighten the flanged nut.  
For less resistance, loosen the flanged nut  
3. Tighten jam nut.  
1. Loosen the screws on a cover plate (see Figure 40).  
46  
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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.  
Figure 41  
1. Spring disc washers  
Figure 40  
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 41.  
47  
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Maintenance  
Clean Hydro Fan Cooling  
Guards  
Cleaning  
Clean Engine and Exhaust  
System Area  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
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.  
conditions.)  
2. Slide seat all the way back, then lift the seat to  
access the LH and RH hydro drive area.  
CAUTION  
3. Remove accumulated debris from the hydro fan  
cooling guards.  
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 Debris From Machine  
Clean all debris from engine and exhaust system  
area.  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. 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.  
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.  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
Remove Engine Shrouds and  
Clean Cooling Fins  
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.  
Service Interval: Every 100 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove cooling shrouds from engine and clean  
cooling fins. Also clean dust, dirt and oil from  
external surfaces of engine which can cause  
inadequate cooling.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
3. Make sure cooling shrouds are reinstalled.  
Operating the engine without cooling shrouds will  
cause engine damage due to overheating.  
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.  
48  
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Maintenance  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
Battery Disposal  
DANGER  
Battery electrolyte contains sulfuric acid, which  
is poisonous and can cause severe burns.  
Swallowing electrolyte can be fatal or if it touches  
skin can cause severe burns.  
• Wear safety glasses to shield eyes, and rubber  
gloves to protect skin and clothing when  
handling electrolyte.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with water  
and call a doctor immediately.  
Federal law states that batteries should not be placed  
in the 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 battery reseller.  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do not attempt to service or replace major  
items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.  
Problem  
Starter does not crank  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not engaged.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery. See Check  
Battery Charge and Recommended  
Jump Starting Procedure sections in  
Maintenance.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
7. Relay or switch is defective.  
8. Faulty module.  
6. Replace the blown fuse.  
7. Contact an Authorized Service Dealer.  
8. Replace module.  
Engine will not start, starts hard, or fails to  
keep running  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle and choke are not in the  
correct position.  
4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
7. Clean or replace the air cleaner element.  
8. Seat switch is not functioning properly.  
8. Check the seat switch indicator. Replace  
seat if needed.  
9. Electrical connections are corroded, loose 9. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
10. Relay or switch is defective.  
11. Faulty spark plug.  
12. Spark plug wire is not connected.  
13. Faulty module.  
10. Contact an Authorized Service Dealer.  
11. Clean, adjust or replace spark plug.  
12. Check the spark plug wire connection.  
13. Replace module.  
14. MIL illuminates and blinks  
14. Contact an Authorized Service Dealer  
50  
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Troubleshooting  
Problem  
Engine loses power  
Possible Cause  
Corrective Action  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
Mower pulls left or right (with levers fully  
forward)  
1. Tire pressure in drive tires not correct.  
1. Adjust tire pressure in the drive tires.  
Machine does not drive  
1. Drive release handle not in “operating”  
position.  
1. Position handle in “operating” position;  
see Drive Wheel Release Valves section  
in Operation.  
2. Drive or pump belt is worn, loose or  
broken.  
2. Change the belt.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Uneven cutting height.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
7. Belt is damaged.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
7. Install new belt.  
Blades do not rotate.  
1. Deck belt is worn, loose or broken.  
2. Deck belt is off pulley.  
1. Install new deck belt.  
2. Install belt on clutch and deck pulleys,  
idlers, and tensioning idler per routing  
decal on deck.  
3. Broken or missing idler spring.  
4. Drive belt not routed correctly.  
3. Replace the spring.  
4. Refer to belt routing decal on deck.  
51  
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Troubleshooting  
Problem  
Possible Cause  
1. Fuse is blown.  
Corrective Action  
Clutch will not engage.  
1. Replace fuse. Check coil resistance,  
battery charge, charging system, and  
wiring connections and replace if  
necessary.  
2. Low voltage supply at the clutch.  
2. Check coil resistance, battery charge,  
charging system, and wiring connections  
and replace if necessary.  
3. Damaged coil.  
3. Replace clutch.  
4. Inadequate current supply.  
4. Repair or replace clutch lead wire or  
electrical system. Clean connector  
contacts.  
5. Remove shim or replace clutch.  
5. Rotor/armature airgap is too large.  
52  
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Schematics  
Schematics  
Electrical Diagram — All units except Kohler EFI  
W H I T E  
W O N R B  
W O Y E L L  
N A T  
B L U E  
P I N K  
C A K B L  
G R E E N  
Y A G R  
V I O L E T  
R E D  
O R A N G E  
P I N K  
P I N K  
C A K B L  
. G T R L E E N  
W O N R B  
P I N K  
53  
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Schematics  
Electrical Diagram — Kohler EFI  
RED  
WHITE  
BLUE  
W H I T E  
W O N R B  
W O Y E L L  
N A T  
B L U E  
P I N K  
C A K B L  
G R E E N  
Y A G R  
V I O L E T  
R E D  
O R A N G E  
P I N K  
P I N K  
C A K B L  
W O N R B  
P I N K  
. G T R L E E N  
54  
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Schematics  
Electrical Logic Schematic — All units except Kohler EFI  
3
4
1
5
2
B +  
Y A  
T _ R R A E T L S  
G A N E M  
K E Y _ S  
K E Y _ A  
O T  
T A S E  
B R A K E  
N E U T R A L  
F U E L _ S O L E N O I D  
O T P  
O R U G N D  
F U E L  
7
4
1
2
8
5
1 0 A  
F 3  
+
55  
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Schematics  
Electrical Logic Schematic — Kohler EFI  
3
1
4
5
2
B +  
Y A  
T _ R R A E T L S  
G A N E M  
K E Y _ S  
K E Y _ A  
O T  
T A S E  
B R A K E  
N E U T R A L  
F U E L _ S O L E N O I D  
O T P  
O R U G N D  
F U E L  
7
4
1
2
8
5
1 0 A  
F 3  
+
56  
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Schematics  
Hydraulic Diagram  
57  
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Exmark Lazer Z X-Series, Lazer Z S-Series, and Vantage Turf Equipment  
3Year Limited Commercial Warranty  
5Year 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.  
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  
402-223-6375.  
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.  
If for any reason you are dissatisfied with the Service Dealer’s analysis or  
with the assistance provided, contact us at:  
Commercial Warranty Conditions  
This warranty applies to Exmark Lazer Z X-Series, Lazer Z S-Series, and  
Vantage turf equipment sold in the U.S. or Canada for a period of three  
years for commercial usage.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
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.  
402-223-6375 or  
Owner’s Responsibilities  
If your product requires warranty service it must be returned to an  
authorized Exmark service dealer within the warranty period. This  
warranty extends only to turf equipment operated under normal  
conditions. You must read the operator’s manual. You must also properly  
service and maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a dealer or by  
you, is at your expense.  
Consumer Warranty Conditions  
This warranty applies to Exmark Lazer Z X-Series, Lazer Z S-Series, and  
Vantage turf equipment sold in the U.S. or Canada for a period of five  
years or 750 hours (whichever occurs first) for residential usage.  
Residential usage means use of the product on the same lot as your home.  
Use at more than one location is considered commercial use, and the  
commercial use warranty detailed above would apply.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company with respect  
to this warranty shall be repair or replacement of defective components as  
set forth herein. Neither Exmark nor Exmark Warranty Company  
shall be liable for any incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor. For the first  
warrantable service repair, Exmark will cover up to $45 for associated  
pick-up and delivery charges to and from any authorized Exmark Service  
Dealer. Additional transportation charges may apply, contact your Dealer  
for details.  
Such damages include but are not limited to:  
Expenses related to gasoline, oil or lubricants.  
Travel time, overtime, after hours time or other extraordinary repair  
charges or charges relating to repairs or replacements outside of  
normal business hours at the place of business of the authorized  
Exmark Service Dealer.  
Rental of like or similar replacement equipment during the period of  
any warranty, repair or replacement work.  
Any telephone or telegram charges or travel charges.  
Loss or damage to person or property other than that covered by the  
terms of this warranty.  
Warranty Exceptions  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
*
• Engine  
* The Engine warranty is covered by the engine manufacturer. Please  
refer to the engine manufacturer’s warranty statement that is included in  
the literature packet.  
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.  
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.  
• Cost of regular maintenance service or parts, such as filters, fuel,  
lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or required  
replacement or repair due to normal wear, accidents, or lack of proper  
maintenance.  
• Any repairs necessary due to use of parts, accessories or supplies,  
including gasoline, oil or lubricants, incompatible with the turf  
equipment or other than as recommended in the operator's manual or  
other operational instructions provided by Exmark.  
All implied warranties of merchantability (that the product is fit for  
ordinary use) and fitness for use (that the product is fit for a  
particular purpose) are limited to the duration of the express  
warranty.  
Some states do not allow exclusions of incidental or consequential  
damages, or limitations on how long an implied warranty lasts, so the  
above exclusions and limitations may not apply to you.  
There are no other express warranties except for engine and special  
emission system coverage.  
This warranty gives you specific legal rights, and you may also have  
other rights which vary from state to state.  
All warranty work must be performed by an authorized Exmark Service  
Dealer using Exmark approved replacement parts.  
G4500-733_B  
58  
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Notes:  
59  
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Notes:  
60  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
61  
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Figure 42  
This page may be copied for personal use.  
1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the  
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold  
along the appropriate line to match the recommended slope.  
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.  
3. Example of how to compare slope with folded edge.  
63  
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EXMARK ACCESSORIES AND OPTIONS*  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
SUN SHADE  
TRASH CONTAINER  
TURF STRIPER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
12V POWER PORT  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
*Some accessories and options not available for some models.  
Place Model No. and Serial No.  
Date Purchased  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
©2012 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4501-196 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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