Lazer Z® Diesel

• Engine Specifications: See your Engine Owner’s Manual

• Engine Oil Type: Exmark Premium Engine Oil is recommended.

  If using an alternative, use high-quality, low-ash engine oil that meets or exceeds the following specifications:

  • API service category CJ-4 or higher

  • ACEA service category E6

  • JASO service category DH-2

  Important: Using engine oil other than API CJ-4 or higher, ACEA E6, or JASO DH-2 may cause the diesel particulate filter to plug or cause engine damage.

  Use the following engine oil viscosity grade:

  • SAE 10W-30 or 5W-30 (all temperatures)

  • SAE 15W-40 (only temperatures above 0°F)

• RPM:

  • 3TNV80FT: 2600 ±50 RPM (PTO not engaged) Idle: 1400 ±50 RPM

  • 3TNV88C: 3000 ±50 RPM (PTO not engaged) Idle: 1400 ±50 RPM

  • 3TNV86CT: 3000 ±50 RPM (PTO not engaged) Idle: 1400 ±50 RPM

• Capacity: 12 gal. (45.4 L)

• Fuel Recommendations:

  • General Notes:

    • Never use kerosene or gasoline instead of diesel fuel.

    • Never mix kerosene or used engine oil with the diesel fuel.

    • Never keep fuel in containers with zinc plating on the inside.

    • Do not use fuel additives.

    • Use only clean, fresh diesel fuel or biodiesel fuels.

    • Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness.

  • Petroleum Diesel

    Cetane rating: 45 or higher

    Sulfur content: Ultra-low sulfur (<15 ppm)

    Diesel Fuel Specification:

    • ASTM D975

    • No. 1-D S15

    • No. 2-D S15

    Use summer-grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter-grade fuel (No. 1-D or No. 1-D/2-D blend) below that temperature.

    Note: Use of winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics which eases starting and reduces fuel filter plugging.Using summer-grade fuel above -7°C (20°F) contributes toward longer fuel pump life and increased power compared to winter-grade fuel.

  • Biodiesel

    This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petroleum diesel).

    Sulfur content: Ultra-low sulfur (<15 ppm)

    Biodiesel fuel specification: ASTM D6751 or EN14214

    Blended fuel specification: ASTM D975, EN590, or JIS K2204

    Important: The petroleum diesel portion must be ultra-low sulfur.

    Observe the following precautions:

    • Biodiesel blends may damage painted surfaces.

    • Use B5 (biodiesel content of 5%) or lesser blends in cold weather.

    • Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time.

    • Fuel filter plugging may be expected for a time after converting to biodiesel blends.

    • Contact your Authorized Exmark Distributor if you wish for more information on biodiesel.

• Charging System: External Alternator

• Charging Capacity:

  • All Except 144 Inch Deck Models: 55 amps

  • 144 Inch Deck Models: 140 amps

• Battery Type: BCI Group 26

• Recommended Minimum Battery CCA: 540 CCA

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses:

  • 3TNV80FT: Three 15 amp blade type; one 10 amp blade type

  • 3TNV88C: Three 15 amp blade type; one 25 amp blade type

  • 3TNV86CT: Three 15 amp blade type; one 25 amp blade type; two 60 amp blade type

• Brake must be engaged, and motion control levers out (neutral lock) to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

• Operator must be in seat when PTO is engaged, brake is disengaged, or motion control levers are moved in or engine will stop.

• Engine will stop if either the left, the right, or both levers are moved from neutral lock position while brake is engaged.

PTO will disengage, an alarm will sound, and a bar graph will display the engine temperature when it reaches an overheat condition. The PTO will not re-engage until the engine has cooled and the PTO switch is manually shut-off and re-engaged.

Note: If the engine coolant level is below the indicator line on the overflow bottle when the engine is cold, the coolant temperature gauge may not register correctly during operation and/or the warning buzzer may not sound if the engine overheats. Refer to Check Engine Coolant Level in Maintenance.

• Fan: Belt driven

• Twin Fan (144 Inch Deck Models Only): Electric driven, variable speed, and reversing.

• Coolant Liquid: 50/50 solution of water and permanent ethylene glycol antifreeze. The use of Havoline® Xtended Life coolant is recommended.

• Coolant Capacity: 10 quarts (9.5 L)

• Steering and Motion Control:

  Note: Motion control levers are adjustable to two heights.

  • Separate levers, on each side of the console, control speed and direction of travel of the respective drive wheels.

  • Steering is controlled by varying the position of the levers relative to each other.

  • Moving motion control levers outward (in slots) locks the drive system in neutral.

• PTO Engagement Switch: Engages wet clutch (to drive belt) which engages mower blades.

• Parking Brake Lever (For All Except 144 Inch Deck Models): Engages parking brake.

• Deck Lift Switch (Hydraulic Cylinder):

  • 60 and 72 Inch Decks: Raises/lowers the deck to set cutting height.

  • 96 and 144 Inch Deck Models: Raises/lowers the center deck to set cutting height and folds/unfolds the wings.

• Type: Deluxe suspension (adjustable spring suspension) seat with high back, padded flip-up armrests, and integral safety switch. Seat height remains the same. Seat Isolation System for reduced vibration, to enhance ride of standard seat.

• Mounting: Hinged to tilt up for access to hydraulic reservoir and other components. Held in tilted position with prop rod. Adjustable fore and aft seat track.

• Armrests: Molded adjustable flip-up armrests.

• Seat Safety Switch: Integrated seat switch. Time delay seat switch eliminates rough ground cut-outs.

• Hydrostatic Transmission: Kanzaki. KPS18T

• Wheel Motors: Two Hydro-Gear “H” Motors (All Models Except 144 Inch Deck Models)

• Wheel Motors: Two Danfoss Motors with Omni gearbox (144 Inch Deck Models Only)

• Hydraulic Oil Type: Exmark Ruby Tran^™ oil.

  Part No. 135-2834

• Hydraulic Oil Capacity:

  • All Models Except 144 Inch Deck: 15 qt. (14.2 L)

  • 144 Inch Deck Models: 14 qt. (13.3 L)

• Hydraulic Filter: Replaceable cartridge type.

  P/N 135-2252: 10 microns

• Drive Wheel Gear Box Oil Type: SAE 75W-90 Synthetic gear lube (144 Inch Deck Models Only)

• Speeds:

  • 3TNV80FT:

    • 0-11.0 mph (17.7 km/hr) forward.

    • 0-6.0 mph (9.7 km/hr) reverse

  • 3TNV88C:

    • 0-12.5 mph (20.1 km/hr) forward

    • 0-7.0 mph (11.3 km/hr) reverse

  • 3TNV86CT:

    • In Low:

      • 0-10 mph (16.1 km/hr) forward

      • 0-6.0 mph (9.7 km/hr) reverse

    • In High:

      • 0-17 mph (27.4 km/hr) forward.

      • 0-9.0 mph (14.5 km/hr) reverse

• Drive wheel release valves allow machine to be moved when engine is not running.

Oil Type: SAE 75W-90 Synthetic gear lube

Capacity: 14 oz (420 ml)

Side Discharge 60 and 72 Inch Models:

Rear Discharge 72 and 96 Inch Models:

Rear Discharge 144 Inch Models:

Side Discharge Models:

Rear Discharge Models:

60, 72, and 96 Inch Deck Models:

144 Units :

Drive Wheels

Caster Wheels

Side Discharge

Rear Discharge

3TNV80FT Models:

3TNV88C Models:

3TNV86CT Models:

The motion control levers located on each side of the console control the forward and reverse motion of the machine.

Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively. Wheel speed is proportional to the amount the lever is moved.

Moving the levers outward from the center position into the T-slot locks them in the neutral position (Figure 6).

Note: When the motion control levers are in the neutral position, a LCD indicator displays on the message display.

Figure 6

1. All Models Except 144 Inch Deck: Neutral lock position (handles out). 144 Inch Deck Models: Neutral lock position and park brake (handles out).
2. Neutral operate position (handles in)
3. Front of Unit
4. Forward
5. Neutral (operate)
6. Reverse

Located on the right console.

Figure 7

1. RED Equipped Logic Display Unit (LDU)
2. Deck lift switch (also folds wings on 96 inch deck)
3. Ignition switch
4. PTO engagement switch

The RED Equipped Logic Display Unit (LDU) monitors and displays machine system information.

Figure 8

LDU (Logic Display Unit)

1. Information screen
2. LED status light
3. Push buttons

Refer to the RED Equipped User’s Guide-Diesel Models for detailed information explaining the Operator interface allowing users to access information, reset counters, modify system settings, and troubleshoot the equipment.

Located on the right console.

Figure 9

1. RED Equipped Logic Display Unit (LDU)
2. Deck lift and fold switch
3. Ignition switch
4. PTO engagement switch
5. Ground drive speed switch

The RED Equipped Logic Display Unit (LDU) monitors and displays machine system information.

Figure 10

LDU (Logic Display Unit)

Refer to the RED Equipped User’s Guide for detailed information explaining the Operator interface allowing users to access information, reset counters, modify system settings, and troubleshoot the equipment.

Located at the top of the LDU, above the push buttons (see Figure 7).

The information screen displays information relative to machine operation and is backlit for viewing in low light situations.

Refer to the RED Equipped User’s Guide-Diesel Models for more information.

Located at the bottom of the LDU, below the information screen.

The icons displayed on the information screen above the buttons indicate the current function. The push buttons allow the user to select the engine speed as well as navigate through system menus.

Refer to the RED Equipped User’s Guide-Diesel Models for more information.

Located on the right side of the LDU.

The LED is multi-colored to indicate the system status. During startup, the LED will illuminate red, then orange, then green to verify functionality.

• Solid Green — indicates normal operating activity

• Blinking Red — indicates a fault is active

• Blinking Green and Orange— indicates a clutch reset is required

Refer to the RED Equipped User’s Guide-Diesel Models for more information.

Located behind the seat and to the left of the lower ROPS leg.

The audible alarm will sound if an error occurs to indicate the issue to the operator. During startup, the alarm will sound briefly to verify functionality.

When the alarm sounds, the error message will display and the LED will turn red.

• Continuous sound indicates critical errors.

• Chirping sound indicates less critical errors, such as required maintenance or service intervals.

Refer to the RED Equipped User’s Guide-Diesel Models for more information.

Located on right side of unit, just to the front of the RH motion control lever.

The brake lever engages a parking brake on the drive wheels.

Note: The LCD indicator appears in the message display on the RH console when the park brake is engaged (see Figure 7).

Pull the lever up and rearward to engage the brake.

Push the lever forward and down to disengage the brake.

The unit must be tied down and brake engaged when transporting.

Moving the levers outward from the center position into the T-slot locks them in the neutral position and sets the parking brake (see Figure 6).

When the lever are in the neutral position, the park brake is activated.

Note: The LCD indicator appears in the message display on the RH console when the park brake is engaged (see Figure 7).

Located on right fuel tank.

The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise to the “ON” position. Rotate clockwise to the next position to engage the starter (key must be held against spring pressure in this position).

Note: Brake must be engaged and the motion control levers out (neutral lock position) to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

Note: The LCD indicators appear when each control meets the “safe to start” mode (e.g. the indicator turns on when the operator is in the seat.)

Note: The engine ECU controls the glow plugs during cold starts. If the coolant is at a low enough temperature, the glow symbol will be displayed on the RED LDU and the starter will not begin cranking the engine when the key is turned to the “START” position. The glow plugs will be activated in the “ON” or “START” position. Once the glow has been on long enough for the current temperature, the glow symbol on the RED LDU will disappear and the engine will crank when turned to “START”.

Note: The system will allow the unit to start with the PTO switch in the pulled out (up) position, but will not engage the blades. The PTO engagement switch must be reset to engage the PTO.

Located on the information screen of the RED Equipped LDU of the RH console.

The hour meter records the number of hours that the engine has run.

Hours are displayed in Engine-Off screen or in the Engine Hour Counter menu (refer to the RED Equipped User’s Guide-Diesel Models for more information).

Located on each side of the hydrostatic pump.

Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running.

Rotate each bypass valve counterclockwise one turn to release; rotate clockwise to reset system. Do Not overtighten. Do Not tow machine.

Figure 11

1. Right bypass valve
2. Left bypass valve

Located on each of the wheel motor gearboxes. Releasing the motor brake is used to allow the machine to be moved without the engine running.

1. Before releasing the motor brakes, the wheels must be chocked or blocked and the machine needs to be parked on a level surface.

2. Remove and retain the bolts from the wheel motor (Figure 12).

3. Flip the cap inward to the wheel motor.

   

   Figure 12

   1. Wheel motor gearbox
   2. Cap
   3. Bolts

4. Use the retained bolts and tighten down the flipped cap until the brake releases.

5. Reverse the process to reapply the brake.

If the engine loses power, the wings can be folded or unfolded manually.

• To fold the wings:

  1. Hold set screws with 1/8 inch allen wrench, loosen sealing nuts with 1/2 inch wrench until nut is flush with the lifting end of the set screw (approximately six turns)–reference Figure 13.

     

     Figure 13

     1. Sealing nuts
     2. Set screw
     3. Manifold

  2. Remove wrenches and tighten the set screw BY HAND approximately four turns until a slight resistance is felt. Continue to turn by hand 1 1/2 more turns to unseat the load holding check valves.

     Important: Do Not tighten the set screws beyond this point, damage may result.

  3. Hold set screws with 1/8 inch allen wrench, snug sealing nuts with 1/2 inch wrench to the manifold body.

  4. Using lifting equipment with at least a 227 kg (500 lb) lifting capacity, carefully pull one wing deck outward, then upward to fold. Secure the wing with the transport lock pin. Repeat for other wing.

• To unfold the wings and reset the wing fold valve:

  1. Using lifting equipment with at least a 227 kg (500 lb) lifting capacity, remove the transport lock pin and carefully lower the wing to the ground.

  2. Hold set screws with 1/8 inch allen wrench, loosen sealing nut with 1/2 inch wrench (reference Figure 13).

  3. Loosen the set screw and turn approximately 6 turns.

  4. Holding the set screws with 1/8 inch allen wrench, snug the sealing nuts to 8 ft-lb (10 N-m) with 1/2 inch wrench to the manifold body.

Located behind the RED Equipped LDU on the RH console (see Figure 7).

Switch must be “ON” (pulled up) to engage the blades. Switch is “OFF” (pushed down) to disengage the blades.

The LCD indicator will appear on the information screen of the RED Equipped LDU when the PTO switch is disengaged.

Note: Engaging and disengaging the PTO switch changes the engine throttle between “mow” and “transport” mode.

Note: The starter will crank with the PTO switch in the “ON” (pulled up) position; however, the system will disengage the PTO and a PTO reset error will occur. Engaging the PTO will require the operator to reset the PTO switch by turning it “OFF” (pushed down) and then turning it “ON”.

Important: On 96 and 144 inch Decks: The wings must be unfolded before the PTO can be engaged.

Located on the back panel of the RH console (see Figure 7).

• 60 and 72 inch Decks:

  • Push the top of the switch to raise the deck.

  • Push the bottom of the switch to lower the deck.

• 96 and 144 inch Decks:

  • Push the top of switch to raise the center deck and fold up the outer wings.

  • Push the bottom of switch to lower the center deck and outer wings.

Located on the back panel of the RH console to the left of the PTO switch (see Figure 9)

• Push the top of switch to place the transmission in high range.

• Push the bottom of switch to place the transmission in low range.

Refer to the RED Equipped User’s Guide-Diesel Models for more information.

With the operator in the seated position, the mirrors should provide a wide-angle view to help with blind spots.

Adjust the left and right mirror for each operator to ensure optimal viewing angle.

1. Move the motion control levers out to the neutral lock position.

2. Engage the parking brake. For all models except 144 inch deck models, pull the lever up and back to engage the parking brake. For 144 inch deck models, the motion control levers placed in the neutral position engages the park brake.

3. Push down on the PTO switch to the “disengage” position.

   Note: It is not necessary for the operator to be in the seat to start the engine.

4. Turn ignition switch to the “START” position. Release the switch as soon as the engine starts.

   Important: Do Not crank the engine continuously for more than ten seconds at a time. If the engine does not start, allow a 60 second cool-down period between starting attempts. Failure to follow these guidelines can burn out the starter motor.

1. Be sure that all persons are clear of the deck wings. Press and hold the top of the deck control switch; the center deck will raise first and then the wings.

2. Stop engine, wait for all moving parts to stop, engage the parking brake and remove the key.

3. Remove the clevis pin and hairpin from the storage location and secure each wing in the up position..

   

   Figure 15

   96 Inch Deck Pin Lock

   1. Clevis pin
   2. Hairpin
   

   Figure 16

   144 Inch Deck Pin Lock

   1. Clevis pin
   2. Hairpin

Important: The outer deck wings need to be lowered into the mowing position before the PTO will engage.

1. Remove the clevis pin and hairpin that secures each wing in the up position. Place them in the storage position.

   

   Figure 17

   1. Pin storage location

2. Be sure that all persons are clear of the deck wings. Press and hold the bottom of the deck control switch; the center deck will lower first, then the outer wings.

The PTO push-pull switch engages the cutting blades. Be sure that all persons are clear of the mower deck and discharge area before engaging PTO.

Important: Operator must be in seat before the PTO can operate.

Important: 96 and 144 Inch Deck Only: Operator must be in seat and the outer deck wings need to be lowered into the mowing position before the PTO will engage.

To engage the PTO, pull the switch outward to engage the blades.

Note: The clutch saver feature allows the PTO to be engaged at any speed.

Push the PTO switch in to disengage the blades.

1. Bring the unit to a full stop.

2. Move the motion control levers out to the neutral lock position.

3. Engage the parking brake.

4. Disengage the PTO.

5. Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the “OFF” position to stop the engine.

6. Remove the key to prevent children or other unauthorized persons from starting engine.

Important: To begin movement (forward or backward) the operator must be in the seat, the brake lever must be disengaged (pushed down, except 144 inch deck models) before the motion control levers can be moved in or the engine will stop.

When the motion control levers are positioned fully outward (apart) in the T-slot, the drive system is in the neutral lock position (Figure 18).

Note: The “N” LCD indicator appears when both levers are in the neutral lock position.

When the motion control levers are moved directly inward (together) the drive system is in the neutral operate position.

Figure 18

1. All Models Except 144 Inch Deck: Neutral lock position (handles out).144 Inch Deck Models: Neutral lock position and park brake (handles out).
2. Neutral operate position (handles in)
3. Front of Unit
4. Forward
5. Neutral (operate)
6. Reverse

Driving Forward

1. Release the parking brake.

2. Move the motion control levers inward to the center to the neutral position.

3. To move forward in a straight line, move both levers forward with equal pressure.

   

   Figure 19

   To turn left or right, pull the motion control lever back toward neutral in the desired turn direction.

   The machine will move faster the farther the motion control levers are moved from the neutral position.

4. To stop, position both motion control levers in the neutral operate position.

Driving in Reverse

1. Move the motion control levers inward to the neutral operate position.

2. To move rearward in a straight line, move both levers rearward with equal pressure.

   

   Figure 20

   To turn right, release pressure on the RH motion control lever and the rear of the machine will move towards the rear and to the right.

   To turn left, release pressure on the LH motion control lever and the rear of the machine will move towards the rear and to the left.

3. To stop, position both motion control levers in the neutral operate position.

The cutting height of the mower deck is adjusted from 1 to 5 1/2 inches (2.54 cm to 14 cm) in 1/4 inch (6.4 mm) increments.

1. Stop the machine and move the motion control levers outward to the neutral locked position.

2. Disengage the PTO.

   Note: When changing the cutting height positions, always come to a complete stop and disengage the PTO.

3. Press the top of deck lift switch, on the panel control, to raise the deck. Push the bottom of the switch to lower the deck.

4. Insert the height adjustment pin into the hole corresponding to the desired cutting height.

   See the decal on the side of the deck lift plate for cut heights.

The cutting height of the mower deck can be adjusted from 1 to 5 1/2 inches (2.54 cm to 14 cm) in 1/4 inch (6.4 mm) increments.

1. Position the mower on a flat surface.

2. Disengage the PTO.

3. Press the top of deck lift switch, on the panel control, to raise the center deck and the outer wings.

4. Stop engine, wait for all moving parts to stop and engage the parking brake.

5. Adjust the center deck:

   1. Remove the height adjustment pin from the deck lift plate on the right side of the center deck.

   2. Insert the height adjustment pin into the hole corresponding to the desired cutting height.

      See the decal on the side of the deck lift plate for cut heights.

6. Adjust the side wing decks:

   1. Make sure the engine is off, the key has been removed, and the deck wings are locked in place.

   2. Unlock the cam locks located on the height of cut channel on the wing deck (see Figure 21).

      

      Figure 21

      1. Unlock cam lock
      2. Height of cut pin
      3. Lynch pin

   3. Remove the lynch pin from the height of cut pin on both the front and rear channels.

   4. Move the wing deck to the appropriate height and reinstall the height of cut pins and lynch pins as shown in Figure 21.

   5. Lock the cam lock.

   6. Repeat for other wing deck.

7. If additional height of cut range is desired, adjust the front and rear gauge wheels on the wing deck:

   1. Remove the mounting hardware from the gauge wheel.

   2. Adjust the front and rear gauge wheels to the appropriate hole location (see the chart below and Figure 22) and reinstall the mounting hardware.

      Hole Location	Height of Cut Range
      Top hole (-1 on decal)	1–3.5 inches (25–89 mm)
      Middle hole (0 on decal)	2–4.5 inches (51–114 mm)
      Bottom hole (+1 on decal)	3–5.5 inches (76–140 mm)

      

      Figure 22

      Height of Cut Range

      1. Top hole (-1 on decal)
      2. Middle hole (0 on decal)
      3. Bottom hole (+1 on decal)

   3. Repeat for other wing deck.

It is recommended to change the anti-scalp roller position when the height of cut has changed.

1. Stop the machine and move the motion control levers outward to the neutral locked position.

2. Disengage the PTO.

3. Engage the park brake.

4. Stop the engine, remove the key and wait for all moving parts to stop.

5. After adjusting the height of cut, adjust the anti-scalp rollers by removing the mounting hardware.

6. Place the rollers in one of the positions shown (Figure 23). Rollers will maintain 3/4 inch (19 mm) clearance to the ground to minimize gouging and roller wear or damage.

   

   Figure 23

   For cutting heights above 3.5 inches (90 mm) use the bottom hole. The rollers will still be effective against scalping.

   1. Anti-scalp roller mounting bracket
   2. Cutting height

   For Maximum Deck Flotation, place the rollers one hole position lower. Rollers should maintain 1/4 inch (6.4 mm) clearance to the ground. Do Not adjust the rollers to support the deck.

7. Reinstall the mounting hardware:

   • Side Discharge Models:

     1. Be sure the roller bolts are installed with the spring disc washer between the head of the bolt and the mounting bracket (see Figure 24).

     2. Torque the 3/8 nyloc nut to 50–55 ft-lb (68-75 N-m).

        

        Figure 24

        1. 3/8-16 X 3 3/4 Grade 8 bolt
        2. Spring disc washer (cone towards bolt head)
        3. Front right anti-scalp bracket shown
        4. 3/8 nyloc-torque to 50-55 ft-lb (68-75 N-m)

   • Rear Discharge Models:

     Torque the 3/8 nyloc nut to 30-35 ft-lb (41-47 N-m) (see Figure 25).

     

     Figure 25

     1. 3/8 nyloc-torque to 30-35 ft-lb (41-47 N-m)
     2. Anti-scalp rollers
     3. Spacer
     4. Bolt

The 96 inch deck has 13 anti-scalp roller locations to adjust see Figure 26.

Figure 26

Underside of 96 Inch Deck

1. Anti-scalp roller

The 144 inch deck has 21 anti-scalp roller locations to adjust see Figure 27.

Figure 27

Underside of 144 Inch Deck

1. Anti-scalp roller

Mount the side bumpers in the top holes when operating in height of cuts higher than 2 1/2 inches (64 mm) and in the center holes when operating in height of cuts lower than 2 1/2 inches (64 mm).

Note: When bumpers become worn, switch the bumpers to the opposite sides of the mower, flipping them over. This allows the bumpers to be used longer before replacing them.

1. Stop the machine and move the motion control levers outward to the neutral locked position.

2. Disengage the PTO.

3. Engage the park brake.

4. Stop the engine, remove the key and wait for all moving parts to stop.

5. Raise the deck to the transport position.

6. Remove the bolts and nuts from each bumper.

   

   Figure 28

   1. Bolt
   2. Bumper
   3. Nut

7. Move each bumper to the desired position and secure them with the bolts and nuts.

   Note: Only use the top or center sets of holes to adjust the bumpers. The bottom holes are used when switching sides, at which time they become the top holes on the other side of the mower.

Important: Refer to the Engine Owner’s Manual for additional maintenance procedures.

1. Stop engine and wait for all moving parts to stop. Make sure unit is on a level surface.

2. Check with engine cold.

3. Raise hood to gain access to dipstick.

4. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick and push it all the way down into the tube. Remove the dipstick and read the oil level.

5. If the oil level is low, wipe off the area around the oil fill cap, remove cap and fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Owner's manual for an appropriate API rating and viscosity. Do Not overfill.

Important: Do Not operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storage.

Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater.

Important: Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart for recommended charger settings).

1. Check the weak battery for terminal corrosion (white, green, or blue “snow”), it must be cleaned off prior to jump starting. Clean and tighten connections as necessary.

   Caution

   Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure.

   Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur.

   Danger

   Jump starting a weak battery that is cracked, frozen, has low electrolyte level, or an open/shorted battery cell, can cause an explosion resulting in serious personal injury.

   Do Not jump start a weak battery if these conditions exist.

2. Make sure the booster is a good and fully charged lead acid battery at 12.6 volts or greater. Use properly sized jumper cables (4 to 6 AWG) with short lengths to reduce voltage drop between systems. Make sure the cables are color coded or labeled for the correct polarity.

   Caution

   Connecting the jumper cables incorrectly (wrong polarity) can immediately damage the electrical system.

   Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries.

   Note: The following instructions are adapted from the SAE J1494 Rev. Dec. 2001 – Battery Booster Cables – Surface Vehicle Recommended Practice (SAE – Society of Automotive Engineers).

   Warning

   Batteries contain acid and produce explosive gases.

   • Shield the eyes and face from the batteries at all times.

   • Do Not lean over the batteries.

   Note: Be sure the vent caps are tight and level. Place a damp cloth, if available, over any vent caps on both batteries. Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only.

3. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in .

   

   Figure 33

   1. Positive (+) cable on discharged battery
   2. Positive (+) cable on booster battery
   3. Negative (–) cable on the booster battery
   4. Negative (–) cable on the engine block
   5. Booster battery
   6. Discharged battery
   7. Engine block

4. Connect the other end of the positive cable to the positive terminal of the booster battery.

5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery.

6. MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE (NOT TO THE NEGATIVE POST) AWAY FROM THE BATTERY. STAND BACK.

7. Start the vehicle and remove the cables in the reverse order of connection (the engine block (black) connection is the first to disconnect).

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift deck and secure in raised position as stated in the Clean Grass Build-Up Under Deck procedure.

3. Inspect blades and sharpen or replace as required.

4. Reinstall the blades (if they were removed) in the following order:

   1. Install bushing through blade with bushing flange on bottom (grass) side of blade.

      

      Figure 34

      1. Install bushing in blade prior to installing bushing in spindle.

   2. Install bushing/blade assembly into spindle.

      

      Figure 35

      1. Use wrench here for blade installation. This nut has been torqued to 130-160 ft-lb (176-217 N-m)
      2. Torque to 55-60 ft-lb (75-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute.

   3. Apply lubricant to threads of blade bolt as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute. Install blade bolt finger tight. Place wrench on the top spindle nut then torque the blade bolts to 55-60 ft-lb (75-81 N-m).

   Important: On rear discharge decks, the RH blade rotates counterclockwise. Be sure to reinstall that blade onto the RH spindle only.

   Warning

   Incorrect installation of the blade or components used to retain the blade can be dangerous. Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death.

   Always install the original Exmark blades, blade bushings, and blade bolts as shown.

Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use.

Note: If machine does not pass any of these tests, Do Not operate. Contact an Authorized Service Dealer.

Note: To prevent engine cut-outs on rough terrain, the seat has a 1/2 second time delay before the engine begins to shutdown.

Check the Normal Engine Starting Chart for All Except 144 Inch Deck Models

		System
		Parking Brake	PTO	Motion Control Levers	Operator	Outcome
	State of System	Engaged	Disengaged (Blades)	Both levers out (neutral lock)	In seat or out of the seat	Starter should crank
		Engaged	Up position, but blades disengaged*	Both levers out (neutral lock)	In seat or out of seat	Starter should crank

*Note: The starter will crank with the PTO switch in the “ON” (pulled up) position; however, the system will disengage the PTO and a reset PTO error will occur. Engaging the PTO will require the operator to reset the PTO switch by turning it “OFF” (pushed down) and then turning it “ON”.

Check the Normal Engine Starting Chart for 144 Inch Deck Models

		System
		Motion Control Levers/Parking Brake	PTO	Operator	Outcome
	State of System	Both Levers Out=Parking Brake Engaged	Disengaged (Blades)	In seat or out of the seat	Starter should crank
		Both Levers Out=Parking Brake Engaged	Up position, but blades disengaged*	In seat or out of seat	Starter should crank

*Note: The starter will crank with the PTO switch in the “ON” (pulled up) position; however, the system will disengage the PTO and a reset PTO error will occur. Engaging the PTO will require the operator to reset the PTO switch by turning it “OFF” (pushed down) and then turning it “ON”.

Check Engine Starting Circuit Chart for All Except 144 Inch Deck Models

Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario.

	System
	Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
State of System	Engaged	Disengaged	Both levers moved in, or either right or left lever moved in	Operator in seat	Starter must not crank
	Disengaged	Disengaged	Both levers out (neutral lock)	Operator in seat	Starter must not crank

Check Engine Starting Circuit Chart for 144 Inch Deck Models

Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario.

	System
	Motion Control Levers/Parking Brake	PTO (Blades)	Operator	Outcome
State of System	Both levers moved in, or right or left lever moved in=Parking Brake Disengaged	Disengaged	Operator in seat	Starter must not crank

Check Shutdown Circuit Chart for All Except 144 Inch Deck Models

Note: The state of system item(s) that is bold is being checked in each scenario.

	System
	Engine	Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
State of System	Running idle (1/3 throttle or efficient mode)	Disengaged	Disengaged	Both levers moved out (neutral lock) or both levers moved in	Raise off of seat (but don’t get off)	Engine must begin shutdown within 1 second
Check Shutdown Circuit Chart (continued)
	System
	Engine	Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
State of System	Running idle (1/3 throttle or efficient mode)	Disengaged	Engaged	Both levers moved in	Raise off of seat (but don’t get off)	Engine must begin shutdown within 1 second
	Running idle (1/3 throttle or efficient mode)	Engaged	Disengaged	Both levers moved in, or either right or left lever moved in	Operator in seat	Engine must begin shutdown within 1 second
	Running idle (1/3 throttle or efficient mode)	Engaged	Engaged	Both levers moved out (neutral lock)	Raise off of seat (but don’t get off)	PTO must begin shutdown within 1 second; engine stays running.
	Running idle (1/3 throttle or efficient mode)	Disengaged	Engaged and Deck wings up	Both levers moved out (neutral lock)	Operator in seat	PTO must begin shutdown within 1 second; engine stays running.

Check Shutdown Circuit Chart for 144 Inch Deck Models

Note: The state of system item(s) that is bold is being checked in each scenario.

	System
	Engine	Motion Control Levers/Parking Brake	PTO (Blades)	Operator	Outcome
State of System	Running idle (1/3 throttle or efficient mode)	Both levers moved in, or right or left lever moved in=Parking Brake Disengaged	Disengaged	Raise off of seat (but don’t get off)	Engine must begin shutdown within 1 second
	Running idle (1/3 throttle or efficient mode)	Both Levers Out=Parking Brake Engaged	Engaged	Raise off of seat (but don’t get off)	PTO must begin shutdown within 1 second; engine stays running.
Check Shutdown Circuit Chart (continued)
	System
	Engine	Motion Control Levers/Parking Brake	PTO (Blades)	Operator	Outcome
State of System	Running idle (1/3 throttle or efficient mode)	Both levers moved in, or right or left lever moved in=Parking Brake Disengaged	Engaged and Deck wings up	Operator in seat	PTO must begin shutdown within 1 second; engine stays running.

Check that both the mounting hardware and the knobs are in good working condition. Make sure the knobs are fully engaged with the ROPS in the raised position. The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged.

Figure 36

1. Engaged
2. Partially engaged — Do Not operate with ROPS in this condition.

1. Position the machine on a flat surface.

2. Shut off the engine, wait for all moving parts to stop, and engage the parking brake.

3. Raise the center deck and fold the wings by pressing down at the rear of the deck lift rocker switch. Hold the switch down until both wings are completely folded.

4. Push on the front corners of the deck near the lower bushings. If the there is more than 1/8 inch (3 mm) of movement, then the bushings need to be replaced.

1. Position the mower on a flat surface.

2. Disengage the PTO and shut off the engine.

3. Remove and retain the clevis pins and hairpins from each wing deck storage location.

4. Be sure that all persons are clear of the deck wings. Press and hold the top of the deck control switch; the center deck will raise first and then the wings.

5. Secure each wing in the up position with the clevis pins and hairpins.

6. Loosen the bolts that secure the upper pivot pins to the deck but Do Not remove.

   For 144 Inch Deck Models Only: Remove and retain the large wing springs.

   

   Figure 37

   1. Front pivot pin
   2. Rear pivot pin

7. Remove and retain the clevis pins and hairpins from each wing deck cylinder. Remove the height adjustment pin from the deck lift plate on the right side of the center deck.

8. Lower the wing decks, but Do Not draw them into the operating position.

9. Remove and retain the left and right wing belt shield lynch pins, belt shield, and the wing deck belts.

10. Remove and retain the locking cotter pins and the cylinder pins that attach to the rod end of the deck fold cylinders and to the wing decks.

    Note: The wing decks must not be pulled into the operating position in order to remove the cylinder pins.

    

    Figure 38

    1. Cylinder rod end
    2. Cotter pin
    3. Cylinder pin

11. Remove and retain the bolts that secure the upper pivot pins to the deck and then remove the pivot pins.

    

    Figure 39

    1. Upper pivot pins
    2. Bolt
    3. Pull outward
    4. Left wing deck

12. Pull the wing deck outward to separate it from the center deck section.

13. Remove the flanged bushings from the upper pivot points and clean the bore.

    

    Figure 40

    1. Upper pivot point bushing
    2. Lower pivot point bolt
    3. Deck pin assembly
    4. Bushing

14. Apply a thin bead of Loctite^® 680 to the entire circumference of the rear edge of the new bushings.

15. Insert and gently tap the new bushings into the opening and properly seat them into place.

16. Place a block of wood under the inside edge of the center deck to make it easier to work on the lower pivot point bushings.

17. Remove and retain the lower pivot point bolts (reference Figure 37 and Figure 40).

18. Remove and discard the flanged bushing from the front and rear of the wing deck and clean the bore.

19. Apply a thin bead of Loctite^® 680 to the entire circumference of the rear edge of the new bushings.

20. Insert and gently tap the new bushings into the opening and properly seat them into place.

21. Reinstall the lower deck pin assemblies and bolts into the lower deck pivot points and hand-tighten.

22. To aid in the ease of reinstalling the wing deck sections, carefully remove the exposed end of the spring that applies pressure to the rear of the wing deck cover.

    

    Figure 41

    1. Spring

23. Push the left wing deck back to the center deck. Align and install the upper pivot deck pins in the front and rear of the deck and secure with the bolts that were removed previously (reference Figure 39).

24. Align the lift cylinder arm and reinstall the pin, making sure that the locking tab is aligned with the associated opening in the mount. Reinstall the locking cotter pin to secure.

25. Reattach the spring that was removed in Step 22 that applies pressure to the rear of the wing deck cover.

26. Reinstall the wing deck belts.

27. Reinstall the wing deck belt shields and secure with the lynch pins.

28. Raise the wings to the transport position and secure them in place with the clevis pins and hairpins.

    For 144 Inch Deck Models Only: Reinstall the large wing springs.

29. Reinstall the height of cut pin.

Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Unhook two air filter canister latches to gain access to the air cleaner element.

3. Remove air cleaner canister cover and remove outer element.

4. Check the condition of the paper element. Replace if dirty, bent or damaged.

5. Check the condition of the inner element. Replace whenever it appears dirty, typically every other time the paper element is replaced. Clean the base around the inner element before removing, so dirt does not get into the engine.

6. Do Not wash or use pressurized air to clean paper element or inner element.

7. Reinstall elements. Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips.

1. Position the machine and mower deck on a level surface.

2. Lower the mower deck to the 1 inch (2.5 cm) height of cut.

3. Disengage the PTO, move the motion-control levers to the neutral-lock position, and engage the parking brake.

4. Stop engine, wait for all moving parts to stop, and remove key.

5. Lift the footrest, exposing the top of the mower deck.

6. Remove the dipstick/fill plug from the top of the gearbox and make sure that the lubricant is between the marks on the dipstick (Figure 42).

   

   Figure 42

   1. Fill plug and dipstick

7. If the lubricant level is low, add lubricant. Screw the dipstick all the way back in; remove and check if the lubricant level is between the marks on the dipstick.

   Important: Do not overfill the gearbox; overfilling the gearbox may damage it.

1. Position the machine and mower deck on a level surface.

2. Stop engine and wait for all moving parts to stop. Engage parking brake.

3. Orient gearbox check plug to the right with fill port on the top (as shown in Figure 43).

   

   Figure 43

   1. Wheel gear box
   2. Check plug
   3. Drain plug
   4. Fill plug

4. Remove and retain check plug. Check oil level is up to check port. Reinstall check plug when complete.

5. Repeat on opposite side.

Important: Do not overfill the gearbox; overfilling the gearbox may damage it.

1. Position the machine and mower deck on a level surface.

2. Stop engine and wait for all moving parts to stop. Engage parking brake.

3. Raise the deck to extend the lift cylinders, shut off the engine, and remove the key.

4. Raise the seat to access the hydraulic fluid tank.

5. Remove the hydraulic fill cap from the filler neck.

6. Remove the dipstick and wipe it with a clean rag.

7. Place the dipstick into the filler neck; then remove it and check the level of fluid.

   

   Figure 44

   1. Full
   2. Add

   If fluid is needed add enough oil to put the level in between the two marks on the dipstick.

   Important: Do Not overfill.

8. Replace the dipstick and fill cap; finger-tighten only.

9. Check all hoses and fittings for leaks.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Check tire pressure in drive tires.

3. Inflate drive tires to:

   • 18 psi (124 kPa) for 60 and 72 inch deck models.

   • 22 psi (152 kPa) for 96 and 144 inch deck models.

4. Semi-pneumatic caster tires do not need to be inflated.

Note: Do Not add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components. Foam filling tires will void the warranty.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove left and right belt shields on deck and lift up floor pan to inspect belts.

Note: See chart for service intervals.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lubricate fittings with one to two pumps of NLGI grade #2 multi-purpose gun grease.

   Refer to the following chart for fitting locations and lubrication schedule.

   60 and 72 Inch Models

   Lubrication Chart
   Fitting Locations	Initial Pumps	Number of Places	Service Interval
   1. Deck drive PTO	1	3	50 hrs
   2. Deck idler pivot	1	1	Every 400 hrs or Yearly
   3. Caster wheel bearings	*0	2	*Yearly
   4. Caster pivots	*0	2	Every 400 hrs or Yearly

   96 and 144 Inch Model

   Lubrication Chart
   Fitting Locations	Initial Pumps	Number of Places	Service Interval
   1. Deck drive PTO	1	3	50 hrs
   2. Deck idler pivot	1	3	Every 400 hrs or Yearly
   3. Caster wheel bearings	*0	4	*Yearly
   4. Caster pivots	*0	5	Every 400 hrs or Yearly

   * See step 3 for special lubrication instructions on the front caster pivots and the Lubricate Caster Wheel Hubs section for special lubrication instructions on the front casters wheel hubs.

3. Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Torque to 85-105 ft-lb (115-142 N-m).

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

   

   Figure 45

   1. Seal guard
   2. Spacer nut with wrench flats

2. Remove caster wheel from caster forks.

3. Remove seal guards from the wheel hub.

4. Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

5. Pry out seals, and inspect bearings for wear or damage and replace if necessary.

6. Pack the bearings with a NLGI grade #1 multi-purpose grease.

7. Insert one bearing, one new seal into the wheel.

   Note: Seals (Exmark P/N 103-0063) must be replaced.

8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do Not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut.

9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

10. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NLGI grade #1 multi-purpose grease.

11. Insert the second bearing and new seal into the wheel.

12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward.

13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut.

14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully.

Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust torque on spacer nut until there is a slight amount of drag. Reapply thread locking adhesive.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Place a drain pan under the fuel filter and loosen the drain plug approximately 1 turn.

   

   Figure 46

   1. Filter

3. Water should drain.

4. When fuel begins to flow from the filter, tighten the drain plug.

Important: Water or other contaminants in fuel can severely damage fuel pump and/or the other engine components.

Figure 47

The 3TNV88C and 3TNV86CT engines have two fuel filters; see Figure 48 for locations.

Figure 48

1. Location

1. Position the machine and cutting unit on a level surface.

2. Lower the mower deck to the 1 inch (2.5 cm) height of cut.

3. Disengage the PTO, move the motion control levers to the neutral-lock position, and engage the parking brake.

4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

5. Lift the footrest, exposing the top of the mower deck.

6. Remove the dipstick/fill plug from the top of the gearbox (reference Figure 42).

7. Extract oil through the fill port using a vacuum devise or remove the gearbox from the deck and pour the oil out.

8. Reinstall the gearbox if it was removed to drain.

9. Add enough lubricant, approximately 14 oz (420 ml), until the level is between the marks on the dipstick.

   Important: Do Not overfill the gearbox; overfilling the gearbox may damage it.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Drain oil while engine is warm from operation.

3. Place pan under machine to catch oil. Remove the oil drain plug. Allow oil to drain and replace oil drain plug.

4. Replace the oil filter every oil change. Clean around oil filter and unscrew filter to remove. Before reinstalling new filter, apply a thin coating of Exmark 4-Cycle Premium Engine Oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 full turn.

5. Unlatch the hood and lift it up to access oil fill. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap. Use oil recommended in the Check Engine Oil Level section. Do Not overfill. Start the engine and check for leaks.

6. Start the engine at idle for 5 minutes. Stop engine and wait three minutes, then check the oil level. If required, add oil to bring level to the “FULL” mark on the dipstick. Do Not overfill.

7. Check for leaks, including around the oil filter.

8. Wipe up any spilled oil.

1. Position the machine and mower deck on a level surface.

2. Stop engine and wait for all moving parts to stop. Engage parking brake.

3. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely once the motor brake is released.

4. Remove wheel and orient gearbox with drain port on the bottom with fill port on the top.

   

   Figure 49

   1. Wheel gear box
   2. Check plug
   3. Drain plug
   4. Fill plug

5. Place a pan under each drain port. Remove, retain, and wipe clean the drain plug, check plug, and fill plug to allow the fluid drain.

6. Reinstall the drain plug and add oil (approximately 18 oz) until it runs out the check port. Install check plug and fill plug back in their respective ports.

7. Repeat on opposite side.

Important: Do Not overfill the gearbox; overfilling the gearbox may damage it.

60, 72, and 96 Inch Models

*May need more often under severe conditions.

Note: Exmark Ruby Transmission Fluid is recommended. Refer to the chart for an acceptable alternative.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Raise seat.

3. There are four drain plugs that need to be removed to do a complete fluid change. Place a pan under each drain plug from the following components: hydraulic reservoir, transmission case, and the left and right wheel motors (see Figure 50).

   

   Figure 50

   Underside of 60, 72 and 96 Inch Deck Models

   1. Rear frame
   2. LH wheel motor drain plug
   3. Hydraulic reservoir drain plug
   4. Transmission case drain plug
   5. RH wheel motor drain plug
   6. Filter

4. Unscrew the filter to remove and allow fluid to drain from reservoir.

   Important: Before reinstalling new filter, apply a thin coat of Exmark Ruby Transmission Fluid on the surface of the rubber seal.

   Install a new filter and turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn.

5. Reinstall all four plugs. The wheel motor drain plugs are magnetic; wipe clean before reinstalling.

6. Remove the fill port plug on the top of each wheel motor.

   

   Figure 51

   1. Fill port

   1. Fill each motor with approximately 1.5 qt (1.4 L) Exmark Ruby Transmission Fluid.

   2. Replace the plugs.

   3. Remove the reservoir cap and dipstick from the fluid tank.

   4. Add 8 qt (7.6 L) of oil in the reservoir.

      Note: The reservoir will be overfull at this point the level will quickly go down once the machine is started and cooling loop oil fills the transmission case.

   Important: Exmark will not assume responsibility for damage caused by improper substitutions.

7. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

8. Allow the engine to run about one minute and then shut it off.

9. Start the engine and check for oil leaks. Move the speed control levers to the full speed and run for several minutes. Shut down machine and recheck fluid level.

10. Check the level of the hydraulic fluid; refer to Check Hydraulic Fluid Level section.

    Add enough oil to put the level between the two marks on the dipstick. it may take 4-5 qt (3.8-4.7 L) depending how much oil stayed in the cooling loop while draining.

11. Replace the dipstick and reinstall the cap.

144 Inch Models

*May need more often under severe conditions.

Note: Exmark Ruby Transmission Fluid is recommended. Refer to the chart for an acceptable alternative.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Raise seat.

3. There are two drain plugs that need to be removed to do a complete fluid change. Place a pan under each drain plug from the following components: hydraulic reservoir, and transmission case (see Figure 52).

   

   Figure 52

   Underside of 144 Inch Deck Model

   1. Rear frame
   2. Filter
   3. Hydraulic reservoir drain plug
   4. Transmission case drain plug

4. Unscrew the filter to remove and allow fluid to drain from reservoir.

   Important: Before reinstalling new filter, apply a thin coat of Exmark Ruby Transmission Fluid on the surface of the rubber seal.

   Install a new filter and turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn.

5. Reinstall all plugs. Wipe clean before reinstalling.

6. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

   1. Remove the reservoir cap and dipstick from the fluid tank.

   2. Add 8 qt (7.6 L) of oil in the reservoir.

   The reservoir will be overfull at this point the level will quickly go down once the machine is started and cooling loop oil fills the transmission case.

7. Allow the engine to run about one minute and then shut it off.

8. Start the engine and check for oil leaks. Move the speed control levers to the full speed and run for several minutes. Shut down machine and recheck fluid level.

9. Check the level of the hydraulic fluid; refer to Check Hydraulic Fluid Level section.

   Add enough oil to put the level between the two marks on the dipstick. it may take 4-5 qt (3.8-4.7 L) depending how much oil stayed in the cooling loop while draining.

10. Replace the dipstick and reinstall the cap.

Note: If the engine coolant level is below the indicator line on the overflow bottle when the engine is cold, the coolant temperature gauge may not register correctly during operation and/or the warning buzzer may not sound if the engine overheats.

1. Position the mower on a flat surface.

2. Stop engine and wait for all moving parts to stop.

3. Check with engine cold.

4. Open the hood and check the coolant level in the expansion tank on the right side of the machine. The coolant level should be between the marks on the overflow bottle.

   

   Figure 53

   1. Expansion tank

5. If the coolant level is low, remove the cap to the overflow bottle and fill to the indicator line. Machines should only be filled a 50/50 mix of water and ethylene glycol.

   Note: The use of Havoline® Xtended Life coolant is recommended. Havoline® can be identified by its orange color.

1. Position the mower on a flat surface.

2. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

3. Tilt hood forward to gain access to the cooling area.

   Warning

   Engine coolant is hot and pressurized and radiator and surrounding parts are hot. Spray or steam from hot, pressurized liquid in the engine cooling system and touching a hot radiator may cause severe burns.

   Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system.

   Caution

   Engine coolant is toxic. Swallowing coolant can cause poisoning.

   • Do Not swallow.

   • Keep out of reach of children and pets.

4. Drain coolant when engine is cool. Remove the radiator cap, place a pan under the radiator, and remove the drain plug at the bottom of the radiator.

5. Remove the coolant hose from the oil cooler and drain the coolant from the engine block (reference Figure 54).

   

   Figure 54

   1. Coolant hose

6. Reinstall all drain plugs and hoses.

7. Fill radiator with a 50/50 mix of water and ethylene glycol.

   Note: The use of Havoline® Xtended Life coolant is recommended.

   Allow some room (approximately 1/2 inch (12.7 mm)) for expansion. Add 50/50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle.

   Warning

   Engine compartment contains open belt drives, fans, and other rotating components that can cause injury. Fingers, hands, loose clothing, or jewelry can get caught by the rotating fan and drive shaft.

   • Do Not operate machine without the covers in place.

   • Keep fingers, hands, and clothing clear of rotating components.

   • Shut off engine, wait for moving parts to stop, engage parking brake and remove key, before performing maintenance.

8. Operate engine until the engine thermostat opens and coolant is circulating through the radiator core. As air is purged from the engine block and the coolant level drops, add additional coolant to the radiator.

9. When the radiator is completely full and no additional coolant can be added, continue running and install the radiator cap. Make sure that the cap is completely seated by pressing down firmly while turning until the cap stops. Once the cap is installed, the engine may be stopped.

Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

Caster wheel spacer nuts.

Mobil HTS grease (or food-grade anti-seize) is used in the following locations:

• Between the cutter housing spindle and bearings.

• Between the cutter housing spindle and sheave.

Copper-based anti-seize is used in the following location:

On threads of Blade Bolts. See Check Mower Blades section.

Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. Dielectric grease should not be applied to sealed connectors.

1. Position the machine on a flat surface.

2. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake.

3. Check the tire pressure in drive tires and pneumatic front caster tires (if equipped). Proper inflation pressure for tires is 18 psi (124 kPa). Adjust if necessary.

4. Using the deck-lift switch, move the deck height out of the transport position (or 5 1/2 inches (140 mm) cutting height).

   

   Figure 55

   1. Height of cut bracket
   2. Height of cut pin

5. Insert the height adjustment pin into the 3 inches (76 mm) cutting height location.

6. Release the transport lock and allow the deck to lower to the cutting height.

7. Raise the discharge deflector (side discharge units only).

8. Measure from the level surface to the front tip of the center blade. The measurement should read 3 inches (76 mm).

   Note: In most conditions, the back tips on the side blades should be adjusted:Side Discharge Units: 1/4 inch (6.4 mm) higher than the front.Rear Discharge Units: to be level with the front.

   

   Figure 56

   1. Side Discharge: 3 1/4 inches (8.3 cm)Rear Discharge: 3 inches (7.6 cm)
   2. Back blade tip
   3. Front blade tip
   4. 3 inches (7.6 cm)
   5. Level surface

9. Adjust the height — to increase, turn the adjuster screw clockwise; to decrease, turn counterclockwise.

   Loosen the jam nuts on the top of each deck adjuster. Fine tune the adjuster on the front deck lift assembly by turning it to get 3 inch (7.6 cm) height (see Figure 57).

   

   Figure 57

   1. Adjuster link
   2. Jam nut
   3. Adjuster

10. Measure the back tip height. Fine tune rear adjusters as required; the single point adjustment can be utilized to gain more adjustment.

    • Side Discharge Units: The back tips of the side blades should measure 3 1/4 inches (8.3 cm).

    • Rear Discharge Units: The back tips of the side blades should measure 3 inches (7.6 cm).

11. Re-measure until all four sides are the correct height. Tighten all the nuts on the deck lift arm assemblies.

12. Lower discharge deflector (side discharge units only).

13. If the four deck adjusters do not have enough adjustment to achieve accurate cut height with the desired rake, the single point adjustment can be utilized to gain more adjustment (see Figure 58).

    

    Figure 58

    1. Single point height adjustment bolt
    2. Front height of cut plate mounting bolt
    3. Rear height of cut plate mounting bolt

14. To adjust the single point system, first loosen the front and rear height of cut plate mounting bolts.

    Note: On Rear Discharge Units: The mower deck is attached in the front holes at the factory (see Figure 59). If needed, use the back holes for further adjustment when leveling the mower deck.

    

    Figure 59

    1. Mower deck
    2. Front hole
    3. Back hole

15. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise.

    Note: Loosen or tighten the single point adjustment bolt enough to move the height of cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This will regain some up and down adjustment on each of the four deck links.

16. Re-tighten front and rear height of cut plate mounting bolts.

    Important: Torque the front and rear height of cut plate mounting bolts to 67-83 ft-lb (91-113 N-m).

17. Repeat steps 8 through 12.

Self-tensioning - No adjustment necessary.

Check to make sure brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced.

1. Drive the machine onto a level surface.

2. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and engage the parking brake (lever is in the “up” position).

3. Stop the engine, wait for all moving parts to stop, and remove the key.

4. Raise the back of the machine up and support the machine with jack stands.

5. Remove the rear tires from the machine.

6. Remove any debris from the brake area.

7. Rotate the drive wheel release handle to the “released” position. Refer to the Drive Wheel Release Valves section in Operation.

8. If the link assembly is attached (see Figure 65)

   • in the front position, the length=8.63 inches (21.9 cm).

   • in the rear position, the length=9.15 inches (23.2 cm).

9. The length of the spring should measure 3 3/4 inches (8.9 cm).

10. Once the spring length is achieved, check to see if there is a visible gap between the trunion and the shoulder.

    

    Figure 65

    1. Front location
    2. Rear location
    3. 3 3/4 inches (8.9 cm)
    4. Gap
    5. Spring
    6. Link assembly
    7. Length

11. Disengage the park brake, the lever should be in the down position. Turn the wheel hub by hand in both directions relative to the caliper; the wheel hub should move freely.

12. If a gap is needed or the wheel hub does not move freely:

    1. Disengage the park brake.

    2. Disconnect and fine-tune the rear linkage assembly:

       • Shorten the link to create a gap.

       • Lengthen the link to allow wheel hub movement.

    3. Reconnect the rear linkage assembly.

13. Engage the parking brake and check the gap.

14. Repeat steps 11 through 14 until a visible gap is achieved and the wheel hub rotates freely. Repeat for the brake on the right side.

    Note: The brake should fully disengage when the brake is in the “released” position.

15. Rotate the drive wheel release handle to the “operating” position. Refer to the Drive Wheel Release Valves section in Operation.

16. Install the rear tires and torque lug nuts to 85-105 ft-lb (115-142 N-m).

17. Remove jack stands.

1. This adjustment must be made with the drive wheels turning. First raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow the drive wheels to rotate freely.

2. Unhook seat latch and tilt seat forward.

3. Remove the electrical connection from the seat safety switch, located directly to the left of the seat switch assembly beside the hydraulic oil reservoir.

   Temporarily install a jumper wire across the terminals in the connector of the main wiring harness.

4. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature.

5. Loosen lock nuts from the ball joints at each end of the pump control linkage (Figure 66).

   

   Figure 66

   Right-Hand Side of Unit

   1. Turn here to adjust
   2. Loosen here (right-hand thread)

6. Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat because of the jumper wire being used. Run engine at full throttle and release brake.

   Note: The motion control lever needs to be in neutral while making any necessary adjustments.The left rod assembly controls the left wheel and the right rod assembly controls the right wheel.

7. Bring the motion control lever into the neutral position. Adjust RH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse. Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral. The wheel must stop turning or slightly creep in reverse. When adjustment is complete, tighten lock nuts onto ball joints. Repeat for LH motion control lever.

8. Shut off unit. Remove jumper wire from wire harness connector and plug connector into seat switch.

The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 67 for mounting options.

Figure 67

RH Motion Control Shown

1. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt must protrude past end of nyloc nut after torque. A T-40 Torx bit will be necessary to hold the stud from turning.
2. Most resistance (firmest feel)
3. Damper
4. Medium resistance (medium feel)
5. Least resistance (softest feel)

Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1/4 of a turn to properly set the pre-load on the bearings. If disassembled, make sure the spring disc washers are reinstalled as shown in Figure 68.

Figure 68

1. Spring disc washers

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean around flywheel, cylinder head, injectors, and injector pump.

3. Clean all debris from the exhaust system area.

4. Wipe up any excessive grease or oil around the engine and exhaust area.

Important: Do Not use water to clean engine. Use low pressure compressed air. See Engine Owner's Manual.

1. Stop engine, wait for all rotating parts to stop and remove key. Engage parking brake.

2. Allow engine to cool.

3. Rotate hood forward

4. Using compressed air, blow out debris stuck between the fins of the entire radiator, both from the top down and from the bottom up.

5. If debris remains, it may be necessary to use water from a low pressure hose. If the radiator is clean, proceed to step 7.

6. Cover the engine with a piece of cardboard, or a plastic sheet. Squirt water through the fins. Blow through with low pressure air from both directions. If debris remains, repeat until clean.

7. Lower hood.

8. Start the engine to ensure the fan is functioning properly.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area.

   Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, under the seat, around the engine, hydraulic pumps, and motors.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean off any debris, or grass build-up on the machine hood screen, hood and around engine and exhaust area.

   Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, under the seat, around the engine, hydraulic pumps, and motors.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Raise deck to the transport position.

   For 96 inch models, raise the center deck and outer wings. Lock each wing in the up position.

3. Lift the front of machine and support it using jack stands or equivalent support.

4. Clean out any grass build-up from underside of deck and in discharge deflector.

Inspect the engine-valve clearance. Refer to the engine owner’s manual.