Exmark Lawn Mower 4500 501 Rev A User Guide

LAZER Z® XS  
DIESEL MODELS  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-501 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Figure 1  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
1. Model and serial number location  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
Model No.  
Serial No.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Belt Guide Adjustment.................................. 40  
Reverse Indicator Adjustment........................ 41  
Motion Control Damper Adjustment............. 43  
Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 18  
Periodic Maintenance ....................................... 29  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
Figure 2  
1. Safety alert symbol  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
CAUTION  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Safe Operating Practices  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
5
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Safety  
DANGER  
WARNING  
In certain conditions diesel fuel is extremely  
flammable and vapors are explosive.  
Diesel fuel is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
A fire or explosion from diesel fuel can burn  
you, others, and cause property damage.  
• Avoid prolonged breathing of vapors.  
• Fill the fuel tank outdoors in an open  
area, when the engine is cold. Wipe up  
any diesel fuel that spills.  
• Keep face away from nozzle and diesel  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill the fuel tank completely full.  
Add diesel fuel to the fuel tank until the  
level is 1/4 to 1/2 inch (6–13 mm) below  
the bottom of the filler neck. This empty  
space in the tank allows diesel fuel to  
expand.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
Operation  
• Never smoke when handling diesel fuel,  
and stay away from an open flame or  
where diesel fuel fumes may be ignited  
by spark.  
WARNING  
Operating engine parts, especially the  
muffler, become extremely hot. Severe burns  
can occur on contact and debris, such as  
leaves, grass, brush, etc. can catch fire.  
• Store diesel fuel in an approved container  
and keep it out of the reach of children.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
• Remove accumulated debris from muffler  
and engine area.  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
6
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Safety  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine. Use seat belts  
with the roll bar in the raised and locked position.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
Slope Operation  
– Before checking, cleaning or working on the  
mower.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
DANGER  
– Before clearing blockages.  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Wheels  
dropping over edges, ditches, steep banks, or  
water can cause rollovers, which may result  
in serious injury, death or drowning.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
– Before dumping the grass catcher.  
• Do Not mow slopes greater than 15  
degrees.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Reduce speed and use extreme caution  
on slopes.  
• Avoid sudden turns or rapid speed  
changes.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
7
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Safety  
Using the Rollover Protection System  
(ROPS)  
A Rollover Protection System (roll bar) is installed  
on the unit.  
WARNING  
There is no rollover protection when the roll  
bar is down. Wheels dropping over edges,  
ditches, steep banks, or water can cause  
rollovers, which may result in serious injury,  
death or drowning.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
Figure 3  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
• Lower the roll bar only when absolutely  
necessary.  
• Do Not wear seat belt when the roll bar  
is down.  
3. Water  
• Drive slowly and carefully.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Raise the roll bar as soon as clearance  
permits.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and Do Not contact  
them.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• In the event of a rollover, take the unit to an  
Authorized Service Dealer to have the ROPS  
inspected.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
Maintenance and Storage  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Keep engine, engine area, and pump drive belt  
compartment free from accumulation of grass,  
leaves, excessive grease or oil, and other debris  
which can accumulate in these areas. These  
materials can become combustible and may result  
in a fire.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• Let engine cool before storing and do not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
8
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Safety  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
WARNING  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
accidentally injected into the skin must be  
surgically removed within a few hours by a  
doctor familiar with this form of injury or  
gangrene may result.  
• Use jack stands to support components when  
required.  
• Carefully release pressure from components with  
stored energy.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
• Make sure all hydraulic fluid hoses  
and lines are in good condition and  
all hydraulic connections and fittings  
are tight before applying pressure to  
hydraulic system.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Keep hands and feet away from moving parts.  
If possible, do not make adjustments with the  
engine running.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
• Charge batteries in an open well ventilated area,  
away from spark and flames. Unplug charger  
before connecting or disconnecting from battery.  
Wear protective clothing and use insulated tools.  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control  
levers in neutral and shutting off the  
engine before performing any work on  
the hydraulic system.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
WARNING  
Fuel system components are under high  
pressure. The use of improper components  
can result in system failure, fuel leakage and  
possible explosion.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
Use only approved fuel lines and clamps for  
high pressure systems.  
9
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
1-633706  
98-5954  
1-403005  
1-513742  
1-513748  
10  
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Safety  
103-2076  
103-0223  
103-7218  
103-0261  
103-1798  
107-2102  
11  
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Safety  
107-2112  
109-1399  
109-0872  
109-2219  
109-1214  
109-2263  
109-1215  
12  
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Safety  
109-2264  
109-2478  
109-2951  
109-3148  
13  
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Safety  
116-0997  
109-6855  
109-7949  
19426-87881  
116-0127  
19426-87903  
116-0404  
14  
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Safety  
107-9866  
3. Neutral  
1. Fast  
2. Slow  
4. Reverse  
15  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
LXS25KD605; LXS25KD665; LXS25KD725  
Systems  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
Engine  
• Engine will stop if either the left, the right, or  
both levers are moved from neutral lock position  
while brake is engaged.  
• Engine Specifications: See your Engine Owner’s  
Manual  
• RPM: Full Speed: 3850 ±50 RPM (No Load)  
Idle: 1400 RPM  
Cooling System  
• Fan: Electric with continuous operation with  
engine running.  
Fuel System  
• Coolant Liquid: 50/50 mix of DexCool©  
• Capacity: 15.5 gal. (58.6 L)  
extended life antifreeze and water.  
• Type of Fuel: Diesel fuel, 40 cetane or higher or  
biodiesel up to B20 (20% biodiesel, 80% petro  
diesel).  
• Coolant Capacity: 4 quarts  
Operator Controls  
• Steering and Motion Control:  
• Fuel Filter: In-line 113 Micron  
Exmark P/N 112-7836.  
Note: Motion control levers are adjustable to  
two heights.  
• Fuel Shut-Off Valve: 1/4 turn increments  
(“OFF”, right tank, left tank, )  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
• Fuel gauge in left hand fuel tank.  
Electrical System  
– Steering is controlled by varying the position  
of the levers relative to each other.  
• Charging System: External Alternator  
• Charging Capacity: 60 amps  
• Battery Type: BCI Group 26  
• Battery Voltage: 12 Volt  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
• PTO Engagement Switch: Engages electric clutch  
(to drive belt) which engages mower blades.  
• Parking Brake Lever: Engages parking brake.  
• Polarity: Negative Ground  
• Deck Height Adjustment Lever: Sets cutting  
height to desired position.  
• Fuses: One 20 amp blade type; One 30 amp blade  
type  
• Deck Lift Assist Lever: Foot pedal that assists  
in raising the deck.  
Safety Interlock System  
• PTO must be disengaged, brake engaged, and  
motion control levers out (neutral lock) to start  
engine. (It is not necessary for the operator to be  
in the seat to start the engine.)  
Seat  
• Type: Deluxe suspension seat high back, low  
profile foam-in-place cushion (dampened,  
adjustable spring suspension) and armrests,  
adjustable back angle.  
16  
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Specifications  
• Mounting: Hinged to tilt up for access to  
hydraulic pumps, battery and other components.  
Held in tilted position with scissor—type links.  
Adjustable fore and aft seat track.  
• Discharge: Side  
• Blade Size: (3 ea.)  
– 60 inch Deck: 20.75 inches (52.7 cm)  
– 66 inch Deck: 22.75 inches (57.8 cm)  
– 72 inch Deck: 24.75 inches (62.9 cm)  
• Armrests: Molded adjustable flip-up armrests.  
• Seat Safety Switch: Incorporated into the  
Safety Interlock System. Time delay seat switch  
eliminates rough ground cut-outs.  
• Blade Spindles: Solid steel spindles with 1.18 inch  
(30 mm) I.D. bearings.  
• Deck Drive:  
Hydrostatic Ground Drive System  
– Electric clutch mounted on horizontal engine  
shaft. “B” Section belt (with self-tensioning  
idler) from electric clutch to transfer shaft  
mounted on deck.  
• Hydrostatic Pumps: Two Hydro Gear PW  
variable displacement piston pumps.  
• Wheel Motors: Two Parker/Ross with 1 1/4 inch  
tapered shafts.  
– Blades are driven by one “B” Section belt  
(w/self-tensioning idler) from transfer shaft  
on deck to blade spindles.  
• Hydraulic Oil Type: Exmark Premium Hydro oil.  
• Hydraulic Oil Capacity: 5.5 qt. (5.2 L)  
• Hydraulic Filter: Replaceable cartridge type.  
P/N 103-2146: 25 microns, No bypass  
• Speeds:  
• Deck:  
Full floating deck is attached to out-front support  
frame. Six anti-scalp rollers provide maximum  
turf protection. Deck design allows for bagging,  
mulching or side discharge.  
– 0-12.0 mph (19.3 km/hr) forward.  
– 0-8.0 mph (12.9 km/hr) reverse.  
• Deck Depth:  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
– 60 inch Deck: 6.0 inches (15.2 cm)  
– 66 inch Deck: 6.0 inches (15.2 cm)  
– 72 inch Deck: 6.0 inches (15.2 cm)  
• Cutting Height Adjustment:  
Tires & Wheels  
Drive  
Front Caster  
An extra-long cushioned lever is used to adjust  
the cutting height from 1 inch (2.5 cm) to 5 inches  
(12.7 cm) in 1/4 inch (6.4 mm) increments. The  
cutting height adjustment handle has a transport  
position and all adjustments can be made while  
the operator remains seated. Units also have a  
foot operated deck lift assist lever to aid in raising  
the deck.  
Pneumatic  
(Air-Filled)  
Semi-Pneumatic  
Deck Size  
Quantity  
60, 66, & 72  
2
All Decks  
2
Tread Size  
“Multi-Trac  
C/S”  
Smooth  
Size  
26 x 12.00-12  
4
13 x 6.50-6  
• Mulching Kit: Optional.  
Ply Rating  
Pressure  
10 psi (69 kPa)  
Cutting Deck  
• Cutting Width:  
– 60 inch (152.4 cm)  
– 66 inch (167.6 cm)  
– 72 inch (182.9 cm)  
17  
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Specifications  
Dimensions  
Torque Requirements  
Bolt Location  
Torque  
Overall Width:  
Blade Drive Sheave  
Mounting Nut  
90-110 ft-lb (122-149 N-m)  
60 inch  
Deck  
66 inch  
Deck  
72 inch  
Deck  
Cutter Housing Spindle  
Nut  
160-185 ft-lb (217-251  
N-m)  
Without  
Deck  
53.5 inches 57.3 inches 61.5 inches  
(135.9 cm) (145.5 cm) (156.2 cm)  
Blade Mounting Bolt  
(lubricate with anti-seize)  
55-60 ft-lb (75-81 N-m)  
30-35 ft-lb (41-47 N-m)  
30-35 ft-lb (41-47 N-m)  
50-55 ft-lb (68-75 N-m)  
Deflector  
Up  
61.4 inches 68.0 inches 74.3 inches  
(156.0 cm) (172.7 cm) (188.7 cm)  
Engine Deck/Front Frame  
Mount Bolts  
Deflector  
Down  
72.8 inches 79.4 inches 85.8 inches  
(184.9 cm) (201.7 cm) (217.9 cm)  
Anti-Scalp Roller Nyloc  
Nut See Figure 10  
Overall Length:  
Anti-Scalp Roller Hex  
Capscrew See Figure 10  
60 inch  
Deck  
66 inch  
Deck  
72 inch  
Deck  
Engine Mounting Bolts  
Wheel Lug Nuts  
15-20 ft-lb (20-27 N-m)  
90-95 ft-lb (122-129 N-m)  
72-77 ft-lb (98-104 N-m)  
Roll Bar -  
Up  
81.9 inches 83.4 inches 85.8 inches  
(208.0 cm) (211.8 cm) (217.9 cm)  
Wheel Motor Mounting  
Bolts  
Roll Bar -  
Down  
92.5 inches 94.0 inches 96.4 inches  
(235.0 cm) (238.8 cm) (244.9 cm)  
Wheel Hub Slotted Nut  
minimum 125 ft-lb  
(169 N-m)  
Rollover Protection System 30-35 ft-lb (41-47 N-m)  
(Roll Bar) Mounting Bolts  
Overall Height:  
Roll Bar - Up  
Roll Bar - Down  
Deck Drive Jackshaft Nut 75-80 ft-lb (102-108 N-m)  
72.7 inches (184.7 cm)  
53.8 inches (136.7 cm)  
Clutch Retaining Bolt  
55-60 ft-lb (75-81 N-m)  
(secured with threadlocker)  
Tread Width: (Center to Center of  
Tires, Widthwise)  
60 inch  
Deck  
66 inch  
Deck  
72 inch  
Deck  
Drive  
Wheels  
41.9 inches 45.9 inches 45.9 inches  
(106.4 cm) (116.6 cm) (116.6 cm)  
Caster  
Wheels  
37.3 inches 42.3 inches 47.3 inches  
(94.7 cm)  
(107.4 cm) (120.1 cm)  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
60 inch Deck  
66 inch Deck  
72 inch Deck  
56.0 inches  
(142.2 cm)  
57.6 inches  
(146.3 cm)  
60.2 inches  
(152.9 cm)  
Curb Weight:  
60 inch Deck  
66 inch Deck  
72 inch Deck  
1545 lb (701 kg) 1595 lb (723 kg) 1645 lb (746 kg)  
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Operation  
Product Overview  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Controls  
Motion Control Levers  
The motion control levers located on each side of the  
console control the forward and reverse motion of  
the machine. The levers control the flow of hydraulic  
oil from the hydrostatic pump to the drive wheel  
motor for each side.  
Moving the levers forward or backward turns the  
wheel on the same side forward or in reverse. Wheel  
speed is proportional to the amount the lever is  
moved.  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 6).  
Figure 4  
1. Motion Control Lever  
2. Parking Brake Lever  
3. Height-of-Cut Lever  
5. Controls  
6. Seat Belt  
7. Roll Bar  
Throttle Control  
Located on right fuel tank.  
4. Fuel Cap (Both Sides)  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
and moving the throttle lever to the rear will decrease  
engine speed. Moving the throttle forward into the  
detent is full throttle.  
Brake Lever  
Located on left side of unit, just to the front of the  
console.  
The brake lever engages a parking brake on the drive  
wheels.  
Pull the lever up and rearward to engage the brake.  
Push the lever forward and down to disengage the  
brake.  
The unit must be tied down and brake engaged when  
transporting.  
Ignition Switch  
Located on right fuel tank.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
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Operation  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position).  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running. Unhook seat  
latch and tilt seat up to gain access to pumps.  
With a 5/8 inch wrench, turn both valves one turn  
counterclockwise to release drive system. Turn  
clockwise to reset system. Do Not overtighten. Do  
Not tow machine.  
Note: Brake must be engaged, motion control levers  
out (neutral lock position) and PTO switch “OFF” to  
start engine. (It is not necessary for the operator to  
be in the seat to start the engine.)  
Tracking Adjustment Knob  
Hour Meter  
Located under the seat on the LH pump control link.  
Located on the right fuel tank.  
Rotating this knob allows fine tuning adjustments so  
that the machine tracks straight with the drive levers  
in the full forward position.  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If the  
ignition switch is left on without engine running,  
hour meter will not run.  
Stop machine and wait for all moving parts to stop.  
Engage park brake. Unhook seat latch and tilt seat  
forward to gain access to the tracking knob. Rotate  
the knob clockwise (as viewed from the rear of the  
machine) to cause the machine to track more to the  
right and counterclockwise to cause the machine  
to track more to the left. Adjust in quarter-turn  
increments until the machine tracks straight. Check  
that the machine does not creep when in neutral with  
the park brake disengaged.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Fuel Shut-Off Valve  
Located directly below the right side of console, next  
to the cubby.  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
Important: Do Not rotate the knob too far, as  
this may cause the machine to creep in neutral.  
Refer to the Motion Control Linkage Adjustment  
section in Maintenance.  
The valve has three positions, each position made  
in 1/4 turn increments.  
PTO Engagement Switch  
Fuel Flow  
“Off ”  
Valve Handle Position  
Located on right fuel tank.  
Right  
Down  
Left  
Switch must be pulled out to the “ROTATE”  
position to engage the blades. Switch is pushed in to  
the “STOP” position to stop the blades.  
Right Tank  
Left Tank  
Coolant Temperature Gauge  
Fuel Gauge  
Located at the front of the left fuel tank.  
Located on the left fuel tank.  
The coolant temperature gauge monitors the  
temperature of the engine coolant. An engine  
overheating condition is indicated by the red area  
on the gauge and an alarm will sound. Refer to the  
Warning Buzzer in the Troubleshooting section.  
The fuel gauge monitors the amount of fuel in the left  
tank only. Use the fuel from the right fuel tank first.  
When the right fuel tank is empty, switch to the left  
fuel tank. Fuel gauge will monitor the remaining fuel.  
Drive Wheel Release Valves  
Voltmeter  
Located on the top right front corner of hydrostatic  
pumps.  
Located next to the Coolant Temperature Gauge at  
the front of the left fuel tank.  
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Operation  
The voltmeter measure the voltage output of the  
alternator. Both high and low voltages will potentially  
damage the battery.  
Use of summer grade diesel fuel above 20°F (-7°C)  
will contribute toward longer life of the pump  
components.  
Important: Do Not use kerosene or gasoline  
instead of diesel fuel. Failure to observe this  
caution will damage the engine.  
Glow Plug Switch and Light  
Located on the right fuel tank.  
Depress and hold the switch to heat the glow plugs.  
The glow plug light comes on when the glow plug  
switch is depressed. The glow plug light indicates the  
glow plugs are preheating the combustion chamber.  
Biodiesel Ready  
This machine can also use a biodiesel blended fuel  
of up to B20 (20% biodiesel, 80% petrodiesel). The  
petrodiesel portion should be low or ultra low sulfur.  
Low Oil Pressure Light  
Observe the following precautions:  
Located on the right fuel tank.  
• The biodiesel portion of the fuel meet  
specification ASTM D6751 or EN14214.  
Light will come on when engine oil pressure is low  
or lost.  
• The blended fuel composition should meet  
ASTM D975 or EN590.  
Warning Buzzer  
• Painted surfaces may be damaged by biodiesel  
blends.  
Located behind the seat under the air deflector on  
the electrical panel.  
• Use B5 (biodiesel contend of 5%) or lesser blend  
in cold weather.  
The buzzer is a warning signal that the engine  
is overheating or the oil pressure is low. See the  
Troubleshooting section.  
• Monitor seals, hoses, gaskets in contact with fuel  
as they may be degrade over time.  
• Fuel filter plugging maybe expected for a time  
after converting to biodiesel blends.  
Pre-Start  
• Contact your distributor if you wish for more  
information on biodiesel.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Filling the Fuel Tank  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
1. Shut the engine off and set the parking brake.  
2. Clean around each fuel tank cap and remove the  
cap. Add fuel to both fuel tanks, until the level is  
1/4 to 1/2 inch (6 to 13 mm) below the bottom  
of the filler neck. This space in the tank allows  
the fuel to expand. Do Not fill the fuel tanks  
completely full.  
Determining Fuel  
The engine runs on clean, fresh diesel fuel with  
a minimum octane rating of 40. Purchase fuel in  
quantities that can be used within 30 days to ensure  
fuel freshness.  
3. Install fuel tank caps securely. Wipe up any fuel  
that may have spilled.  
Use summer grade diesel fuel (No. 2-D) at  
temperatures above 20°F (-7°C) and winter grade  
diesel fuel (No. 1-D or No. 1-D/2-D blend) below  
20° F (-7° C). Use of winter grade diesel fuel at lower  
temperatures provides lower flash point and pour  
point characteristics, therefore easing startability and  
lessening chances of chemical separation of the fuel  
due to lower temperatures (wax appearance, which  
may plug filters).  
4. If possible, fill the fuel tank after each use. This  
will minimize possible buildup of condensation  
inside the fuel tank.  
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Operation  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
Operating Instructions  
3. Push in on the PTO switch to the “STOP”  
position.  
Raise the Rollover Protection System  
(ROPS)  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
Important: Lower the roll bar only when  
absolutely necessary.  
4. On a warm engine, place the throttle in the  
“SLOW” position.  
1. Remove the hairpin cotter pins and remove the  
two roll bar pins (Figure 5).  
5. On a cold engine, (below 14°F (-10°C)), place the  
throttle in the “MIDWAY” position.  
2. Raise the roll bar to the upright position and  
install the two pins and secure them with the  
hairpin cotter pins (Figure 5).  
Note: Do Not use fuel left over from summer.  
Important: Always use the seat belt with the  
roll bar in the raised position. Ensure that the  
rear part of the seat is secured with the seat  
latch.  
6. Turn ignition switch to the “ON” position.  
Depress the glow plug switch and the glow plug  
light will turn on. Hold switch as required by  
chart below. Turn the ignition switch to the  
“START” position. Release the ignition switch as  
soon as the engine starts.  
Glow Plug Chart  
Ambient Temperature  
Above 50°F (10°C)  
Hold Glow Plugs On  
NO NEED  
Approximately 5 seconds  
Approximately 10 seconds  
20 seconds  
50°F (10°C) to 23°F (-5°C)  
Below 23°F (-5°C)  
Limit of continuous use  
The glow plug light, located near the glow  
plug switch, will illuminate when the switch is  
depressed. The glow plug light indicates the glow  
plugs are preheating the combustion chamber.  
Important: Do Not crank the engine  
continuously for more then ten seconds at a  
time. If the engine does not start, allow a 30  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor and/or fuel  
solenoid.  
Figure 5  
1. Roll bar  
2. Raised position  
3. Pin  
4. Hairpin cotter pin  
7. Move the throttle to the “SLOW” (if in  
“MIDWAY”) and let the engine warm up a few  
minutes before moving the throttle to the “FAST”  
position.  
Open the Fuel Shut-Off Valve  
Turn the valve to the LH or RH tank.  
Starting the Engine  
1. Move the motion control levers out to the neutral  
lock position.  
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Operation  
5. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Engaging the PTO  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
DANGER  
An uncovered discharge opening will allow  
objects to be thrown in an operator’s or  
bystander’s direction. Also, contact with the  
blade could occur. Thrown objects or blade  
contact can cause serious injury or death.  
Driving the Machine  
CAUTION  
Machine can spin very rapidly by positioning  
one lever too much ahead of the other.  
Operator may lose control of the machine,  
which may cause damage to the machine  
or injury.  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless  
there is a grass collection system or mulch  
kit in place and working properly.  
• Use caution when making turns.  
The PTO push-pull switch engages the cutting blades.  
Be sure that all persons are clear of the mower deck  
and discharge area before engaging PTO.  
• Slow the machine down before making  
sharp turns.  
Important: Operator must be in seat before the  
PTO can be engaged.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
before the motion control levers can be moved in  
or the engine will stop.  
1. Set the throttle to the “MIDWAY” position.  
2. Pull the PTO switch outward to the “ROTATE”  
position.  
When levers are centered in the T-slot the drive  
system is in the neutral position. With levers moved  
out in the T-slot the drive system is in the neutral lock  
position (Figure 6).  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
1. Set the throttle to the “MIDWAY” position.  
2. Push the PTO switch in to the “STOP” position  
to disengage the blades.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Disengage the PTO.  
3. Move the motion control levers out to the neutral  
lock position.  
4. Engage the parking brake.  
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Operation  
Figure 6  
1. Handles Out (Neutral  
Lock)  
5. Neutral  
2. Handles In (Neutral)  
6. Reverse  
3. Front of Unit  
4. Forward  
7. Neutral Lock  
Figure 7  
1. Handles Out (Neutral  
4. Forward  
Driving Forward  
Lock)  
1. Release the parking brake.  
2. Handles In (Neutral)  
3. Front of Unit  
5. Reverse  
2. Move the motion control levers inward to the  
center to the neutral unlocked position.  
Driving in Reverse  
3. To move forward in a straight line apply equal  
forward pressure to both levers.  
1. Move the motion control levers inward to the  
center to the neutral unlocked position.  
To turn left or right, pull the motion control lever  
back toward neutral in the direction desired.  
2. To move rearward in a straight line applying equal  
pressure pull both motion control levers rearward.  
The machine will move faster the farther the  
motion control levers are moved away from  
neutral.  
To turn left or right, release pressure on the  
motion control lever toward the direction desired.  
3. To stop, push the motion control levers to the  
neutral position.  
4. To stop, pull the motion control levers back to  
the neutral position.  
Adjusting the Cutting Height  
The cutting height of the mower deck is adjusted  
from 1 to 5 inches (2.54 cm to 12.7 cm) in 1/4 inch  
(6.4 mm) increments.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
2. Disengage the PTO.  
3. Raise the deck height lever to the transport  
position (also the 5 inch (12.7 cm) cutting height  
position)(Figure 8).  
The deck can be raised by pulling the deck lever  
up and/or by pushing down on the foot operated  
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Operation  
deck lift assist lever located at the front right  
corner of the floor pan.  
6. Place the rollers in one of the positions shown  
(Figure 9). Rollers will maintain 3/4 inch (19 mm)  
clearance to the ground to minimize gouging and  
roller wear or damage.  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
Figure 9  
For cutting heights above 4.0 inches (102 mm) use the  
bottom hole. The rollers will still be effective against  
scalping.  
Figure 8  
1. Anti-scalp roller  
mounting bracket  
2. Cutting height  
1. Lever in transport and 5 inch (12.7 cm) cutting height  
position  
For Maximum Deck Flotation, place the rollers  
one hole position lower. Rollers should maintain  
1/4 inch (6.4 mm) clearance to the ground. Do  
Not adjust the rollers to support the deck.  
4. Insert the height adjustment pin into the hole  
corresponding to the desired cutting height and  
install the hairpin cotter pin.  
See the decal on the side of the deck lift plate for  
cut heights.  
7. Be sure the roller bolts are installed with the  
spring disc washer between the head of the bolt  
and the mounting bracket.  
5. Move the deck height lever out of the transport  
position (or 5 inch (12.7 cm) cutting height) and  
down onto the height adjustment pin to mow at  
selected height.  
Note: The foot operated deck lift assist lever  
can be used to momentarily lift the deck to clear  
objects. Be sure that PTO is disengaged.  
Note: The foot operated deck lift assist lever  
can be used to momentarily lift the deck to clear  
objects. Be sure that PTO is disengaged.  
8. Torque the 3/8–24 x 2 Gr 8 hex capscrew to  
50–55 ft-lb (68–75 N-m) (Figure 10).  
Adjusting the Anti-Scalp Rollers  
It is recommended to change the anti-scalp roller  
position when the height of cut has changed.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
2. Disengage the PTO.  
3. Engage the park brake.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
5. After adjusting the height of cut, adjust the  
anti-scalp rollers by removing the bolt and spring  
disc washer.  
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Operation  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over.  
Backward tip-over could cause serious injury  
or death.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
Figure 10  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
1. Spring disc washer  
3. 3/8 nyloc-torque to 30-35  
ft-lb (41-47 N-m)  
4. 3/8-24 x 2 GR8 torque to  
50-55 ft-lb (68-75 N-m)  
(cone towards bolt head)  
2. Front right anti-scalp  
bracket shown  
• Avoid sudden acceleration while driving  
unit up a ramp to avoid tipping backward.  
9. If the 3/8 nyloc nut has been removed,  
re-install and torque to 30–35 ft-lb (41–47 N-m)  
(Figure 10).  
• Avoid sudden deceleration while backing  
unit down a ramp to avoid tipping  
backward.  
Transporting  
Loading a Unit  
Transporting a Unit  
Use extreme caution when loading units on trailers or  
trucks. One full width ramp that is wide enough to  
extend beyond the rear tires is recommended instead  
of individual ramps for each side of the unit. The  
lower rear section of the tractor frame extends back  
between the rear wheels and serves as a stop for  
tipping backward. Having a full width ramp provides  
a surface for the frame members to contact if the  
unit starts to tip backward. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
CAUTION  
This unit does not have proper turn  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck do not exceed 15°. A steeper angle  
may cause mower deck components to get caught as  
the unit moves from ramp to trailer or truck. Steeper  
angles may also cause the unit to tip backward. If  
loading on or near a slope, position the trailer or  
truck so it is on the down side of the slope and the  
ramp extends up the slope. This will minimize the  
ramp angle. The trailer or truck should be as level  
as possible.  
Do Not drive a unit on a public street or  
roadway.  
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Operation  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Avoid sudden acceleration when driving up a ramp  
and sudden deceleration when backing down a ramp.  
Both maneuvers can cause the unit to tip backward.  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch and  
engage parking brake, before you do any  
maintenance.  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check the rollover protections systems (roll bar) pins.  
• Check the seat belt.  
• Check for loose hardware.  
• Check engine coolant level.  
Before each use or daily  
• Clean the engine cooling system.  
• Remove accumulated debris from engine.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the deck.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the height adjustment shaft bearings.  
• Grease the rear deck struts.  
Every 40 hours  
• Drain fuel filter/water separator.  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
Owner’s Manual for additional information.)  
• Clean the engine cooling system.  
Every 50 hours  
Every 100 hours  
Every 160 hours  
• Change the engine oil. (May need more often under severe conditions.)  
• Lubricate the brake handle pivot.  
• Lubricate the brake rod bushings.  
• Lubricate the motion control bronze bushings.  
• Grease the brake brackets.  
Every 200 hours  
Every 400 hours  
• Replace the fuel filter/water separator (more often in dirty or dusty conditions).  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
Every 500 hours  
Every 600 hours  
• Replace the air cleaner elements. (May need more often under severe conditions. See the  
Engine Owner’s Manual for additional information.)  
Every 4,000 hours  
Monthly  
Change engine coolant. Dex-Cool© extended life coolant (orange color)  
• Check the battery charge.  
• Change the engine oil if operated less than 100 hours.  
• Grease the front caster wheel hubs.  
• Grease front caster pivots.  
• Grease the deck drive belt idler arm.  
• Grease the mule drive belt idler arm.  
• Grease the pump drive belt idler arm.  
• Lubricate the caster wheel hubs.  
Yearly  
Periodic Maintenance  
Check Battery Charge  
Service Interval: Monthly  
Check Engine Oil Level  
Service Interval: Before each use or daily  
WARNING  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
CALIFORNIA  
Proposition 65 Warning  
2. Check with engine cold.  
Battery posts, terminals, and related  
accessories contain lead and lead  
3. Raise radiator to gain access to dipstick.  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
CAUTION  
If the radiator prop rod is not securely  
positioned in the notch the radiator may fall.  
Falling radiator could cause serious injury.  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
Be sure the prop rod is engaged securely in  
the notch at the far right side of the slot.  
4. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Remove the dipstick  
and read the oil level.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
5. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Use oil as specified in  
Engine Owner’s Manual. Do Not overfill.  
Check the voltage of the battery with a digital  
voltmeter. Locate the voltage reading of the battery  
in the table below and charge the battery for the  
recommended time interval to bring the charge up to  
a full charge of 12.6 volts or greater.  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Important: Make sure the negative battery  
cables are disconnected and the battery charger  
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Maintenance  
used for charging the battery has an output of  
16 volts and 7 amps or less to avoid damaging  
the battery (see chart for recommended charger  
settings).  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
Figure 12  
1. Use wrench here for  
1 Hour  
16 volts/7  
amps  
2. Torque to 55-60 ft-lb  
(75-81 N-m) Apply  
lubricant to threads  
as needed to prevent  
seizing. Copper-based  
anti-seize preferable.  
Grease acceptable  
substitute.  
blade installation. This  
nut has been torqued to  
90–110 ft-lb (122–149  
N-m)  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
C. Apply lubricant to threads of blade bolt as  
needed to prevent seizing. Copper-based  
anti-seize preferable. Grease acceptable  
substitute. Install blade bolt finger tight. Place  
wrench on the top spindle nut then torque the  
blade bolts to 55-60 ft-lb (75-81 N-m).  
Check Mower Blades  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lift deck and secure in raised position as stated  
in the Clean Grass Build-Up Under Deck  
procedure.  
WARNING  
Incorrect installation of the blade or  
components used to retain the blade can  
be dangerous. Failure to use all original  
components and assembled as shown could  
allow a blade or blade component to be  
thrown out from under the deck resulting in  
serious personal injury or death.  
3. Inspect blades and sharpen or replace as required.  
4. Reinstall the blades (if they were removed) in the  
following order:  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
Figure 11  
1. Install bushing in blade prior to installing bushing in  
spindle.  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
B. Install bushing/blade assembly into spindle.  
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Maintenance  
motion control levers moved out in the neutral  
lock position. The operator does not need to be  
in the seat to start the engine.  
Check Rollover Protections  
Systems (Roll Bar) Pins  
Service Interval: Before each use or daily  
Try to start with operator in seat, parking brake  
disengaged, PTO disengaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Make sure latch pin and hair pin are fully installed  
and lanyard is in good condition.  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Check Seat Belt  
Service Interval: Before each use or daily  
Visually inspect seat belt for wear, cuts, and proper  
operation of retractor and buckle. Replace before  
operating if damaged.  
Try to start with operator in seat, parking  
brake engaged, PTO disengaged, and the left  
motion control lever in, starter must not crank,  
repeat again with the right lever in, then with  
both levers in - starter must not crank.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
2. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
Run engine at one-third throttle, engage PTO  
and raise offof seat (but do not get off of  
machine) engine must initiate shutdown after  
1/2 second has elapsed.  
Service Air Cleaner  
Service Interval: Every 50 hours—Service  
the air cleaner. (May  
Run engine at one-third throttle, with brake  
disengaged, move levers in and raise off seat (but  
do not get off of machine) engine must initiate  
shutdown after 1/2 second has elapsed.  
need more often under  
severe conditions. See  
the Engine Owner’s  
Manual for additional  
information.)  
Again, run engine at one-third throttle, brake  
engaged, and move left motion control lever in  
- engine must initiate shutdown.  
Every 600 hours— Replace  
the air cleaner elements.  
(May need more often  
under severe conditions.  
See the Engine Owner’s  
Manual for additional  
information.)  
Repeat again moving the right lever in, then  
moving both levers in - engine must initiate  
shutdown whether operator is on seat or not.  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
2. Unhook two air filter canister latches to gain  
access to the air cleaner element.  
3. Remove air cleaner canister cover and remove  
outer element.  
4. Check the condition of the paper element.  
Replace if dirty, bent or damaged.  
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Maintenance  
5. Check the condition of the inner element. Replace  
whenever it appears dirty, typically every other  
time the paper element is replaced. Clean the base  
around the inner element before removing, so  
dirt does not get into the engine.  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
6. Do Not wash or use pressurized air to clean  
2. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use Exmark  
Premium Hydro oil. Replace hydraulic reservoir  
cap and tighten until snug. Do Not overtighten.  
paper element or inner element.  
7. Reinstall elements. Position the cover so that the  
rubber dust ejector is pointing downward and  
secure with retaining clips.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
Change Engine Oil  
temperature of the oil. The “HOT” level shows  
the level of oil when it is at 225°F (107°C). The  
“COLD” level shows the level of the oil when  
it is at 75°F (24°C). Fill to the appropriate level  
depending upon the temperature of the oil. For  
example: If the oil is about 150°F (65°C), fill to  
halfway between the “HOT” and “COLD” levels.  
If the oil is at room temperature (about 75°F  
(24°C)), fill only to the “COLD” level.  
Service Interval: After the first 5 hours  
Every 100 hours/Yearly  
(whichever comes first)  
(May need more often  
under severe conditions.)  
Yearly if operated less  
than 100 hours.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Drain oil while engine is warm from operation.  
Check Tire Pressures  
Service Interval: Every 40 hours  
3. Fasten deck belt spans together with mechanics  
wire or tie wrap to prevent oil from draining onto  
belt.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
4. Place pan under machine to catch oil. Remove  
the oil drain plug. Allow oil to drain and replace  
oil drain plug.  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 10 psi (69 kPa).  
5. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of oil on the surface of the rubber seal. Turn  
filter clockwise until rubber seal contacts the filter  
adapter then tighten filter an additional 1 full turn.  
4. Semi-pneumatic caster tires do not need to be  
inflated.  
Note: Do Not add any type of tire liner or foam  
fill material to the tires. Excessive loads created by  
foam filled tires may cause failures to the hydro drive  
system, frame, and other components. Foam filling  
tires will void the warranty.  
6. Unlatch radiator and lift it up to access oil fill.  
Clean around oil fill cap and remove cap. Fill  
to specified capacity and replace cap. Use oil  
recommended in engine owner’s manual. Do Not  
overfill.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
7. Remove wire or tie wrap from belt spans  
8. Start the engine at idle for 5 minutes. Stop engine  
and wait three minutes, then check the oil level.  
If required, add oil to bring level to the “FULL”  
mark on the dipstick. Do Not overfill.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up. Remove the  
air detector panel on front side of the engine  
compartment to check pump drive belt and  
alternator belt.  
9. Check for leaks, including around the oil filter.  
10. Wipe up any spilled oil.  
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Maintenance  
3. Remove left and right belt shields on deck and lift  
up floor pan to inspect deck drive belt.  
4. Check under machine to inspect the mule  
drive belt. Refer to Mule Drive Belt Tension  
Adjustment section in Adjustments.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Number 6 (Mule Drive Belt Idler Arm) Located  
Under Engine Frame  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
Number 7 (Pump Drive Belt Idler Arm) Located  
Under Engine Frame  
1. Front  
Caster wheel  
hubs  
*0  
*0  
1
2
2
5
*Yearly  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
2. Front  
Caster  
Pivots  
*Yearly  
3. Height  
Adjustment  
Shaft  
40 Hours  
Lubricate Caster Wheel Hubs  
Bearings  
Service Interval: Yearly  
1
1
4. Deck  
Drive Belt  
Idler Arm  
Yearly  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1
1
2
1
200 Hours  
Yearly  
5. Brake  
Brackets  
6. Mule  
Drive Belt  
Idler Arm  
7. Pump  
Drive Belt  
Idler Arm  
1
1
1
2
Yearly  
8. Deck  
40 Hours  
Rear Struts  
Figure 13  
1. Seal guard  
2. Spacer nut with wrench  
flats  
* See step 3 for special lubrication instructions on  
the front caster pivots and the Lubricate Caster  
Wheel Hubs section for special lubrication  
instructions on the front casters wheel hubs.  
2. Remove caster wheel from caster forks.  
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Maintenance  
3. Remove seal guards from the wheel hub.  
Lubricate Brake Handle Pivot  
Service Interval: Every 160 hours  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate bronze bushings on brake handle pivot  
with a spray type lubricant or light oil.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
Lubricate Brake Rod  
Bushings  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
Service Interval: Every 160 hours  
7. Insert one bearing, one new seal into the wheel.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
2. Unhook seat latch and tilt seat up.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
3. Lubricate bronze bushings on each end of brake  
rod shaft with a spray type lubricant or a light oil  
(bushings are located to the inside of the flange  
bearings).  
Lubricate Motion Control  
Bronze Bushings  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
2. Unhook seat latch and tilt seat up.  
3. Lubricate bronze bushings on flange bearings  
securing the motion control arm shafts with a  
light oil or a spray type lubricant.  
11. Insert the second bearing and new seal into the  
wheel.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
Drain Fuel Filter/Water  
Separator  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
2. Place a drain pan under the fuel filter and loosen  
the drain plug approximately 1 turn.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
3. Water should drain.  
4. When fuel begins to flow from the filter, tighten  
the drain plug.  
Important: Water or other contaminants in fuel  
can severely damage fuel pump and/or the other  
engine components.  
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Maintenance  
Important: Before reinstalling new filter, fill  
it with Exmark Premium Hydro oil and apply  
a thin coat of oil on the surface of the rubber  
seal.  
Change Fuel Filter/Water  
Separator  
Service Interval: Every 400 hours/Yearly  
(whichever comes first)  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
(more often in dirty or  
dusty conditions).  
5. Fill reservoir as stated in Check Hydraulic Oil  
Level section.  
DANGER  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Use of improper components can result in  
system failure, fuel leakage and possible  
explosion.  
Hydro Oil  
Change Interval  
500 Hours  
• Ensure that an Authorized Service Dealer  
replace the fuel filter and any components  
for the fuel system.  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
• Use only approved fuel lines, hose clamps  
and fuel filters for high pressure systems.  
6. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
Change Inline Fuel Filter  
Service Interval: As required  
7. Start engine and move throttle control ahead to  
full throttle position. Move the speed control  
levers to the full speed and run for several  
minutes. Shut down machine and recheck oil  
level.  
An inline fuel filter is installed between the fuel tank  
and the fuel pump. Replace when necessary.  
Replacement Filters  
Note: Do Not change hydraulic system oil (except  
for what can be drained when changing filter), unless  
it is felt the oil has been contaminated or been  
extremely hot.  
Exmark P/N 112-7836  
Change Hydraulic System  
Filter  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
Service Interval: After the first 250 hours  
Wheel Hub - Slotted Nut  
Torque Specification  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
Service Interval: After the first 100 hours  
Every 500 hours thereafter  
When tightening the slotted nut on the wheel motor  
tapered shaft:  
Note: Use only Exmark P/N 103-2146.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. Torque the slotted nut to 125 ft-lb (169 N-m).  
2. Raise seat.  
2. Check distance from bottom of slot in nut to  
inside edge of hole. Two threads (0.1 inch) or less  
should be showing.  
3. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
3. If more than two threads (0.1 inch) are showing  
remove nut and install washer (P/N 1-523157)  
between hub and nut.  
4. Unscrew filter to remove and allow oil to drain  
from reservoir.  
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Maintenance  
4. Torque the slotted nut to 125 ft-lb (169 N-m).  
Change Engine Coolant  
Service Interval: Every 4,000 hours/Every 4  
years (whichever comes  
5. Then tighten nut until the next set of slots line up  
with the cross hole in shaft.  
©
first) Dex-Cool extended  
life coolant (orange color)  
6. Replace cotter pin.  
Note: Do Not use anti-seize on wheel hub.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake. Machine must  
be positioned on level surface.  
Check Engine Coolant Level  
2. Unhook seat latch, tilt seat up and tilt hood  
forward to gain access to the cooling area. Do  
Not raise radiator, as it may not fully drain in that  
position.  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
3. View coolant level in overflow bottle on the left  
side of the engine compartment. Coolant level  
should be at the indicator line on the overflow  
bottle.  
WARNING  
Engine coolant is hot and pressurized and  
radiator and surrounding parts are hot. Spray  
or steam from hot, pressurized liquid in the  
engine cooling system and touching a hot  
radiator may cause severe burns.  
4. If the coolant level is low, open hood or raise  
radiator, remove the cap to the overflow bottle  
and fill to the indicator line. Units should only be  
filled with a 50/50 mix of Dex-Cool© extended  
life coolant and water. Dex-Cool© can be  
identified by its orange color.  
Allow the engine to cool completely before  
removing the radiator cap or servicing any  
component of the cooling system.  
WARNING  
CAUTION  
Engine coolant is toxic. Swallowing coolant  
can cause poisoning.  
Engine coolant is hot and pressurized and  
radiator and surrounding parts are hot. Spray  
or steam from hot, pressurized liquid in the  
engine cooling system and touching a hot  
radiator may cause severe burns.  
• Do Not swallow.  
• Keep out of reach of children and pets.  
Allow the engine to cool completely before  
removing the radiator cap or servicing any  
component of the cooling system.  
3. Drain coolant when engine is cool. Coolant may  
be drained from the radiator by removing the  
drain plug in the right rear corner. The engine  
block may be drained by removing the rear  
radiator hose and/or by opening the drain cock  
on the right-hand side of the engine block (see  
Figure 14).  
CAUTION  
Engine coolant is toxic. Swallowing coolant  
can cause poisoning.  
• Do Not swallow.  
• Keep out of reach of children and pets.  
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Maintenance  
7. Operate engine until the engine thermostat opens  
and coolant is circulating through the radiator  
core. As air is purged from the engine block and  
the coolant level drops, add additional coolant to  
the radiator.  
8. When the radiator is completely full and no  
additional coolant can be added, continue running  
and install the radiator cap. Make sure that the  
cap is completely seated by pressing down firmly  
while turning until the cap stops. Once the cap is  
installed, the engine may be stopped.  
Fuel Tank — Mounting  
Hardware Specifications  
Service Interval: As required  
Figure 14  
2. Drain cock  
1. Oil dipstick  
When installing the nuts on the fuel tank studs, fully  
tighten the nyloc nut and back off 1/2 turn. This  
allows for normal fuel tank expansion and contraction  
with changes in temperature and fuel levels.  
4. Reinstall all drain plugs and hoses and tighten  
drain cock.  
5. Fill radiator with a 50/50 mix of water and  
Dex-Cool© coolant as specified in the Check  
Engine Coolant Level Section, allowing some  
room (approximately 1/2 inch (12.7 mm)) for  
expansion. Add 50/50 coolant mix to overflow  
bottle on the left side of the engine as required  
to bring the level up to the indicator line on the  
bottle.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
• Pump drive sheave set screws.  
• Square head setscrews on Hydro pump control  
arms.  
WARNING  
• Sheave retaining bolt in the end of engine  
crankshaft.  
Engine compartment contains open belt  
drives, fans, and other rotating components  
that can cause injury. Fingers, hands, loose  
clothing, or jewelry can get caught by the  
rotating fan and drive shaft.  
• Caster wheel spacer nuts.  
• Fuel tank bulkhead fitting nuts.  
• Bolts retaining stub shaft to engine flywheel.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
• Do Not operate machine without the  
covers in place.  
• Keep fingers, hands, and clothing clear of  
rotating components.  
Fuel tank studs, where studs are inserted into tank.  
• Shut off engine, wait for moving parts to  
stop, engage parking brake and remove  
key, before performing maintenance.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
6. With the cap off the radiator, tilt hood closed and  
put the seat down. Start the engine as stated in  
the Operating Instructions Section. Return the  
seat up and hood forward to the open position.  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
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Maintenance  
• Under top cutter housing bearing guard.  
Adjustments  
Note: Disengage PTO, shut off engine, wait for  
all moving parts to stop, engage parking brake, and  
remove key before servicing, cleaning, or making any  
adjustments to the unit.  
• Between the jackshaft and bearings and the  
jackshaft and sheaves.  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
locations:  
Deck Leveling  
1. Position mower on a flat surface.  
On threads of Blade Bolts See Check Mower Blades  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
section.  
3. Check tire pressure in drive tires. Proper inflation  
pressure for tires is 10 psi (69 kPa). Adjust if  
necessary.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
4. Set anti-scalp rollers to top holes or remove them  
completely for this adjustment.  
5. Raise the deck to the 5 inch (12.7 cm) height  
position (also transport position) and take all force  
off of the two large deck lift springs by loosening  
the nuts at the front of each spring (Figure 15).  
6. Lower the deck to the 1 inch (2.54 cm) height  
position. Force the left rear deck support arm  
downward about 1/4 inch (6.4 mm) to get the  
deck to rest at the 1 inch height position. Place  
locking pliers between the rear swivel and spring  
stop to hold the deck in this position (Figure 15).  
7. Place a 3/4 inch (19 mm) thick block of wood  
under each of the two rear anti- scalp roller  
brackets and place one under one of the front  
center anti-scalp roller brackets.  
8. Loosen the two top chain bolts in slots in the rear  
deck lift arms. Loosen jam nuts and back off the  
socket head adjusting screws on the bottom of  
the arms until the chains are just loose. Turn the  
socket head adjusting screws in until slack is taken  
out of each chain. Tighten the jam nuts. Tighten  
the chain bolts in the deck lift arms making sure  
they don’t move while tightening.  
9. Loosen the four nuts which secure the front  
swivels (two per side) until the front chains are  
loose and front of deck is supported by the 3/4  
inch (19 mm) block. Do Not loosen the front  
chain hardware.  
10. On left side, adjust front swivel using the locking  
nut behind the swivel until the front chain is tight  
and all slack is removed from linkage. Do Not lift  
front of deck off 3/4 inch (19 mm) block. Secure  
38  
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Maintenance  
front swivel using locking nut in front of swivel.  
Repeat for right side.  
side engine deck support, is positioned between  
the centers of the two alignment holes in the  
left support plate (Figure 16 and Figure 17). It  
is necessary to adjust the belt tension when the  
center of the bolt head is at or below the center  
of the bottom alignment hole.  
11. Recheck that the 3/4 inch (19 mm) blocks fit just  
snugly under the brackets and that the tension on  
all the chains is approximately equal. Make sure  
all chain attachment bolts are tight. Reposition  
anti-scalp rollers and tighten securely.  
3. When adjustment is necessary, loosen the idler  
pulley on the right-hand side so it can move up  
and down in the slot.  
Place a wrench on the 3/8 inch nut in the center  
of the spring loaded pulley and apply upward  
pressure to relieve tension on the spring (a 1/2  
inch drive breaker bar and 9/16 inch socket works  
best).  
Figure 15  
Reposition the adjusting pulley to the bottom of  
the slot.  
1. Apply downward pressure here  
2. Place locking pliers here to hold spring  
3. 13–1/2 inches (34.3 cm) for cut heights at 2 inches or  
above or 14 inches (35.6 cm) for cut heights below 2  
inches  
4. Remove force on deck springs by loosening nuts here  
5. Swivel  
Note: When installing a new belt, it is necessary  
to reposition the right adjusting pulley upward in  
the slot in order to position the center of the spring  
loaded pulley between the alignment holes.  
6. Front of unit  
7. Socket head adjusting screw  
8. Jam nut  
12. Raise deck lift lever to the 5 inch (12.7 cm)  
cutting height position (Figure 8). Adjust spring  
compression until proper distance is obtained  
between the two large washers (Figure 15).  
Adjustment is made by turning the nut at the  
front of each spring (clockwise will shorten the  
spring, counterclockwise will lengthen the spring).  
Lock in position with jam nuts.  
Note: When above adjustments have been made,  
the front of the deck will be slightly lower than the  
rear of the deck.  
Figure 16  
1. Front of unit  
2. Alignment holes  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Mule Drive Belt Tension  
Adjustment  
Self-tensioning idler, adjust as follows:  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Check to make sure the center of the bolt head  
in the center of the spring loaded pulley, on left  
39  
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Maintenance  
be 1/8 inch (3.2 mm) away from the belt, with  
bolt-end of guide near end of slot (Figure 18).  
4. If adjustment is necessary, loosen the bolt securing  
the belt guide and make proper adjustment.  
Tighten hardware.  
Figure 17  
3. Right side idler pulley  
1. Spring idler pulley  
2. Front of unit  
(adjustable)  
Figure 18  
1. End of slot  
2. Belt guide  
Deck Belt Tension  
Self-tensioning - No adjustment necessary.  
Brake Link Adjustment  
Check to make sure brake is adjusted properly.  
1. Disengage brake lever (lever down).  
Alternator Belt Tension  
Stop engine, wait for all moving parts to stop and  
remove key. Engage parking brake.  
2. Measure the length of the spring. Measurement  
should be 2 13/16 inches (7.1 cm) between  
washers. (Figure 19).  
3. If adjustment is necessary, adjust the nyloc nut  
at the bottom of the spring to achieve 2 13/16  
inches (7.1 cm).  
Tilt seat and remove air deflector panel  
To tighten alternator belt, loosen both upper and  
lower alternator mounting bolts. Rotate alternator  
out, away from engine and retighten hardware to  
secure in place.  
When properly tensioned, the alternator belt will  
deflect 1/4 to 3/8 inch (7-9 mm) while applying 22  
pounds of force to the belt midway between fan and  
alternator.  
Belt Guide Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove the belt shield on the right side of mower  
deck.  
3. Note belt guide bolted to deck near the shield  
support stud and right-hand pulley. Guide should  
40  
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Maintenance  
Electric Clutch Adjustment  
No adjustment necessary.  
Reverse Indicator  
Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat forward.  
3. Begin with either the left or right motion control  
lever. Move lever to the neutral position and pull  
lever back until the clevis pin (on arm below pivot  
shaft) contacts the end of the slot (just beginning  
to put pressure on spring). (Figure 20).  
Figure 19  
6. Remove pin to adjust  
4. Check where lever is relative to notch in console  
(should be centered allowing lever to pivot  
outward to the neutral lock position).  
1. Lever down  
(disengaged)  
rod length for additional  
brake adjustment  
7. Trunnion roller  
2. Lever up (engaged)  
3. Nyloc nut below trunnion 8. Spring retainer bracket  
roller  
5. If adjustment is needed, loosen the nut against the  
yoke and while applying slight rearward pressure  
on the motion control lever, turn the head of the  
adjustment bolt in the appropriate direction until  
lever is centered (keeping rearward pressure on  
the lever will keep the pin at the end of the slot  
and allow the adjustment bolt to move the lever  
to the appropriate position). Tighten lock nut.  
4. Nyloc nut below spring  
5. 1/8 to 3/16 inch (3.2 to 10. Jam nut above trunnion  
4.8 mm)  
roller  
9. 2 13/16 inches (7.1 cm)  
Brake Adjustment  
1. Check for brake link 2 13/16 inches (7.1 cm)  
measurement as described in the Brake Link  
Adjustment section.  
6. Repeat on opposite side of unit.  
2. Engage the brake lever (lever up). The space  
between the brake spring bracket and the nyloc  
nut under the spring should measure 1/8 inch to  
3/16 inch (3.2–4.8 mm).  
3. If adjustment is necessary, loosen jam nut above  
the trunnion roller. Adjust the nyloc nut under  
the trunnion roller until distance listed above  
exists between the spring retainer bracket and the  
adjacent nyloc nut. Tighten the jam nut above  
the trunnion roller.  
4. If the correct gap can no longer be achieved  
because there is no clearance between the nyloc  
nut below the spring and the jam nut above  
the trunnion or there are no threads left on the  
bottom nyloc nut, the length of the brake rod can  
be adjusted. Remove a pin from a yoke at either  
end of the brake rod and lengthen (or shorten) the  
brake rod until the correct gap can be achieved by  
following steps 2 and 3.  
Figure 20  
1. Turn bolt here  
2. Lever centered in notch 5. Loosen here  
3. End of slot  
6. Reverse indicator  
4. Yoke  
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Maintenance  
Motion Control Linkage  
Adjustment  
WARNING  
Engine must be running and drive  
wheels must be turning so motion control  
adjustment can be performed. Contact with  
moving parts or hot surfaces may cause  
personal injury.  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
Figure 21  
Right-Hand Side of Unit  
1. Turn here to adjust  
2. Loosen here (right-hand  
thread)  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
6. Start engine. Brake must be engaged and  
motion control levers out to start engine.  
Operator does not have to be in the seat  
because of the jumper wire being used. Run  
engine at full throttle and release brake.  
7. The reverse indicator spring must be correct  
before the following adjustments can be made.  
See the Reverse Indicator Adjustment section.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
Note: The motion control lever needs to be in  
neutral while making any necessary adjustments.  
The left rod assembly controls the left wheel and  
the right rod assembly controls the right wheel.  
1. This adjustment must be made with the drive  
wheels turning. First raise the rear of machine  
up and support with jack stands (or equivalent  
support) just high enough to allow the drive  
wheels to rotate freely.  
8. Bring the motion control lever into the neutral  
position. Adjust RH pump control rod length  
by rotating the double nuts on the rod in the  
appropriate direction until the wheels slightly  
creep in reverse (Figure 21). Move the motion  
control lever to the reverse position and while  
applying slight pressure to the lever allow the  
reverse indicator spring to bring the levers back to  
neutral. The wheel must stop turning or slightly  
creep in reverse. When adjustment is complete,  
tighten lock nuts onto ball joints.  
2. Unhook seat latch and tilt seat forward.  
3. Remove the electrical connection from the seat  
safety switch, located directly to the left of the seat  
switch assembly beside the hydraulic oil reservoir.  
Temporarily install a jumper wire across the  
terminals in the connector of the main wiring  
harness.  
4. Run the unit at least 5 minutes with the drive  
levers at full forward speed to bring hydraulic  
system oil up to operating temperature.  
9. Bring the LH motion control lever into the  
neutral position. Adjust the LH pump control rod  
length by rotating the tracking adjustment knob in  
the appropriate direction until the wheels slightly  
creep in reverse. Move the motion control lever  
to the reverse position and while applying slight  
pressure to the lever allow the reverse indicator  
spring to bring the levers back to neutral. The  
5. Loosen lock nuts from the ball joints at each end  
of the pump control linkage (Figure 21).  
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Maintenance  
wheel must stop turning or slightly creep in  
reverse (Figure 22).  
Caster Pivot Bearings  
Pre-Load Adjustment  
Remove dust cap from caster and tighten nyloc  
nut until washers are flat and back off 1/4 of a  
turn to properly set the pre-load on the bearings.  
If disassembled, make sure the spring washers are  
reinstalled as shown in Figure 24.  
Figure 22  
Left-Hand Side of Unit  
1. Turn LH tracking adjustment knob. (Do Not loosen any  
nuts on LH side)  
10. Shut off unit. Remove jumper wire from wire  
harness connector and plug connector into seat  
switch.  
Motion Control Damper  
Adjustment  
Figure 24  
The top damper mounting bolt can be adjusted to  
obtain a more desired motion control lever resistance.  
See Figure 23 for mounting options.  
1. Spring disc washers  
Clutch Shim  
Some later model year units have been built with  
clutches that contain a brake shim. When the clutch  
brake has worn to the point where the clutch no  
longer engages consistently, the shim can be removed  
to extend the clutch life.  
Figure 23  
1. Motion control bracket  
2. Least resistance (softest feel)  
3. Medium resistance (medium feel)  
4. Most resistance (firmest feel)  
5. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt must  
protrude past end of nyloc nut after torque.  
6. Damper  
7. Damper must move freely on bolt.  
43  
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Maintenance  
A. Loosen both brake mounting bolts one-half  
to one full turn as shown below.  
Note: Do Not remove the brake pole from  
the field shell/armature. The brake pole has  
worn to match the armature and needs to  
continue to match after the shim is removed  
to ensure proper brake torque.  
Figure 25  
5. Brake spacer  
1. Armature  
2. Field shell  
3. Rotor  
6. Re-gap shim  
7. Brake pole  
4. Brake mounting bolt  
Figure 27  
Removing the Shim:  
1. Brake mounting bolt  
1. Stop engine, wait for all moving parts to stop,  
and remove key. Engage parking brake. Allow  
the machine to cool completely before starting  
these instructions.  
B. Using needle nose pliers, or by hand, take  
hold of the tab and remove the shim (Do Not  
discard the shim until proper clutch function  
has been confirmed).  
2. Using a pneumatic line, blow out any debris  
from under the brake pole and around the brake  
spacers.  
Figure 28  
Figure 26  
1. Shim  
C. Using a pneumatic line, blow out any debris  
from under the brake pole and around the  
brake spacers.  
3. Check the condition of the wire harness leads,  
connectors, and terminals. Clean or repair as  
necessary.  
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13  
N-m) +/-0.5 ft-lb (0.7 N-m).  
4. Verify that 12V is present at the clutch connector  
when the PTO switch is engaged.  
5. Measure the gap between the rotor and armature.  
If the gap is greater than .04 inch (1 mm), proceed  
with the following steps:  
E. Using a 0.010 inch thick feeler gauge, verify  
that a gap is present between the rotor and  
armature face on both sides of the brake pole  
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Maintenance  
as shown. (Due to the way the rotor and  
armature faces wear (peaks and valleys) it is  
sometimes difficult to measure the true gap.)  
does not engage properly, reference the  
Troubleshooting section.  
Figure 29  
1. Feeler gauge  
Figure 30  
1. Feeler gauge  
• If the gap is less than 0.010 inch, then  
reinstall the shim and reference the  
Troubleshooting section.  
• If the gap is sufficient, proceed to the  
safety check in step F.  
F. Perform the following safety check:  
a. Sit on the seat and start the engine.  
b. Make sure the blades Do Not engage  
with the PTO switch “off ” and the clutch  
disengaged.  
If the clutch does not disengage,  
reinstall the shim and reference the  
Troubleshooting section.  
c. Engage and disengage the PTO switch  
ten consecutive times to ensure the clutch  
is functioning properly. If the clutch  
45  
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Maintenance  
2. Remove air deflector panel from behind seat.  
Cleaning  
3. Clean around flywheel, cylinder head, injectors,  
and injector pump.  
Clean Engine Cooling  
System  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
4. Reinstall the air deflector panel.  
Important: Do Not use water to clean engine.  
Use low pressure compressed air. See Engine  
Owner’s Manual.  
conditions.)  
Cleaning of the Radiator  
Service Interval: Every 50 hours (May be  
required more often in dry  
CAUTION  
Excessive debris around the engine cooling  
air intake and inside of the pump drive  
belt compartment and damaged or missing  
rubber baffles can cause the engine and  
hydraulic system to overheat which can  
create a fire hazard.  
or dirty conditions.)  
1. Stop engine, wait for all rotating parts to stop and  
remove key. Engage parking brake.  
2. Allow engine to cool.  
3. Rotate seat and engine cover forward.  
• Clean all debris from inside of pump drive  
belt compartment daily.  
4. While holding fan up, remove the four screws  
attaching the fan to the shroud. Disconnect and  
remove the fan.  
• Clean debris from radiator screen and  
core daily.  
5. Using compressed air, blow out debris stuck  
between the fins of the entire radiator, both from  
the top down and from the bottom up.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean all debris from inside of pump drive belt  
compartment.  
6. If debris remains, it may be necessary to use water  
from a low pressure hose. If the radiator is clean,  
proceed to step 8.  
3. Wipe debris from screen in engine cover.  
4. Rotate engine cover forward and wipe debris  
from radiator core as required.  
7. Cover the engine with a piece of cardboard, or a  
plastic sheet. Squirt water down through the fins.  
Blow through with low pressure air from both  
directions. If debris remains, repeat until clean.  
5. Clean debris from radiator fins with compressed  
air.  
8. Re-assemble the fan to the radiator. Reconnect  
the fan.  
Important: If debris or air can not be blown  
through the radiator, see Cleaning of the  
Radiator section.  
9. Start the engine to ensure the fan is functioning  
properly.  
6. Inspect seals in engine cover and replace if  
necessary.  
Clean Debris From Machine  
Service Interval: Before each use or daily  
Remove Accumulated Debris  
from Engine  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Service Interval: Before each use or daily  
Engine parts should be kept clean to reduce the risk  
of overheating and ignition of accumulated debris.  
2. Clean off any oil, debris, or grass build-up on the  
machine and cutting deck, especially under deck  
belt shields, around the fuel tank, around engine  
and exhaust area.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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Maintenance  
Federal law states that batteries should not be placed  
in the garbage. Management and disposal practices  
must be within relevant federal, state, or local laws.  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
If a battery is being replaced or if the unit containing  
the battery is no longer operating and is being  
scrapped, take the battery to a local certified recycling  
center. If no local recycling is available return the  
battery to any certified battery reseller.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Raise deck to the transport (5 inch (12.7 cm)  
cutting height) position. Lift the front of unit  
and support unit using jack stands or equivalent  
support.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
3. Clean out any grass build-up from underside of  
deck and in discharge chute.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
Battery Disposal  
DANGER  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Do Not swallow electrolyte.  
47  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Starter does not crank.  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not set.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
6. Replace the blown fuse.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running.  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle is not in the correct position. 4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
7. Clean or replace the air cleaner element.  
8. Electrical connections are corroded, loose 8. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
9. Relay or switch is defective.  
1. Engine load is excessive.  
9. Contact an Authorized Service Dealer.  
Engine loses power.  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Vent hole in the fuel cap is plugged.  
6. Dirt in fuel filter.  
5. Clean or replace the fuel cap.  
6. Replace the fuel filter.  
7. Dirt, water, or stale fuel is in the fuel  
system.  
7. Contact an Authorized Service Dealer.  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats.  
1. Engine load is excessive.  
1. Reduce the ground speed.  
2. Oil level in the crankcase is low.  
3. Dirty air filter.  
4. Coolant level is low.  
2. Add oil to the crankcase.  
3. Clean or replace the air cleaner element.  
4. Add coolant.  
5. Debris on or around radiator.  
5. Remove debris.  
6. Water pump or alternator belt is worn,  
loose, or broken.  
6. Contact an Authorized Service Dealer.  
Mower pulls left or right (with levers fully  
forward).  
1. Tracking needs adjustment.  
1. Adjust the tracking.  
2. Tire pressure in drive tires not correct.  
2. Adjust tire pressure in the drive tires.  
3. Reverse indicator and motion control  
linkage need adjustment.  
3. Adjust the reverse indicator and the  
motion control linkage.  
Machine does not drive.  
1. By pass valve is not closed tight.  
1. Tighten the by pass valve.  
2. Change the belt.  
2. Drive or pump belt is worn, loose or  
broken.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Uneven cutting height.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration.  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
7. Belt is damaged.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
7. Install new belt.  
Blades do not rotate.  
1. Drive belt is worn, loose or broken.  
2. Drive belt is off pulley.  
1. Check the belt tension.  
2. Check belt for damage; replace if  
necessary. Install drive belt and check belt  
guide for correct position.  
3. Deck belt is worn, loose or broken.  
4. Deck belt is off pulley.  
3. Install new deck belt.  
4. Install deck pulley and check the idler  
pulley, idler arm and spring for correct  
position and function.  
5. Broken or missing idler spring.  
5. Replace the spring.  
Warning buzzer emits continuous beep. (See  
also Engine overheats).  
1. Temperature is increasing on coolant  
temperature gauge.  
1. Turn unit off and allow engine and engine  
components to cool.  
2. Coolant level is low.  
2. Add coolant.  
3. Debris on or around radiator.  
3. Remove debris.  
4. Water pump or alternator belt is worn,  
loose or broken.  
4. Contact Authorized Service Dealer.  
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Troubleshooting  
Problem  
Possible Cause  
1. Oil level is low.  
Corrective Action  
1. Check oil level.  
Warning buzzer emits intermittent beep.  
2. Oil leaking from engine.  
1. Fuse is blown.  
2. Contact Authorized Service Dealer.  
Clutch will not engage.  
1. Replace fuse. Check coil resistance,  
battery charge, charging system, and  
wiring connections and replace if  
necessary.  
2. Low voltage supply at the clutch.  
2. Check coil resistance, battery charge,  
charging system, and wiring connections  
and replace if necessary.  
3. Damaged coil.  
3. Replace clutch.  
4. Inadequate current supply.  
4. Repair or replace clutch lead wire or  
electrical system. Clean connector  
contacts.  
5. Remove shim or replace clutch.  
5. Rotor/armature airgap is too large.  
50  
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Schematics  
Schematics  
Electrical Diagram  
K C A  
K C A  
W O N R / B B L  
W O N R / B B L  
K C A  
P I N K / B L  
C A K B L  
C A K B L  
O R A N G E  
R E D  
K C A B L  
K C A  
W O N R / B B L  
K C A W O / B L Y E L L  
K C A W O / B L Y E L L  
O R A N G E  
K C A B L  
D E R / W O Y E L L  
K C A B L  
K C A B L  
K C A  
P I N K / B L  
E T I H W / K C A B L  
K C A  
K C A  
W O N R / B B L  
O R A N G E / B L  
P I N K  
. G R D E K E N  
. G R D E K E N  
K C A  
K C A  
O R A N G E / B L  
O R A N G E / B L  
C A K B L  
Y A G R  
C A K B L  
W O Y E L L  
. G R D E K E N  
. G R D E K E N  
V I O L E T  
Y A G R  
O R A N G E  
E U L B . T L  
E U L B . T L  
E U L B . T L  
O R A N G E  
V I O L E T  
O R A N G E  
O R A N G E  
Y A G R  
Y A G R  
. G R D E K E N  
N E E R G . T L  
Y A G R  
K C A B L  
. G T L R E E N  
E U L B . T L  
A T N  
N W O R B  
N W O R B  
R E D  
R E D  
K C A W O / B L Y E L L  
K C A W O / B L Y E L L  
E U L B . T L  
E U L B . T L  
K C A B L  
P I N K  
K C A B L  
K C A W O / B L Y E L L  
A T N  
A T N  
C A K B L  
C A K B L  
R E D  
G010235  
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Schematics  
Electrical Logic Schematic  
52  
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Schematics  
Hydraulic Diagram  
53  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of two years.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. or Canada. This warranty may only be  
assigned or transferred to a second (or third) owner by an  
authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
Owner’s Responsibilities  
The Exmark turf equipment, including any defective part,  
must be returned to an authorized Exmark service dealer  
within the warranty period. This warranty extends only to turf  
equipment operated under normal conditions. You must read  
the operator’s manual. You must also properly service and  
maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a  
dealer or by you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the turf equipment or other than as recommended in  
the operator's manual or other operational instructions  
provided by Exmark.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-425  
54  
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Notes:  
55  
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Notes:  
56  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
57  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
© 2009 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-501 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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