Exmark Pioneer S Series 0 Users Manual

000 & Higher to the manual 3b080a2c-fe74-4524-93e7-5ace2fe07048

2015-02-04

: Exmark Exmark-Pioneer-S-Series-0-Users-Manual-366997 exmark-pioneer-s-series-0-users-manual-366997 exmark pdf

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PIONEERS-SERIES

ForSerialNos.

312,000,000&Higher

PartNo.4501-000Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot

equippedwithasparkarrestermufer.Itisa

violationofCaliforniaPublicResourceCode

(CPRC)Section4442touseoroperatethis

engineonanyforest-covered,brush-covered,

orgrass-coveredlandasdenedinCPRC4126.

Otherstatesorfederalareasmayhavesimilar

laws.

Toacquireasparkarresterforyourunit,seeyour

EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe

CanadianstandardICES-002.Cesystèmed’allumage

parètincelledevèhiculeestconformeàlanorme

NMB-002duCanada.

TheenclosedEngineOwner’sManualis

suppliedforinformationregardingTheU.S.

EnvironmentalProtectionAgency(EPA)and

theCaliforniaEmissionControlRegulationof

emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.

ShouldthisengineOwner’sManualbecome

damagedorillegible,replaceimmediately.

Replacementsmaybeorderedthroughthe

enginemanufacturer.

Exmarkreservestherighttomakechangesor

addimprovementstoitsproductsatanytime

withoutincurringanyobligationtomakesuch

changestoproductsmanufacturedpreviously.

Exmark,oritsdistributorsanddealers,accept

noresponsibilityforvariationswhichmaybe

evidentintheactualspecicationsofitsproducts

andthestatementsanddescriptionscontained

inthispublication.

IndustrialParkBox808

Beatrice,NE683102

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour

ExmarkMower.Thisproducthasbeencarefully

designedandmanufacturedtogiveyouamaximum

amountofdependabilityandyearsoftrouble-free

operation.

Thismanualcontainsoperating,maintenance,

adjustment,andsafetyinstructionsforyourExmark

mower.

BEFOREOPERATINGYOURMOWER,

CAREFULLYREADTHISMANUALINITS

ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety

instructions,youwillprolongthelifeofyourmower,

maintainitsmaximumefciency,andpromotesafe

operation.

Ifadditionalinformationisneeded,orshould

yourequiretrainedmechanicservice,contactyour

authorizedExmarkequipmentdealerordistributor.

Exmarkpartsmanualsareavailableonlineat

http://www.exmark.com

AllExmarkequipmentdealersanddistributorsare

keptinformedofthelatestmethodsofservicing

andareequippedtoprovidepromptandefcient

serviceintheeldorattheirservicestations.They

carryamplestockofservicepartsorcansecurethem

promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected

beforeleavingthefactory,however,attentionis

requiredonyourpartifyouaretoobtainthefullest

measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,

oradditionalinformation,contactanAuthorized

ServiceDealerorExmarkCustomerServiceandhave

themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe

spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals......................11

Specications........................................................15

ModelNumbers.............................................15

Systems..........................................................15

Dimensions....................................................17

TorqueRequirements.....................................18

ProductOverview.................................................18

Operation..............................................................19

Controls.........................................................19

Pre-Start.........................................................21

OperatingInstructions...................................22

Transporting..................................................26

Maintenance..........................................................27

RecommendedMaintenanceSchedule(s)............27

PeriodicMaintenance........................................28

CheckEngineOilLevel..................................28

CheckBatteryCharge.....................................28

CheckMowerBlades......................................29

CheckSafetyInterlockSystem........................30

CheckRolloverProtectionsSystems(Roll

Bar)Knobs.................................................31

CheckSeatBelt...............................................31

CheckforLooseHardware.............................31

ServiceAirCleaner.........................................31

ChangeEngineOil.........................................31

CheckHydraulicOilLevel..............................32

CheckTirePressures......................................32

CheckConditionOfBelts...............................32

LubricateGreaseFittings................................32

CheckSparkPlugs..........................................33

ChangeHydraulicSystemFilterand

Fluid..........................................................33

CheckSparkArrester(ifequipped)..................34

ThreadLockingAdhesives..............................35

Copper-BasedAnti-seize...............................35

DielectricGrease............................................35

Adjustments......................................................35

DeckLeveling................................................35

AdjustingtheBladeSlope...............................36

PumpDriveBeltTension................................37

DeckBeltTension..........................................37

AdjustingtheParkingBrake............................37

MotionControlHandleAdjustment...............38

FullForwardTrackingAdjustment..................38

MotionControlLinkageAdjustment..............39

AdjustingtheSeatRideSuspension.................40

ElectricClutchAdjustment.............................40

Cleaning............................................................42

CleanEngineandExhaustSystem

Area...........................................................42

RemoveEngineShroudsandClean

CoolingFins...............................................42

CleanHydroFanCoolingFins........................42

CleanDebrisFromMachine...........................42

CleanGrassBuild-UpUnderDeck.................42

WasteDisposal...............................................42

Troubleshooting....................................................44

Schematics............................................................46

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4

specicationsoftheAmericanNationalStandards

Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer

reasonablysafeservice;however,failuretocomply

withthefollowinginstructionsmayresultinpersonal

injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin

thismanualandonthemachinetoidentifyimportant

safetymessageswhichmustbefollowedtoavoid

accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation

whichalertsyoutounsafeactionsorsituations

andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if

notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.

Indicatesapotentiallyhazardoussituationwhich,if

notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground.

Indicatesapotentiallyhazardoussituationwhich,if

notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight

information.Importantcallsattentiontospecial

mechanicalinformationandNoteemphasizes

generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining

material.Iftheoperator(s)ormechanic(s)can

notreadEnglishitistheowner’sresponsibilityto

explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate

orservicetheequipment.Localregulationsmay

restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate

amower,andevenmatureteenagersshouldhave

adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe

mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor

herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand

safelyperformthejob.Onlyuseaccessoriesand

attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,

substantialfootwear,longtrousers,andhearing

protection.DoNotoperatewhenbarefootor

whenwearingopensandals.Longhair,loose

clothingorjewelrymaygettangledinmoving

parts.

CAUTION

Thismachineproducessoundlevelsinexcess

of85dBAattheoperator’searandcancause

hearinglossthroughextendedperiodsof

exposure.

Wearhearingprotectionwhenoperatingthis

machine.

Safety

•Inspecttheareawheretheequipmentistobe

usedandremoveallrocks,toys,sticks,wires,

bones,andotherforeignobjectswhichcanbe

thrownbythemachineandmaycausepersonal

injurytotheoperatororbystanders.

DANGER

Incertainconditionsgasolineisextremely

ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn

you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,

inanopenarea,whentheengineiscold.

Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe

machineindoorsorinsideanenclosed

trailer.

•DoNotllthefueltankcompletelyfull.

Fillthefueltanktothebottomoftheller

neck.Theemptyspaceinthetankallows

gasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengine

oremissionsystem.

•Neversmokewhenhandlinggasoline,and

stayawayfromanopenameorwhere

gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer

andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoradd

fuelwhenengineisrunningorwhenthe

engineishot.

•Iffuelisspilled,DoNotattempttostart

theengine.Moveawayfromtheareaof

thespillandavoidcreatinganysourceof

ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust

systeminplaceandinproperworking

condition.

DANGER

Incertainconditionsduringfueling,static

electricitycanbereleasedcausingaspark

whichcanignitegasolinevapors.Areor

explosionfromgasolinecanburnyouand

othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe

groundawayfromyourvehiclebefore

lling.

•DoNotllgasolinecontainersinsidea

vehicleoronatruckortrailerbedbecause

interiorcarpetsorplastictruckbedliners

mayinsulatethecontainerandslowthe

lossofanystaticcharge.

•Whenpractical,removegas-powered

equipmentfromthetruckortrailerand

refueltheequipmentwithitswheelson

theground.

•Ifthisisnotpossible,thenrefuelsuch

equipmentonatruckortrailerfroma

portablecontainer,ratherthanfroma

gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe

used,keepthenozzleincontactwiththe

rimofthefueltankorcontaineropening

atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.

Long-termexposuretovaporshascaused

cancerinlaboratoryanimals.Failuretouse

cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas

tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator'spresencecontrols,

safetyswitches,andshieldsareattachedand

functioningproperly.DoNotoperateunlessthey

arefunctioningproperly.

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer,

becomeextremelyhot.Severeburnscanoccur

oncontactanddebris,suchasleaves,grass,

brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to

coolbeforetouching.

•Removeaccumulateddebrisfrommuferand

enginearea.

•Installandmaintaininworkingordera

sparkarresterbeforeusingequipment

onforest-covered,grass-covered,or

brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,

whichisanodorlessdeadlypoisonthatcankill

you.

DoNotrunengineindoorsorinasmallconned

areawheredangerouscarbonmonoxidefumes

cancollect.

•Operateonlyindaylightorgoodarticiallight,

keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake

isengagedbeforestartingengine.Useseatbelts

withtherollbarintheraisedandlockedposition.

•Neveroperatethemowerwithdamagedguards,

shields,orcovers.Alwayshavesafetyshields,

guards,switchesandotherdevicesinplaceandin

properworkingcondition.

•Nevermowwiththedischargedeectorraised,

removedoralteredunlessthereisagrass

collectionsystemormulchkitinplaceand

workingproperly.

•DoNotchangetheenginegovernorsettingor

overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait

forallmovingpartstostop,removekeyand

engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting

andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and

engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

Hands,feet,hair,clothing,oraccessoriescan

becomeentangledinrotatingparts.Contact

withtherotatingpartscancausetraumatic

amputationorseverelacerations.

•DoNotoperatethemachinewithout

guards,shields,andsafetydevicesinplace

andworkingproperly.

•Keephands,feet,hair,jewelry,orclothing

awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate

themowerwhenpeople,especiallychildren,or

petsareinthearea.

•Bealert,slowdownandusecautionwhen

makingturns.Lookbehindandtothesidebefore

changingdirections.

•Stoptheblades,slowdown,andusecaution

whencrossingsurfacesotherthangrassandwhen

transportingthemowertoandfromtheareato

bemowed.

•Beawareofthemowerdischargepathanddirect

dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence

ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe

machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning

onslopesaslossoftractionand/ortip-overcould

occur.Theoperatorisresponsibleforsafeoperation

onslopes.

Safety

DANGER

Operatingonwetgrassorsteepslopescancause

slidingandlossofcontrol.Wheelsdroppingover

edges,ditches,steepbanks,orwatercancause

rollovers,whichmayresultinseriousinjury,

deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon

slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Keeptherollbarintheraisedandlocked

positionanduseseatbelt.

•Seeinsidethebackcovertodeterminethe

approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer

neardrop-offs,ditches,steepbanksorwater.

(Figure3).

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15

degrees

2.DangerZone-Useawalkbehindmowerand/orhand

trimmeronslopesgreaterthan15degrees,near

drop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree

limbs,etc.fromthemowingarea.Tallgrasscan

hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat

changetheoperatingangle,asroughterraincould

overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause

themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep

slopesordownhillmaycausethemowertolose

traction.Lossoftractiontothedrivewheelsmay

resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona

slope.Iftireslosetraction,disengagetheblades

andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor

wheelweightsorcounterweightstoimprove

stability.

•Useextremecarewithgrasscatchersor

attachments.Thesecanchangethestabilityofthe

machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem

(ROPS)

ARolloverProtectionSystem(rollbar)isinstalled

ontheunit.

WARNING

Thereisnorolloverprotectionwhentherollbar

isdown.Wheelsdroppingoveredges,ditches,

steepbanks,orwatercancauserollovers,which

mayresultinseriousinjury,deathordrowning.

•Keeptherollbarintheraisedandlocked

positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely

necessary.

•DoNotwearseatbeltwhentherollbaris

down.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance

permits.

•Checkcarefullyforoverheadclearances(i.e.

branches,doorways,andelectricalwires)before

drivingunderanyobjectsandDoNotcontact

them.

•Intheeventofarollover,taketheunittoan

AuthorizedServiceDealertohavetheROPS

inspected.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking

brake,stopengineandremovekeyordisconnect

sparkplugwire.Waitforallmovementtostop

beforeadjusting,cleaningorrepairing.

Safety

•Keepengineandengineareafreefrom

accumulationofgrass,leaves,excessivegrease

oroil,andotherdebriswhichcanaccumulate

intheseareas.Thesematerialscanbecome

combustibleandmayresultinare.

•LetenginecoolbeforestoringandDoNotstore

nearameoranyenclosedareawhereopenpilot

lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do

Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow

untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectbatteryorremovesparkplugwire

beforemakinganyrepairs.Disconnectthe

negativeterminalrstandthepositivelast.

Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)

orweargloves,andusecautionwhenservicing

them.Onlyreplacedamagedblades.Never

straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.

Ifpossible,DoNotmakeadjustmentswiththe

enginerunning.

•Chargebatteriesinanopenwellventilatedarea,

awayfromsparkandames.Unplugcharger

beforeconnectingordisconnectingfrombattery.

Wearprotectiveclothinganduseinsulatedtools.

DANGER

Chargingorjumpstartingthebatterymay

produceexplosivegases.Batterygasescan

explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway

frombattery.

•Ventilatewhenchargingorusingbattery

inanenclosedspace.

•Makesureventingpathofbatteryis

alwaysopenoncebatteryislledwith

acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid,

whichispoisonousandcancausesevere

burns.Swallowingelectrolytecanbefatalor

ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and

rubberglovestoprotectskinandclothing

whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith

waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere

ispotentialforsparksandengagementof

components.Sparkscouldcauseanexplosion

ormovingpartscouldaccidentallyengage

causingpersonalinjury.

Besureignitionswitchisinthe“OFF”

positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin

placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper

tightness.

•Frequentlycheckforwornordeteriorating

componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts

andaccessoriesmayalterthewarranty,traction,

andsafetyofthemachine.Failuretouseoriginal

Exmarkpartscouldcauseseriousinjuryor

death.Makingunauthorizedchangestothe

engine,fuelorventingsystem,mayviolateEPA

andCARBregulations.

Replaceallpartsincluding,butnotlimitedto,

tires,belts,blades,andfuelsystemcomponents

withoriginalExmarkparts.

Safety

WARNING

Hydraulicuidescapingunderpressure

canpenetrateskinandcauseinjury.Fluid

accidentallyinjectedintotheskinmustbe

surgicallyremovedwithinafewhoursbyadoctor

familiarwiththisformofinjuryorgangrenemay

result.

•Ifequipped,makesureallhydraulicuid

hosesandlinesareingoodconditionandall

hydraulicconnectionsandttingsaretight

beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole

leaksornozzlesthatejecthighpressure

hydraulicuid.

•Usecardboardorpaper,notyourhands,to

ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic

systembyplacingthemotioncontrollevers

inneutralandshuttingofftheenginebefore

performinganyworkonthehydraulicsystem.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,

dirtanddebrisfromsafetysignsandinstructional

labels.

•Replaceallworn,damaged,ormissingsafety

signs.

•Whenreplacementcomponentsareinstalled,be

surethatcurrentsafetysignsareafxedtothe

replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,

makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom

yourauthorizedExmarkequipmentdealeror

distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe

backingtoexposetheadhesivesurface.Apply

onlytoaclean,drysurface.Smoothtoremove

anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns

andinstructionlabels.Theyarecriticaltothesafe

operationofyourExmarkcommercialmower.

1-303508

1-403005

1-633922

98-5954

103-2076

Safety

107-2102

109-3148

109-6014

116-1119

116-1496

116-3303

Safety

116-4308

1.Latch2.Unlatch

116-4465

1.Fast3.Choke-on

2.Slow4.Choke-off

116-6363

1.Rotatethedriverelease

knobtoloosen,slidethe

knob,andtighten.

2.Pushthemachine.

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

Safety

109-6016

1.Readtheinstructionsbeforeservicingorperforming

maintenance

4.RefertotheOperator'smanualforgreaseinstructions

2.Timeinterval5.CheckhydraulicoillevelandrefertotheOperator's

manualorfurtherinstructions

3.Checkoillevel6.Checktirepressure

116-4430

1.Parkbrake—engage4.Neutral

2.Fast5.Reverse

3.Slow

Specications

ModelNumbers

SerialNos:312,000,000andHigher

PNS600KA443;PNS651KA483;PNS680KC523;PNS740KC604

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s

Manual

•EngineOilType:Exmark4–CyclePremium

EngineOil

•RPM:FullSpeed:

Kawasaki:3750±50RPM(PTOnotengaged)

Idle:1500±100RPM

Kohler:3700±50RPM(PTOnotengaged)Idle:

1500±100RPM

FuelSystem

•Capacity:7.0gal.(26.5L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher

((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol

byvolume.Performanceproblemsand/or

enginedamagemayresultwhichmaynotbe

coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel

stabilizerisused.

–DoNotaddoiltogasoline.

•FuelFilter:

Kohler:KohlerP/N2405013

Kawasaki:KawasakiP/N49019-7005

•FuelShut-OffValve:

AllUnits:1/4turnincrements(“ON”,“OFF”).

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1

•RecommendedMinimumBatteryCCA:260CCA

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:

Allunits:

–25ampmainfuse

–20ampchargingsystemfuse

–10ampPTOfuse

–15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearforthePTO,parkbrake,

drivelevers,andoperatorpresenceinthemessage

displayontheRHcontrolpanel.

•PTOmustbedisengaged,brakeengaged,and

motioncontrolleversout(neutrallock)tostart

engine.(Itisnotnecessaryfortheoperatortobe

intheseattostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged,

brakeisdisengaged,ormotioncontrolleversare

movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or

bothleversaremovedfromneutrallockposition

whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto

threeheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe

respectivedrivewheels.

Specications

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch

(todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentLever:Setscutting

heighttodesiredposition.

•DeckLiftPedal:Footpedalthatliftsdeck.

•TransportLock:Latchingposition:Automatically

latchesatthetransportposition.

Seat

•Type:Standardseatwithfoampaddedseat

cushionwitharmrestsandintegralsafetyswitch.

Optionalseat:Seatwithhighback,extra

widefoampaddedseatcushionwithinternal

suspension,thickbolstering,two-tonecover,

armrests,integralsafetyswitch,andseatvibration

isolationsystem.

Optionalseataccessoriesforunitswithstandard

seats:

–Customridesuspensionsystemtoenhance

StandardSeat.Addsapproximately3inches

(7.6cm)toseatheight.

–Deluxesuspensionseatwithhighback,

(dampened,adjustablespringsuspension),

armrests,andintegralsafetyswitch.Adds

approximately1/2inch(1.3cm)toseatheight.

•Mounting:Adjustableforeandaftonseattracks.

•Armrests:Moldedip-uparmrests.

•SeatSafetySwitch:

Integratedseatswitch.Timedelayseatswitch

eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•Twounitizedhydrostatictransmissions:

–Unitswith44,48,or52inchdecks:

HydroGearZT3100

–Unitswith60inchdeck:

HydroGearZT3400

•HydraulicOilType:ExmarkPremiumHydroOil.

•HydraulicOilCapacity:77oz(2.3L)perside

•HydraulicFilter:P/N109-3321

•Speeds:

–Forward:

◊Unitswith44,48,or52inchdecks:

0-8mph(12.9km/hr)forward.

◊Unitswith60inchdeck:

0-9mph(14.5km/hr)forward.

–Reverse:

◊Unitswith44,48,or52inchdecks:

0-5mph(8.0km/hr)reverse.

◊Unitswith60inchdeck:

0-6mph(9.7km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe

movedwhenengineisnotrunning.

Tires&Wheels

Drive

Pneumatic(Airlled)

DeckSize44,48,&5260

Quantity22

TreadTurfMasterK500SuperTurf

Size22x9.50-1223x10.50-12

PlyRating44

Pressure13psi(90kPa)13psi(90kPa)

FrontCaster

Pneumatic(Airlled)

DeckSizeAllUnits

Quantity2

TreadSmooth

Size13x5.00-6

PlyRating4

Pressure13psi(90kPa)

CuttingDeck

•CuttingWidth:

–44inchDeck:(111.8cm)

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

•Discharge:Side

•BladeSize:

Specications

–44inchDeck:22.25inches(56.5cm)–(2ea.)

–48inchDeck:16.25inches(41.3cm)–(3ea.)

–52inchDeck:18.00inches(45.7cm)–(3ea.)

–60inchDeck:20.50inches(52.1cm)–(3ea.)

•BladeSpindles:Solidsteelspindleswith.98inch

(25mm)I.D.bearings.

•DeckDrive:“B”Sectionbeltwithself-tensioning

idler.

•Electricclutch:

–44,48,&52inchdecks:175ft-lbMagStop

–60inchdeck:200ft-lbMagStopw/spotbrake

•Deck:Fulloatingdeckisattachedtoout-front

supportframe.Anti-scalprollersprovide

maximumturfprotection.Deckdesignallowsfor

bagging,mulchingorsidedischarge.

–44inchDeck:2anti-scalprollers

–48inchDeck:3anti-scalprollers

–52inchDeck:3anti-scalprollers

–60inchDeck:4anti-scalprollers

•DeckDepth:

–44inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

–52inchDeck:5.0inches(12.7cm)

–60inchDeck:5.5inches(14.0cm)

•CuttingHeightAdjustment:

Footactivatedleverisusedtoadjustthecutting

heightfrom11/2inch(3.8cm)to5inches(12.7

cm)in1/4inch(6.4mm)increments.

•MulchingKit:Optional.

Dimensions

OverallWidth:

44inchDeck48inchDeck

WithoutDeck45.8inches

(116.3cm)

45.8inches

(116.3cm)

DeectorUp48.2inches

(122.4cm)

50.7inches

(128.8cm)

DeectorDown56.4inches

(143.3cm)

59.5inches

(151.1cm)

52inchDeck60inchDeck

WithoutDeck45.8inches

(116.3cm)

50.4inches

(128.0cm)

DeectorUp54.2inches

(137.7cm)

61.4inches

(156.0cm)

DeectorDown64.3inches

(163.3cm)

72.8inches

(185.0cm)

OverallLength:

44inchDeck48inchDeck

RollBar-Up78.8inches

(200.2cm)

77.8inches

(197.6cm)

RollBar-Down79.6inches

(202.2cm)

78.6inches

(199.6cm)

52inchDeck60inchDeck

RollBar-Up77.8inches

(197.6cm)

78.8inches

(200.2cm)

RollBar-Down78.6inches

(199.6cm)

79.9inches

(202.9cm)

OverallHeight:

RollBar-UpRollBar-Down

71.3inches(181.1cm)48inches(121.9cm)

TreadWidth:(CentertoCenterof

Tires,Widthwise)

44inchDeck48inchDeck

DriveWheels36.8inches

(93.5cm)

36.8inches

(93.5cm)

CasterWheels26.8inches

(68.1cm)

33.5inches

(85.1cm)

52inchDeck60inchDeck

DriveWheels36.8inches

(93.5cm)

39.7inches

(100.8cm)

CasterWheels33.5inches

(85.1cm)

38.3inches

(97.3cm)

ProductOverview

WheelBase:(CenterofCasterTireto

CenterofDriveTire)

44inch

Deck

48inch

Deck

52inch

Deck

60inch

Deck

49.7inches

(126.2cm)

48.7inches

(123.7cm)

48.7inches

(123.7cm)

49.7inches

(126.2cm)

CurbWeight:

44inch

Deck

48inch

Deck

52inch

Deck

60inch

Deck

Kawasaki

Units

822lb

(373kg)

862lb

(391kg)

873lb

(396kg)

948lb

(430kg)

TorqueRequirements

BoltLocationTorque

BladeDriveSheave

MountingNut

130-160ft-lb(176-217

N-m)

BladeMountingBolt

(lubricatewithanti-seize)

50-60ft-lb(68-81N-m)

Anti-ScalpRollerNyloc

NutSeeFigure18

27-33ft-lb(37-45N-m)

Anti-ScalpRollerWhizlock

NutSeeFigure18

27-33ft-lb(37-45N-m)

EngineMountingBolts27-33ft-lb(37-45N-m)

WheelLugNuts70-90ft-lb(95-122N-m)

RolloverProtection

System(RollBar)1/2

inchMountingBolts

77-95ft-lb(104-129N-m)

ClutchRetainingBolt

(securedwiththreadlocker)

49-61ft-lb(66-83N-m)

ProductOverview

Figure4

1.RolloverProtection

System(ROPS)

5.Motioncontrollevers

2.EngineControls(right

console)

6.Parkingbrake

3.Seatbelt7.Heightofcutadjustment

4.Fuelcap

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof

theconsolecontroltheforwardandreversemotion

ofthemachine.

Movingtheleversforwardorbackwardturns

thewheelonthesamesideforwardorreverse

respectively.Wheelspeedisproportionaltothe

amounttheleverismoved.

Movingtheleversoutwardfromthecenterposition

intotheT-slotlocksthemintheneutralposition

(Figure5).

Figure5

1.Neutrallockposition

(handlesout)

4.Forward

2.Neutraloperateposition

(handlesin)

5.Neutral(operate)

3.Frontofunit6.Reverse

ChokeControl

Locatedonrightconsole(blacklever)(seeFigure6).

Thechokeisusedtoaidinstartingacoldengine.

Movingthechokeleverforwardwillputthechokein

the“ON”positionandmovingthechokelevertothe

rear,tothedetent,willputthechokeinthe“OFF”

position.DoNotrunawarmenginewithchokein

the“ON”position.

Figure6

1.Throttlelever4.Bladecontrolswitch

(powertake-off)

2.Chokelever5.Ignitionswitch

3.Hourmeter

ThrottleControl

Locatedonrightconsole(redlever)(seeFigure6).

Thethrottleisusedtocontrolenginespeed.Moving

thethrottleleverforwardwillincreaseenginespeed

andmovingthethrottlelevertotherearwilldecrease

enginespeed.Movingthethrottleforwardintothe

detentisfullthrottle.

BrakeLever

Locatedonleftsideofunit,justtothefrontofthe

LHmotioncontrollever.

Thebrakeleverengagesaparkingbrakeonthedrive

wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe

brake.

Theunitmustbetieddownandbrakeengagedwhen

transporting.

IgnitionSwitch

Locatedonrightconsole(seeFigure6).

Operation

Theignitionswitchisusedtostartandstopthe

engine.Theswitchhasthreepositions“OFF”,“ON”

and“START”.Insertkeyintoswitchandrotate

clockwisetothe“ON”position.Rotateclockwiseto

thenextpositiontoengagethestarter(keymustbe

heldagainstspringpressureinthisposition).Allow

thekeytoreturntothe“on”positionimmediately

aftertheenginestarts.

Figure7

1.Off3.Start

2.On

Note:Brakemustbeengaged,motioncontrol

leversout(neutrallockposition)andPTOswitch

disengagedtostartengine.(Itisnotnecessaryforthe

operatortobeintheseattostarttheengine.)

HourMeter

Locatedonthecontrolpanel(seeFigure6and

Figure8).

Thehourmeterrecordsthenumberofhoursthat

theenginehasrun.

Figure8

1.LCDindicators3.Hour/Voltagedisplay

2.Lowvoltageindicator

light

FuelShut-OffValve

LocatedbythelowerLHROPStubemounting.

Thefuelshut-offvalveisusedtoshutoffthefuel

whenthemachinewillnotbeusedforafewdays,

duringtransporttoandfromthejobsite,andwhen

parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate

90°toclose.

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating

drivecomponentsbelowtheenginedeck,which

couldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving

partstostopbeforeaccessingthedrivewheel

releasevalves.

WARNING

Theengineandhydraulicdriveunitscanbecome

veryhot.Touchingahotengineorhydraulic

driveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto

coolcompletelybeforeaccessingthedrivewheel

releasevalves.

Locatedontheleftandrightsidesunderneaththe

enginedeck.

Duringnormaloperatingconditions,thedrivewheel

releasevalvesarepositionedinfrontoftheslots.If

themachinehastobepushedbyhand,thevalves

mustbeinthe“released”position(seeFigure9).

Operation

Figure9

1.Frontofthemachine

2.Rotatebypassreleaseknobcounterclockwisetoloosen

3.Leverpositionforoperatingthemachine

4.Pullleverinthisdirectiontopushthemachine

5.Leverpositionforpushingthemachine

6.Rotatebypassreleaseknobclockwisetotighten

7.Releaselever

Toreleasethedrivesystem(seeitem1inFigure9),

loosentheknobbyturningcounterclockwise.Then

pullthereleaseleverontheundersideofmachine

towardsthebackofthemachineandretightenthe

knobtoholdthereleaseleverbackinthereleased

state.Repeatthisoneachsideofthemachine.

Releasetheparkingbrake.Themachineisnowable

tobepushedbyhand.

Toresetthedrivesystem(seeitem2inFigure9),

loosentheknobbyturningcounterclockwise.Then

pushthereleaseleverontheundersideofmachine

towardsthefrontofthemachineandretightenthe

knobtoholdthereleaseleverintheoperatingstate.

Repeatthisoneachsideofthemachine.

DoNottowmachine.

PTOEngagementSwitch

Locatedonrightconsole(seeFigure6).

Switchmustbepulledout(up)toengagetheblades.

Switchispushedintodisengagetheblades.

DeckLiftPedal

Locatedattherightfrontcorneroftheoorpan.

Pushthepedalforwardwithyourfoottoraisethe

cuttingdeck.Allowthepedaltomoverearwardto

lowerthecuttingdecktothecutheightthathasbeen

set.

Figure10

1.Transportlockhandle3.Heightofcutdecal

2.Heightadjustmentpin4.Deckfootpedal

TransportLock

Locatedontheheightofcutadjustmentplate(see

Figure10).

Thetransportlatchingmechanismwillautomatically

engagewhenthedeckisraisedtothetransport

position.Toreleasethedeckfromthetransport

position:pushthefootpedaltoremovetheloadfrom

thetransportlatchingmechanism,pullthetransport

lockhandlerearward,andletthepedalcomebackto

lowerthedeckdowntothedesiredcutheight.

Pre-Start

Fillfueltanks.SeeFuelRecommendationsin

theSpecicationssectionforadditionalgasoline

information.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe

tankallowsgasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengineoremission

system.

Operation

Makesureyouunderstandthecontrols,their

locations,theirfunctions,andtheirsafety

requirements.

RefertotheMaintenancesectionandperformallthe

necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem

(ROPS)

Important:Therollbarisanintegraland

effectivesafetydevice.Keeptherollbarinthe

raisedandlockedpositionwhenoperatingthe

mower.Lowertherollbartemporarilyonlywhen

absolutelynecessary.

1.Theknobmustbecompletelylatchedwiththe

tabsinterlockingasshowninFigure11tolock

therollbarintheraised,operateposition.

2.Applyforwardpressuretotheupperhoopofthe

rollbar.

3.Pulltheknobandrotate90°toholdinthe

unlatchedpositiontolowertherollbar.

4.Toreturntotheoperateposition,raisetheroll

bar,andthenrotateknobs90°sothatthetabs

interlockpartially.Applyforwardpressuretothe

rollbarupperhoopandobservethattheknobs

returntothecompletelylatchedposition.

G014402

234

Figure11

1.Rollbarupperhoop

2.Knobin“latched”position

3.Pullknobtounlatch

4.Rotate90°toholdunlatched

5.Knobin“unlatched”position

5.Makesuretheknobsarefullyengagedwiththe

rollbarintheraisedposition.Theupperhoopof

therollbarmayneedtobepushedforwardor

pulledrearwardtogetbothknobsfullyengaged

(seeFigure12).

Figure12

1.Engaged2.Partiallyengaged—Do

NotoperatewithROPS

inthiscondition.

Important:Alwaysusetheseatbeltwiththe

rollbarintheoperate(raised)position.Ensure

thattherearpartoftheseatissecuredwiththe

seatlatch.

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

Operation

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral

lockposition.

2.Pullupandbackontheparkingbrakeleverto

engagetheparkingbrake.

3.PushdownonthePTOswitchtothe“disengage”

position.

Note:Itisnotnecessaryfortheoperatortobe

intheseattostarttheengine.

4.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

5.Onacoldengine,pushthechokeleverforward

intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF”

position.

6.Turnignitionswitchtothe“START”position.

Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine

continuouslyformorethantensecondsata

time.Iftheenginedoesnotstart,allowa60

secondcool-downperiodbetweenstarting

attempts.Failuretofollowtheseguidelines

canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually

returnchoketothe“OFF”positionastheengine

warmsup.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeckare

dangerous.Bladecontactcancauseserious

injuryorkillyou.

DoNotputhandsorfeetunderthemoweror

mowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow

objectstobethrowninanoperator’sor

bystander’sdirection.Also,contactwiththe

bladecouldoccur.Thrownobjectsorblade

contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge

deectorraised,removed,oralteredunlessthere

isagrasscollectionsystemormulchkitinplace

andworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades.

Besurethatallpersonsareclearofthemowerdeck

anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe

PTOcanbeengaged.

1.Setthethrottlemidwaybetweenthe“SLOW”and

“FAST”positions.

2.PullthePTOswitchoutwardtoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin

mowing.

DisengagingthePTO

1.Setthethrottlemidwaybetweenthe“SLOW”and

“FAST”positions.

2.PushthePTOswitchintodisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Movethemotioncontrolleversouttotheneutral

lockposition.

3.Engagetheparkingbrake.

4.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

5.DisengagethePTO.

6.Allowtheenginetorunforaminimumof15

seconds,thenturntheignitionswitchtothe

“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother

unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine

willnotbeinuseforafewdays,when

transporting,orwhentheunitisparkedinside

abuilding.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone

levertoomuchaheadoftheother.Operatormay

losecontrolofthemachine,whichmaycause

damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp

turns.

Operation

Important:Tobeginmovement(forwardor

backward)theoperatormustbeintheseat,the

brakelevermustbedisengaged(pusheddown)

beforethemotioncontrolleverscanbemovedin

ortheenginewillstop.

Whenthemotioncontrolleversarepositionedfully

outward(apart)intheT-slot,thedrivesystemisin

theneutrallockposition(Figure13).

Whenthemotioncontrolleversaremoveddirectly

inward(together)thedrivesystemisintheneutral

operateposition.

Figure13

1.Neutrallockposition

(handlesout)

4.Forward

2.Neutraloperateposition

(handlesin)

5.Neutral(operate)

3.FrontofUnit6.Reverse

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe

centertotheneutralposition.

3.Tomoveforwardinastraightline,moveboth

leversforwardwithequalpressure.

Figure14

Toturnleftorright,pullthemotioncontrollever

backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe

motioncontrolleversaremovedfromtheneutral

position.

4.Tostop,positionbothmotioncontrolleversin

theneutraloperateposition.

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe

neutraloperateposition.

2.Tomoverearwardinastraightline,moveboth

leversrearwardwithequalpressure.

Figure15

Operation

Toturnright,releasepressureontheRHmotion

controlleverandtherearofthemachinewill

movetowardstherearandtotheright.

Toturnleft,releasepressureontheLHmotion

controlleverandtherearofthemachinewill

movetowardstherearandtotheleft.

3.Tostop,positionbothmotioncontrolleversin

theneutraloperateposition.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted

from11/2to5inches(3.8cmto12.7cm)in1/4

inch(6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol

leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Raiseandlockthedecktothe5inch(12.7cm)

transportposition(Figure16).

Thedeckisraisedbypushingthefootoperated

deckliftpedalforward.Thepedalislocatedatthe

frontrightcorneroftheoorpan.

Note:Whenchangingthecuttingheight

positions,alwayscometoacompletestop

anddisengagethePTO.

Figure16

1.Transportlockhandle3.Heightofcutdecal

2.Heightadjustmentpin4.Deckfootpedal

4.Inserttheheightadjustmentpinintothehole

correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor

cutheights.

5.Pushthefootleverforward,pullthetransport

lockhandlerearwardandletthedecklower

downtothepredeterminedcutheightbyslowly

decreasingfootpressureallowingthefootlever

totravelrearward.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller

position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol

leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall

movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe

anti-scalprollersbyremovingthenylocnut,

bushing,springdiscwasherandwhizlocknut.

6.Placetherollersinoneofthepositionsshown

(Figure17).Rollerswillmaintain3/4inch(19

mm)clearancetothegroundtominimizegouging

androllerwearordamage.

Figure17

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller

mountingbracket

2.Cuttingheight

ForMaximumDeckFlotation,placetherollers

oneholepositionlower.Rollersshouldmaintain

1/4inch(6.4mm)clearancetotheground.Do

Notadjusttherollerstosupportthedeck.

7.Besurethewhizlocknutsareinstalledwiththe

springdiscwasherbetweentheheadofthenut

andthemountingbracket.

Note:Thefootoperateddeckliftassistlever

canbeusedtomomentarilyliftthedecktoclear

objects.BesurethatPTOisdisengaged.

Operation

8.Torquethe3/8–16whizlocknutto27-33ft-lb

(37-45N-m)(Figure18).

9.Torquethe3/8nylocnutto27-33ft-lb(37-45

N-m).

Figure18

1.Springdiscwasher

(conetowardsnut)

3.3/8nyloc-torqueto27-33

ft-lb(37-45N-m)

2.Frontrightanti-scalp

bracketshown

4.3/8-16whizlocknut

torqueto27-33ft-lb

(37-45N-m)

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe

machine.Lockbrakeandblockwheels.Securely

fastenthemachinetothetrailerortruckwithstraps,

chains,cable,orropes.Besurethatthetrailerortruck

hasallnecessarylightingandmarkingasrequiredby

law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturnsignals,

lights,reectivemarkings,oraslowmoving

vehicleemblem.Drivingonastreetorroadway

withoutsuchequipmentisdangerousand

canleadtoaccidentscausingpersonalinjury.

Drivingonastreetorroadwaywithoutsuch

equipmentmayalsobeaviolationofStatelaws

andtheoperatormaybesubjecttotrafctickets

and/ornes.

DoNotdriveaunitonapublicstreetorroadway.

WARNING

Loadingaunitonatrailerortruckincreases

thepossibilityofbackwardtip-over.Backward

tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit

onaramp.

•Useonlyasingle,fullwidthramp;DoNot

useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough

rampstocreateanunbrokenrampsurface

widerthantheunit.

•DoNotexceeda15°anglebetweenrampand

groundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit

uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit

downaramptoavoidtippingbackward.

LoadingaUnit

Useextremecautionwhenloadingunitsontrailersor

trucks.Onefullwidthrampthatiswideenoughto

extendbeyondthereartiresisrecommendedinstead

ofindividualrampsforeachsideoftheunit.The

lowerrearsectionofthetractorframeextendsback

betweentherearwheelsandservesasastopfor

tippingbackward.Havingafullwidthrampprovides

asurfacefortheframememberstocontactifthe

unitstartstotipbackward.Ifitisnotpossibletouse

onefullwidthramp,useenoughindividualrampsto

simulateafullwidthcontinuousramp.

Rampshouldbelongenoughsothattheangles

betweentherampandthegroundandtherampand

thetrailerortruckDoNotexceed15°.Asteeper

anglemaycausemowerdeckcomponentstoget

caughtastheunitmovesfromramptotraileror

truck.Steeperanglesmayalsocausetheunittotip

backward.Ifloadingonornearaslope,position

thetrailerortrucksoitisonthedownsideofthe

slopeandtherampextendsuptheslope.Thiswill

minimizetherampangle.Thetrailerortruckshould

beaslevelaspossible.

Important:DoNotattempttoturntheunit

whileontheramp,youmaylosecontroland

driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp

andsuddendecelerationwhenbackingdownaramp.

Bothmaneuverscancausetheunittotipbackward.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing

made,someonecouldstarttheengine.

Accidentalstartingoftheenginecouldseriously

injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage

parkingbrake,andpullthewire(s)offthespark

plug(s)beforeyoudoanymaintenance.Also

pushthewire(s)asidesoitdoesnotaccidentally

contactthesparkplug(s).

WARNING

Theenginecanbecomeveryhot.Touchingahot

enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore

serviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

MaintenanceService

IntervalMaintenanceProcedure

Aftertherst5hours•Changetheengineoil.

Aftertherst100hours•Changethehydrauliclteranduid.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)knobs.

•Checktheseatbelt.

•Checkforloosehardware.

•Checkthehydraulicoillevelintheexpansiontank.

•Cleantheengineandexhaustsystemarea.

•Cleanthehydrofancoolingguards.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthecuttingdeck.

Every50hours

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethedeckandpumpidlerpivots.

•Checksparkarrester(ifequipped).

Every100hours•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Removetheengineshroudsandcleanthecoolingns.

Every200hours•Checkthesparkplugs.

Every250hours

•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement;replaceif

dirty.(Mayneedmoreoftenundersevereconditions.SeetheEngineOwner'sManualfor

additionalinformation.)

Every500hours

•Replacethesecondaryaircleanerelement(Mayneedmoreoftenundersevereconditions.

SeetheEngineOwner'sManualforadditionalinformation.)

•Changethehydrauliclteranduid(Every250hoursifusingMobil115W50)

•Checktheparkbrakeadjustment.

Monthly•Checkthebatterycharge.

Maintenance

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.

Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstick

andwipeoiloff.Reinsertthedipstickaccording

totheenginemanufacturer'srecommendations.

Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow,wipeofftheareaaroundthe

oilllcap,removecapandlltothe“FULL”

markonthedipstick.Exmark4-CyclePremium

EngineOilisrecommended;refertotheEngine

Owner'smanualforanacceptablealternative.Do

Notoverll.

Important:DoNotoperatetheenginewiththe

oillevelbelowthe“LOW”(or“ADD”)markon

thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof

timewithoutrechargingthemwillresultinreduced

performanceandservicelife.Topreserveoptimum

batteryperformanceandlife,rechargebatteriesin

storagewhentheopencircuitvoltagedropsto12.4

volts.

Note:Topreventdamageduetofreezing,battery

shouldbefullychargedbeforeputtingawayfor

winterstorage.

Checkthevoltageofthebatterywithadigital

voltmeter.Locatethevoltagereadingofthebatteryin

thetableandchargethebatteryfortherecommended

timeintervaltobringthechargeuptoafullcharge

of12.6voltsorgreater.

Important:Makesurethenegativebatterycable

isdisconnectedandthebatterychargerusedfor

chargingthebatteryhasanoutputof16voltsand

7ampsorlesstoavoiddamagingthebattery(see

chartforrecommendedchargersettings).

Voltage

Reading

Percent

Charge

Maximum

Charger

Settings

Charging

Interval

12.6or

greater

100%16volts/7

amps

Charging

Required

12.4–12.675–100%16volts/7

amps

30Minutes

12.2–12.450–75%16volts/7

amps

1Hour

12.0–12.225–50%14.4volts/4

amps

2Hours

11.7–12.00–25%14.4volts/4

amps

3Hours

11.7orless0%14.4volts/2

amps

6Hoursor

RecommendedJump

StartingProcedure

ServiceInterval:Asrequired

1.Checktheweakbatteryforterminalcorrosion

(white,green,orblue“snow”),itmustbecleaned

offpriortojumpstarting.Cleanandtighten

connectionsasnecessary.

CAUTION

Corrosionorlooseconnectionscancause

unwantedelectricalvoltagespikesatanytime

duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor

corrodedbatteryterminalsordamagetothe

enginemayoccur.

Maintenance

DANGER

Jumpstartingaweakbatterythatiscracked,

frozen,haslowelectrolytelevel,oran

open/shortedbatterycell,cancausean

explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese

conditionsexist.

2.Makesuretheboosterisagoodandfullycharged

leadacidbatteryat12.6voltsorgreater.Use

properlysizedjumpercables(4to6AWG)with

shortlengthstoreducevoltagedropbetween

systems.Makesurethecablesarecolorcodedor

labeledforthecorrectpolarity.

CAUTION

Connectingthejumpercablesincorrectly

(wrongpolarity)canimmediatelydamagethe

electricalsystem.

Becertainofbatteryterminalpolarityand

jumpercablepolaritywhenhookingup

batteries.

Note:Thefollowinginstructionsareadapted

fromtheSAEJ1494Rev.Dec.2001–Battery

BoosterCables–SurfaceVehicleRecommended

Practice(SAE–SocietyofAutomotive

Engineers).

WARNING

Batteriescontainacidandproduceexplosive

gases.

•Shieldtheeyesandfacefromthebatteries

atalltimes.

•DoNotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel.

Placeadampcloth,ifavailable,overanyvent

capsonbothbatteries.Besurethevehiclesdo

nottouchandthatbothelectricalsystemsare

offandatthesameratedsystemvoltage.These

instructionsarefornegativegroundsystemsonly.

3.Connectthepositive(+)cabletothepositive(+)

terminalofthedischargedbatterythatiswiredto

thestarterorsolenoidasshowninFigure19.

Figure19

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe

positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother

terminal(negative)oftheboosterbattery.

6.MAKETHEFINALCONNECTIONON

THEENGINEBLOCKOFTHESTALLED

VEHICLE(NOTTOTHENEGATIVEPOST)

AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe

reverseorderofconnection(theengineblock

(black)connectionisthersttodisconnect).

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin

theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe

followingorder:

A.Installthesplinedbushingthroughtheblade

withthebushingangeonbottom(grass)

sideofblade.

Maintenance

Figure20

1.Spindle

2.Blade

3.Splinedbushing

4.Bladeboltwasherassembly—T orqueto50-60ft-lb

(68-81N-m)Applylubricanttothreadsasneededto

preventseizing.Copper-basedanti-seizepreferable.

Greaseacceptablesubstitute.

B.Applylubricanttothethreadsoftheblade

boltasneededtopreventseizing.Copper

basedanti-seizeispreferable.Greaseisan

acceptablesubstitute.

C.Installthesplinedbushing/bladeassembly

andbladeboltwasherassemblyintothe

spindle.Installbladeboltngertight.

D.Placewrenchonthetopspindlenutthen

torquethebladeboltsto50-60ft-lb(68-81

N-m).

WARNING

Incorrectinstallationofthebladeor

componentsusedtoretainthebladecan

bedangerous.Failuretousealloriginal

componentsandassembledasshowncould

allowabladeorbladecomponenttobe

thrownoutfromunderthedeckresultingin

seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,

bladebushings,andbladeboltsasshown.

CheckSafetyInterlock

System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith,

parkingbrakeengaged,PTOdisengagedand

motioncontrolleversmovedoutintheneutral

lockposition.Theoperatordoesnotneedtobe

intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake

disengaged,PTOdisengagedandmotioncontrol

leversintheneutrallockposition-startermust

notcrank.

Trytostartwithoperatorinseat,parkingbrake

engaged,PTOengagedandmotioncontrol

leversintheneutrallockposition-startermust

notcrank.

Trytostartwithoperatorinseat,parking

brakeengaged,PTOdisengaged,andtheleft

motioncontrolleverin,startermustnotcrank,

repeatagainwiththerightleverin,thenwith

bothleversin-startermustnotcrank.

2.Checkthekillcircuits.Runengineatone-third

throttle,disengageparkingbrakeandraiseoff

ofseat(butdonotgetoffofmachine)engine

mustinitiateshutdownafterapproximately1/2

secondhaselapsed(seathastimedelaykillswitch

topreventcut-outsonroughterrain).

Runengineatone-thirdthrottle,engagePTO

andraiseoffofseat(butdonotgetoffof

machine)enginemustinitiateshutdownafter

onesecondhaselapsedifthehandlesarein.The

delaywillbe1/2secondifthehandlesareout.

Runengineatone-thirdthrottle,withbrake

disengaged,moveleversinandraiseoffseat(but

donotgetoffofmachine)enginemustinitiate

shutdownafter1/2secondhaselapsed.

Again,runengineatone-thirdthrottle,brake

engaged,andmoveleftmotioncontrollever

in-enginemustinitiateshutdownafter1/2

secondhaselapsed.

Repeatagainmovingtherightleverin,then

movingbothleversin-enginemustinitiate

shutdownafter1/2secondhaselapsedwhether

operatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests,

donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety

mechanismsbeconnectedandinproper

operatingconditionpriortouseformowing.

Maintenance

CheckRolloverProtections

Systems(RollBar)Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandthe

knobsareingoodworkingcondition.Makesurethe

knobsarefullyengagedwiththeROPSintheraised

position.Theupperhoopoftherollbarmayneed

tobepushedforwardorpulledrearwardtogetboth

knobsfullyengaged.

Figure21

1.Engaged2.Partiallyengaged—Do

NotoperatewithROPS

inthiscondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper

operationofretractorandbuckle.Replacebefore

operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware

oranyotherpossibleproblem.Tightenhardware

orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

theprimaryaircleaner

element—check

secondaryaircleaner

element;replaceifdirty.

(Mayneedmoreoften

undersevereconditions.

SeetheEngineOwner's

Manualforadditional

information.)

Every500hours—Replace

thesecondaryaircleaner

element(Mayneedmore

oftenundersevere

conditions.Seethe

EngineOwner'sManual

foradditionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.SeetheEngineOwner'sManualformaintenance

instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours/Yearly

(whichevercomesrst)

(Mayneedmoreoften

undersevereconditions.)

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.TheoildrainhoseonKawasakienginesislocated

onrighthandsideofengineattherear.Itis

locatedonthelefthandsideforKohlerengines.

Placepanundermachinetocatchoil.Remove

plugfromendofdrainhose.Allowoiltodrain

andreplaceoildrainplug.Torqueplugto20-24

ft-lb.

4.Replacetheoilltereveryotheroilchange.Clean

aroundoillterandunscrewltertoremove.

Beforereinstallingnewlter,applyathincoating

ofExmark4–CyclePremiumEngineoilonthe

surfaceoftherubberseal.Turnlterclockwise

untilrubbersealcontactsthelteradapterthen

tightenlteranadditional1/2to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto

speciedcapacityandreplacecap.

6.UseoilrecommendedintheCheckEngineOil

Levelsection.DoNotoverll.Starttheengine

andcheckforleaks.

7.Wipeupanyspilledoilfromenginedeck

mountingsurfaces.

Maintenance

CheckHydraulicOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.

Engageparkingbrake.

2.Waituntiltheunitcoolsbeforecheckingthe

hydraulicoil.

3.Checkexpansiontankandifnecessaryadd

ExmarkPremiumHydroOiltotheFULLCOLD

line(seeFigure22).

Figure22

1.Engine2.Expansiontank

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Checktirepressureincastertires.

5.Inatecastertiresto13psi(90kPa).

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Removeleftandrightbeltshieldsondeckand

lowerthedecktoinspectdeckdrivebelt.

3.Checkundermachinetoinspectthepumpdrive

belt.

Note:Noadjustmentsarerequiredforbelt

tension.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Lubricatettingswithonetotwopumpsof

NGLIgrade#2multi-purposegungrease.

Refertothefollowingchartforttinglocations

andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Deckand

PumpIdler

Pivots

1250hours

LubricateCasterWheelHubs

ServiceInterval:Asrequired

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

Figure23

1.Sealguard2.Spacernutwithwrench

ats

Maintenance

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle

assemblyinthecasterwheel.Notethatthread

lockingadhesivehasbeenappliedtolockthe

spacernutstotheaxle.Removetheaxle(withthe

otherspacernutstillassembledtoit)fromthe

wheelassembly.

5.Pryoutseals,andinspectbearingsforwearor

damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1

multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkP/N103-0063)mustbe

replaced.

8.Iftheaxleassemblyhashadbothspacernuts

removed(orbrokenloose),applyathreadlocking

adhesivetoonespacernutandthreadontothe

axlewiththewrenchatsfacingoutward.Do

Notthreadspacernutallofthewayontotheend

oftheaxle.Leaveapproximately1/8inch(3mm)

fromtheoutersurfaceofthespacernuttothe

endoftheaxleinsidethenut.

9.Inserttheassemblednutandaxleintothewheel

onthesideofthewheelwiththenewsealand

bearing.

10.Withtheopenendofthewheelfacingup,ll

theareainsidethewheelaroundtheaxlefullof

NGLIgrade#1multi-purposegrease.

11.Insertthesecondbearingandnewsealintothe

wheel.

12.Applyathreadlockingadhesivetothe2ndspacer

nutandthreadontotheaxlewiththewrenchats

facingoutward.

13.Torquethenutto75-80in-lb(8-9N-m),loosen,

thenre-torqueto20-25in-lb(2-3N-m).Make

sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband

insertwheelintocasterfork.Reinstallcasterbolt

andtightennutfully.

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoften.Spinthe

castertire.Thetireshouldnotspinfreely

(morethan1or2revolutions)orhaveanyside

play.Ifthewheelspinsfreely,adjusttorqueon

spacernutuntilthereisaslightamountofdrag.

Reapplythreadlockingadhesive.

CheckSparkPlugs

ServiceInterval:Every200hours

Removesparkplugs,checkconditionandresetgaps,

orreplacewithnewplugs.SeeEngineOwner's

Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe

engine.Replacewhennecessary.

ReplacementFilters

KawasakiKawasaki

P/N49019-7005

KohlerKohler

P/N2405013

Note:Itisimportanttoreinstallthefuellinehoses

andsecurewithplastictiesthesameastheywere

originallyinstalledatthefactorytokeepthefuelline

awayfromcomponentsthatcouldcausefuelline

damage.

ChangeHydraulicSystem

FilterandFluid

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

(Every250hoursifusing

Mobil115W50)

1.Stopengine,waitforallmovingpartstostop,and

allowenginetocool.Removekeyandengage

parkingbrake.

2.Locatethetwoltersunderthetransmissions.

Removelterguards.

3.Carefullycleanareaaroundlters.Itisimportant

thatnodirtorcontaminationenterhydraulic

system.

4.Unscrewlterstoremoveandallowoiltodrain

fromdrivesystem.

Important:Beforereinstallingnewlters,

applyathincoatofExmarkPremiumHydro

Oilonthesurfaceoftheltersrubberseal.

Turntheltersclockwiseuntilrubberseal

contactsthelteradapterthentightenthelter

anadditional3/4to1fullturn.

Maintenance

5.Removetheventplugoneachtransmissionand

llthroughexpansionreservoir,whenoilcomes

outofventreinstallplug.

ExmarkPremiumHydroOilisrecommended.

Refertothechartforanacceptablealternative:

HydroOilChangeInterval

ExmarkPremiumHydro

Oil(Preferred)

500Hours

Mobil115W50250Hours

Torqueplugsto180in-lb(244N-m).Continueto

addoiluntilitreachestheFULLCOLDlineon

theexpansionreservoir.

Figure24

1.Oillter3.Leftreartire

2.Ventplug

6.Raisetherearofmachineupandsupportwith

jackstands(orequivalentsupport)justhigh

enoughtoallowdrivewheelstoturnfreely.

CAUTION

Raisingthemowerdeckforserviceor

maintenancerelyingsolelyonmechanical

orhydraulicjackscouldbedangerous.The

mechanicalorhydraulicjacksmaynotbe

enoughsupportormaymalfunctionallowing

theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

jacksforsupport.Useadequatejackstands

orequivalentsupport.

7.Startengineandmovethrottlecontrolaheadto

1/2throttleposition.Disengageparkingbrake.

WARNING

Enginemustberunninganddrivewheels

mustbeturningsoadjustmentscanbe

performed.Contactwithmovingpartsorhot

surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof

rotatingcomponentsandhotsurfaces.

A.Withthebypassvalveopenandtheengine

running,slowlymovethedirectionalcontrol

inbothforwardandreverse(5or6times).

B.Withthebypassvalveclosedandtheengine

running,slowlymovethedirectionalcontrol

inbothforwardandreversedirections(5to

6times).Checktheoillevel,andaddoilas

requiredafterstoppingtheengine.

C.ItmaybenecessarytorepeatstepsAandB

untilalltheairiscompletelypurgedfrom

thesystem.Whenthetransaxleoperatesat

normalnoiselevelsandmovessmoothly

forwardandreverseatnormalspeeds,then

thetransaxleisconsideredpurged.

Note:DoNotchangethehydraulicsystemoil

(exceptforwhatcanbedrainedwhenchanginglter),

unlessitisfelttheoilhasbeencontaminatedorbeen

extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic

systembyintroducingcontaminantsintothesystem.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite

gasolinevaporsevenaftertheengineisstopped.

Hotparticlesexhaustedduringengineoperation

mayigniteammablematerials.Firemayresult

inpersonalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester

isinstalled.

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Waitformufertocool.

Maintenance

3.Ifanybreaksinthescreenorweldsareobserved,

replacearrester.

4.Ifpluggingofthescreenisobserved,remove

arresterandshakelooseparticlesoutofthe

arresterandcleanscreenwithawirebrush(soak

insolventifnecessary).Reinstallarresteron

exhaustoutlet.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”

or“Fel-Pro,Pro-LockNutType”areusedonthe

followingfasteners:

•ROPSspringpinhousing.

•Sheaveandclutchretainingboltintheendof

enginecrankshaft.

•Hydrocrossmembermountingbolts

Threadlockingadhesivesarerequiredforsome

hardwareonengines—seetheEnginemanual.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing

location:

OnthreadsofBladeBolts.SeeCheckMower

Bladessection.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical

connectionstopreventcorrosionandlossofcontact.

Dielectricgreaseshouldnotbeappliedtosealed

connectors.

Adjustments

Note:DisengagePTO,shutoffengine,waitfor

allmovingpartstostop,engageparkingbrake,and

removekeybeforeservicing,cleaning,ormakingany

adjustmentstotheunit.

CAUTION

Raisingthemowerdeckforserviceor

maintenancerelyingsolelyonmechanical

orhydraulicjackscouldbedangerous.The

mechanicalorhydraulicjacksmaynotbeenough

supportormaymalfunctionallowingtheunitto

fall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

jacksforsupport.Useadequatejackstandsor

equivalentsupport.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper

inationpressurefortiresis13psi(90kPa).

Adjustifnecessary.

4.Positionthetransportlockinthelatching

position.

5.Carefullyrotatethebladesfromsidetoside.

6.Measurebetweentheoutsidecuttingedgesand

theatsurface(Figure25andFigure26).Ifboth

measurementsarenotwithin3/16inch(5mm),

anadjustmentisrequired;continuewiththis

procedure.

Figure25

48,52,and60InchDecks

1.Bladessidetoside2.Measurehere

Maintenance

Figure26

44InchDeck

1.Bladessidetoside2.Measurehere

7.Setanti-scalprollerstotopholesorremove

completelyforthisadjustment.

8.Settheheight-of-cutlevertothe3inch(76mm)

position.Placetwo“B”thickblocks(seeBlock

HeightandRakeTable)undertherearedgeofthe

cuttingdeckskirt;oneoneachsideofthecutting

deck.Placetwo“A”thickblocksundereachside

ofthefrontedgeofthedeck,butnotunderthe

anti-scalprollerbrackets.

BlockHeightandRakeTable

Deck

Size

FrontBlock

Height“ A ”

RearBlock

Height“B”

Rake“R”

442.69inches

(6.8cm)

2.99inches

(7.6cm)

1/8–3/8inch

(3.2–9.5mm)

48,52,

&60

2.77inches

(7.0cm)

2.81inches

(7.1cm)

1/16–5/16inch

(1.6–7.9mm)

9.Carefullyrotatethebladessidetoside

(Figure25andFigure26).

10.Loosenthelevelingadjustlockingnuts(item1

Figure27)onallfourcornerssothatthedeckis

sittingsecurelyonallfourblocks.Makesurethat

theslackisremovedfromthedeckhangersand

thedeckliftfootleverispushedbackagainstthe

stop,thentightenthefourlevelingadjustlocking

nuts.

Figure27

1.Levelingadjustlocking

nuts

3.Deckhanger

2.Deckliftarm4.Chain

11.Recheckthatblockstjustsnuglyunderthedeck

skirt.Makesureallattachmentboltsaretight

12.Continuelevelingthedeckbycheckingthe

front-to-rearbladeslope;refertoAdjustingthe

BladeSlope.

13.Recheckbladesforlevelnessandrepeatdeck

levelingprocedureifnecessary.

AdjustingtheBladeSlope

1.Checkthefront-to-rearbladelevelanytimeyou

installthemower.Ifthefrontbladetipisnot

“R”(seeBlockHeightandRakeTableinDeck

Leveling)lowerthantherearbladetip,adjustthe

bladelevelusingthefollowinginstructions:

2.Parkthemachineonalevelsurfaceanddisengage

thebladecontrolswitch.

3.Movethemotioncontrolleversoutwardtothe

neutralposition,engagetheparkingbrake,stop

theengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating

position.

4.Checktheairpressureofallfourtires.Ifneeded,

adjusttotherecommendedination;referto

CheckingtheTirePressureinDriveSystem

Maintenancesection.

5.Checkandadjusttheside-to-sidebladelevelif

youhavenotcheckedthesetting;refertoDeck

Leveling.

6.Settheheight-of-cutlevertothe3inch(76mm)

position.Placetwo“B”thickblocks(seeBlock

HeightandRakeTableinDeckLeveling)under

therearedgeofthecuttingdeckskirt;oneon

Maintenance

eachsideofthecuttingdeck.Placetwo“ A”thick

blocks(seeBlockHeightandRakeTableinDeck

Leveling)undereachsideofthefrontedgeofthe

deck,butnotundertheanti-scalprollerbrackets.

7.Loosenthelevelingadjustlockingnuts(item1

Figure27)onallfourcornerssothatthedeckis

sittingsecurelyonallfourblocks.Makesurethat

theslackisremovedfromthedeckhangersand

thedeckliftfootleverispushedbackagainstthe

stop,thentightenthefourlevelingadjustlocking

nuts.

8.Carefullyrotatethebladessotheyarefacingfront

torear(Figure28).

9.Measurefromthetipofthefrontbladetotheat

surfaceandthetipoftherearbladetotheat

surface(Figure28).Ifthefrontbladetipisnot

“R”(seeBlockHeightandRakeTableinDeck

Leveling)lowerthantherearbladetip,adjustthe

frontdeckhanger.

Figure28

1.Bladesfronttorear2.Measurehere

10.Whenthefront-to-rearbladeslopeiscorrect

checktheside-to-sidelevelofthemoweragain;

refertoDeckLeveling.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

AdjustingtheParkingBrake

ServiceInterval:Every500hours

Checktomakesurebrakeisadjustedproperly.This

proceduremustbefollowedaftertherst100hours

orwhenabrakecomponenthasbeenremovedor

replaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),move

themotioncontrolleverstotheneutrallocked

positionandsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop,

andremovethekey.

4.Setupthemachinetobepushedbyhand(see

DriveWheelReleaseValvesintheOperation

section).

5.Raisethebackofthemachineupandsupportthe

machinewithjackstands.

CAUTION

Raisingthemowerdeckforserviceor

maintenancerelyingsolelyonmechanical

orhydraulicjackscouldbedangerous.The

mechanicalorhydraulicjacksmaynotbe

enoughsupportormaymalfunctionallowing

theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

jacksforsupport.Useadequatejackstands

orequivalentsupport.

6.Engage/disengagethebrakeandcheckeachdrive

tiretomakesureeachbrakeengages/disengages.

7.Ifadjustmentisnecessary,loosenthejamnut

fromtheyokeonthesidethatneedsadjustment.

Removethehairpinandclevispin(seeFigure29).

Maintenance

Figure29

1.Hairpin3.Yoke

2.Clevispin4.Jamnut

•AdjustingtheBraketoEngage:Shortenthe

linkagebyturningtheyokeclockwise.

•AdjustingtheBraketoDisengage:

Lengthenthelinkagebyturningtheyoke

counterclockwise.

8.Reinstalltheclevispinandhairpinandtighten

downthejamnut.Repeatstep6andreadjustif

necessary.

9.Whenadjustmentiscomplete,removethejack

standsorequivalentsupportandlowerthe

machine.

10.Placethemachineintothe“operating”position.

RefertotheDriveWheelReleaseValvessection

inOperation.

MotionControlHandle

Adjustment

Adjustingtheheight:

Themotioncontrolleverscanbeadjustedhigheror

lowerformaximumoperatorcomfort.

1.Removethehardwareholdingthecontrolleverto

thecontrolarmshaft(Figure30).

Figure30

1.Bolts4.Controlarmshaft

2.Washer5.Slottedhole

3.Controllever

2.Movethecontrollevertothenextsetofholes.

Securetheleverwiththehardware.

3.Repeattheadjustmentfortheoppositecontrol

lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor

maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever

tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe

controlleverforeoraftFigure30.Tightenboth

boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol

lever.

FullForwardTracking

Adjustment

Ifthemachinetravelsorpullstoonesidewhenthe

motioncontrolleversareinthefullforwardposition,

adjustthecoverplates.

1.Loosenthescrewsonacoverplate(seeFigure31).

2.Slidethecoverplatebackwardorforwardto

adjustthetraveloftheleverandtightenthe

screws.

3.Drivethemachineandcheckthefullforward

tracking.

4.Repeatsteps1through3untildesiredtracking

isobtained.

Maintenance

Figure31

1.Controlarmshaft3.Trackingplate

2.Trackingplatescrew

MotionControlLinkage

Adjustment

Locatedoneithersideoftheunit,belowtheseatare

thepumpcontrollinkages.Rotatingtheturnbuckle

witha1/2inchwrenchallowsnetuningadjustments

sothatthemachinedoesnotmoveinneutral.Any

adjustmentsshouldbemadeforneutralpositioning

only.

WARNING

Enginemustberunninganddrivewheelsmust

beturningsoadjustmentscanbeperformed.

Contactwithmovingpartsorhotsurfacesmay

causepersonalinjury.

Keepngers,hands,andclothingclearof

rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift

pedalandremovetheheightofcutpin.Lower

decktotheground.

2.Raisetherearofmachineupandsupportwith

jackstands(orequivalentsupport)justhigh

enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat

safetyswitch,locatedunderthebottomcushion

oftheseat.Theswitchisapartoftheseat

assembly.

4.Temporarilyinstallajumperwireacrossthe

terminalsintheconnectorofthemainwiring

harness.

5.Startengine.Brakemustbeengagedand

motioncontrolleversouttostartengine.

Operatordoesnothavetobeintheseat.Run

engineatfullthrottleandreleasebrake.

6.Runtheunitatleast5minuteswiththedrive

leversatfullforwardspeedtobringhydraulicoil

uptooperatingtemperature.

Note:Themotioncontrolleverneedstobein

neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral

position.Thecontrolplatetabsshouldtouchthe

returntoneutralplatesonthehydros.Adjust

pumpcontrolrodlengthsbylooseningthenuts

androtatingtheturnbuckleintheappropriate

directionuntilthewheelsslightlycreepinreverse

(Figure32).Movethemotioncontrolleverstothe

reversepositionandwhileapplyingslightpressure

totheleverallowthereverseindicatorspringsto

bringtheleversbacktoneutral.Thewheelsmust

stopturningorslightlycreepinreverse.

Figure32

1.Nut4.Controlplate

2.Turnbuckle5.Returntoneutralplate

3.Stationaryplate6.Tabstouchingreturnto

neutralplate

8.Tightennuts.

9.Shutoffunit.Removejumperwirefromwire

harnessandplugconnectorintoseatswitch.

10.Removethejackstands.

Maintenance

11.Raisethedeckandre-installtheheightofcutpin.

12.Checkthatthemachinedoesnotcreepinneutral

withtheparkbrakedisengaged.

AdjustingtheSeatRide

Suspension

Thenumberofseatspringscanbechangedto

maximizeridercomfort.Morespringsshouldbeused

withheavieroperatorsandonroughterrain.Fewer

springsshouldbeusedwithlighteroperatorsand

whenmowingsmooth,wellestablishedlawns.Always

keepthenumberofspringsontheleftandrightside

thesamewhenaddingandremovingsprings.

Figure33

1.Bolt3.Nut

2.Spring4.Additionalmounting

holes

Uptovespringscanbesecuredtotheseatboxwith

anutandbolt,seeFigure33.

RefertothePartsManualforspringandhardware

partnumbers.

ElectricClutchAdjustment

Figure34

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

1.Stopengine,waitforallmovingpartstostop,

andremovekey.Engageparkingbrake.Allow

themachinetocoolcompletelybeforestarting

theseinstructions.

2.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthebrake

spacers.

3.Checktheconditionofthewireharnessleads,

connectors,andterminals.Cleanorrepairas

necessary.

4.Verifythat12Vispresentattheclutchconnector

whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature.

Ifthegapisgreaterthan.04inch(1mm),proceed

withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-half

toonefullturn(seeFigure35).

Note:DoNotremovethebrakepolefrom

theeldshell/armature.Thebrakepolehas

worntomatchthearmatureandneedsto

continuetomatchaftertheshimisremoved

toensureproperbraketorque.

Maintenance

Figure35

1.Brakemountingbolt2.Shim

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot

discardtheshimuntilproperclutchfunction

hasbeenconrmed).

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe

brakespacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13

N-m)+/-0.5ft-lb(0.7N-m).

E.Usinga0.010inchthickfeelergauge,verify

thatagapispresentbetweentherotorand

armaturefaceonbothsidesofthebrakepole

asshown.(Duetothewaytherotorand

armaturefaceswear(peaksandvalleys)itis

sometimesdifculttomeasurethetruegap.)

G011733

Figure36

1.Feelergauge

Figure37

1.Feelergauge

•Ifthegapislessthan0.010inch,then

reinstalltheshimandreferencethe

Troubleshootingsection.

•Ifthegapissufcient,proceedtothe

safetycheckinstepF.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewith

thePTOswitch“off”andtheclutch

disengaged.

Iftheclutchdoesnotdisengage,

reinstalltheshimandreferencethe

Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch

isfunctioningproperly.Iftheclutch

doesnotengageproperly,referencethe

Troubleshootingsection.

Maintenance

Cleaning

CleanEngineandExhaust

SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore

oftenindryordirty

conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair

intakeandexhaustsystemareacancauseengine,

exhaustarea,andhydraulicsystemtooverheat

whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem

area.

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake

screen,aroundengineshrouding,andexhaust

systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe

engineandexhaustsystemarea.

RemoveEngineShroudsand

CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean

coolingns.Alsocleandust,dirtandoilfrom

externalsurfacesofenginewhichcancause

inadequatecooling.

3.Makesurecoolingshroudsarereinstalled.

Operatingtheenginewithoutcoolingshroudswill

causeenginedamageduetooverheating.

CleanHydroFanCooling

Fins

ServiceInterval:Beforeeachuseordaily

Removingdebrisfromthehydrofancoolingnswill

allowthehydrosystemtoruncoolerandimprovethe

lifeofthehydrosystem.

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Slideseatallthewayforward.

3.Removeaccumulateddebrisfromthehydrofan

coolingnsanduppersurfaces.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe

machineandcuttingdeck,especiallyunderdeck

beltshields,aroundthefueltank,aroundengine

andexhaustarea.

CleanGrassBuild-UpUnder

Deck

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurfaceanddisengage

thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

3.Raisedecktothetransport(5inch(12.7cm)

cuttingheight)position.Liftthefrontofunit

andsupportunitusingjackstandsorequivalent

support.

CAUTION

Raisingthemowerdeckforserviceor

maintenancerelyingsolelyonmechanical

orhydraulicjackscouldbedangerous.The

mechanicalorhydraulicjacksmaynotbe

enoughsupportormaymalfunctionallowing

theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

jacksforsupport.Useadequatejackstands

orequivalentsupport.

4.Cleanoutanygrassbuild-upfromundersideof

deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto

theenvironment.Disposeofusedoilatacertied

Maintenance

recyclingcenteroraccordingtoyourstateandlocal

regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which

ispoisonousandcancausesevereburns.

Swallowingelectrolytecanbefatalorifittouches

skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber

glovestoprotectskinandclothingwhen

handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater

andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced

inthegarbage.Managementanddisposalpractices

mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining

thebatteryisnolongeroperatingandisbeing

scrapped,takethebatterytoalocalcertiedrecycling

center.Ifnolocalrecyclingisavailablereturnthe

batterytoanycertiedbatteryreseller.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused

byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.Donotattempttoserviceorreplacemajor

itemsoranyitemsthatcallforspecialtimingofadjustmentprocedures(suchasvalves,governor,etc.).Have

thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.1.DisengagethePTO.

2.Parkingbrakeisnotengaged.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock

position.

3.Ensurethedriveleversareintheneutral

lockposition.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.SeeCheck

BatteryChargeandRecommended

JumpStartingProceduresectionsin

Maintenance.

5.Electricalconnectionsarecorroded,loose

orfaulty.

5.Checktheelectricalconnectionsfor

goodcontact.Cleanconnectorterminals

thoroughlywithelectricalcontactcleaner,

applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

Starterdoesnotcrank

8.Faultymodule.8.Replacemodule.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thethrottleandchokearenotinthe

correctposition.

4.Besurethethrottlecontrolismidway

betweenthe“SLOW”and“FAST”

positions,andthechokeisinthe“ON”

positionforacoldengineorthe“OFF”

positionforawarmengine.

5.Dirtinfuellter.5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel

system.

6.ContactanAuthorizedServiceDealer.

7.Aircleanerisdirty.7.Cleanorreplacetheaircleanerelement.

8.Seatswitchisnotfunctioningproperly.8.Checktheseatswitchindicator.Replace

seatifneeded.

9.Electricalconnectionsarecorroded,loose

orfaulty.

9.Checktheelectricalconnectionsfor

goodcontact.Cleanconnectorterminals

thoroughlywithelectricalcontactcleaner,

applydielectricgreaseandreconnect.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.11.Clean,adjustorreplacesparkplug.

12.Sparkplugwireisnotconnected.12.Checkthesparkplugwireconnection.

Enginewillnotstart,startshard,orfailsto

keeprunning

13.Faultymodule.13.Replacemodule.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe

engineareplugged.

4.Removetheobstructionsfromthecooling

nsandairpassages.

5.Dirtinfuellter.5.Replacethefuellter.

Enginelosespower

6.Dirt,water,orstalefuelisinthefuel

system.

6.ContactanAuthorizedServiceDealer.

Mowerpullsleftorright(withleversfully

forward)

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

1.Drivereleasehandlenotin“operating”

position.

1.Positionhandlein“operating”position;

seeDriveWheelReleaseValvessection

inOperation.

2.Driveorpumpbeltisworn,looseor

broken.

2.Changethebelt.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

Machinedoesnotdrive

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

cooldown.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

front-to-rear.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

7.Tipsofadjacentbladesareatanuneven

cuttingheight.Bladestipsshouldbeeven

within3/16inchwhichisapproximately

onebladethickness.

7.Replaceblades,spindlesand(or)check

fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade

pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

Abnormalvibration

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Deckbeltisworn,looseorbroken.2.Installnewdeckbelt.

3.Deckbeltisoffpulley.3.Installbeltonclutchanddeckpulleys,

idlers,andtensioningidlerperrouting

decalondeck.

4.Brokenormissingidlerspring.4.Replacethespring.

Bladesdonotrotate.

5.Drivebeltnotroutedcorrectly.5.Refertobeltroutingdecalondeck.

Schematics

ElectricalDiagram

Schematics

ElectricalLogicSchematic

General Warranty Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company,

pursuant to an agreement between them, jointly warrant on the terms and

conditions herein, that we will repair, replace or adjust any part on these

products and found by us (in the exercise of our reasonable discretion) to

be defective in factory materials or workmanship.

This warranty may only be assigned or transferred to a second (or third)

owner by an authorized Exmark dealer. The warranty period commences

upon the date of the original retail purchase.

Commercial Warranty Conditions

This warranty applies to Exmark Pioneer S-Series turf equipment sold in

the U.S. or Canada for a period of two years for commercial usage.

This warranty includes the cost of parts and labor for a period of two

years. This warranty does not cover pickup and delivery charges to and

from any authorized Exmark Service Dealer.

Consumer Warranty Conditions

This warranty applies to Exmark Pioneer S-Series turf equipment sold in

the U.S. or Canada for a period of four years or 500 hours (whichever

occurs first) for residential usage.

Residential usage means use of the product on the same lot as your home.

Use at more than one location is considered commercial use, and the

commercial use warranty detailed above would apply.

This warranty only includes the cost of parts and labor. For the first

warrantable service repair, Exmark will cover up to $45 for associated

pick-up and delivery charges to and from any authorized Exmark Service

Dealer. Additional transportation charges may apply, contact your Dealer

for details.

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine *

* The Engine warranty is covered by the engine manufacturer. Please

refer to the engine manufacturer’s warranty statement that is included in

the literature packet.

Items and Conditions Not Covered

This warranty does not cover the following:

• Any damage or deterioration due to normal use, wear and tear, or

 exposure.

• Cost of regular maintenance service or parts, such as filters, fuel, 

 lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or required 

 replacement or repair due to normal wear, accidents, or lack of proper

 maintenance.

• Any repairs necessary due to use of parts, accessories or supplies, 

 including 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.

There are no other express warranties except for engine and special

emission system coverage.

All warranty work must be performed by an authorized Exmark Service

Dealer using Exmark approved replacement parts.

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase by an

Exmark Service Dealer before obtaining any warranty service.

Contact any Exmark Service Dealer to arrange service at their dealership.

To locate a dealer convenient to you, access our website at

www.exmark.com. U.S. or Canada customers may also call

402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s analysis or

with the assistance provided, contact us at:

 Exmark Customer Service Department

 The Exmark Warranty Company

 2101 Ashland Avenue

 Beatrice, NE 68310

 402-223-6375 or

 service@exmark.com

Owner’s Responsibilities

If your product requires warranty service it must be returned to an

authorized Exmark service dealer within the warranty period. This

warranty extends only to turf equipment operated under normal

conditions. You must read the operator’s manual. You must also properly

service and maintain your Exmark product as described in the operator’s

manual. Such routine maintenance, whether performed by a dealer or by

you, is at your expense.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect

to this warranty shall be repair or replacement of defective components as

set forth herein. Neither Exmark nor Exmark Warranty Company

shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other extraordinary repair

 charges or charges relating to repairs or replacements outside of 

 normal business hours at the place of business of the authorized 

 Exmark Service Dealer.

• Rental of like or similar replacement equipment during the period of

 any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that covered by the

 terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as  

 a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation or

rescission of the contract of sale of any Exmark mower.

All implied warranties of merchantability (that the product is fit for

ordinary use) and fitness for use (that the product is fit for a

particular purpose) are limited to the duration of the express

warranty.

Some states do not allow exclusions of incidental or consequential

damages, or limitations on how long an implied warranty lasts, so the

above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

Pioneer S-Series Turf Equipment

2 Year Limited Commercial Warranty

4 Year or 500 Hours Limited Consumer Warranty

G4500-748_A

ServiceRecord

Date:DescriptionofWorkDone:ServiceDoneBy:

G01 1841

Figure38

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopeindicatortodeterminethe

degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan15degrees.Fold

alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

MID-MOUNT RIDING ACCESSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OUT-FRONT RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

IndustrialParkBox808

Beatrice,NE68310

AllRightsReserved

PartNo.4501-000Rev.A

(402)223-6300

Fax(402)223-5489

PrintedintheUSA

www.exmark.com

Exmark Pioneer S Series 0 Users Manual

000 & Higher to the manual 3b080a2c-fe74-4524-93e7-5ace2fe07048

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