LAZERZ®DS-SERIES
SetupInstructions
ForSerialNos.314,000,000&Higher
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCalifornia
tocausecancer,birthdefects,andotherreproductiveharm.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#
DescriptionQty.Use
323-6
CapScrew,Hex3/8-16x1inch
8
98-5975
Washer,SpringDisc
8
3290-357
Nut,HexFlange3/8-16inch
8
InstallingtheRolloverProtection
System(RollBar).
103-7599-03Guard1
109-2394U-Bolt2
104-8301
Nut-Nyloc3/8-16Flg
4
Installingtheaircleanerguard.
104-8301
Nut-Nyloc3/8-16Flg
6
3231-7
Bolt-Carriage3/8-16x21/4
6
Installingthesidebumpers(Rear
DischargeUnitsOnly).
103-2106
Key,ExmarkLogo
1
1-603511
Key,Standard
1
Fillouttheonlinewarrantyregistration
formandplacekeysintoliterature
pack.
LiteraturePack
Manual,Operator's
Manual,EngineOperator's
InstallingtheRolloverProtection
System(RollBar)
1.Removesidesandtopofcratefromthebase.
2.Removerollbarcomponentsfromthecrate.
3.Removerollbartubesfromsidesofcrate.
4.Removethetwobracketsusedtomountthebottom
oftheupperrollbartubetothecrate.
5.Removethe1/2-13x31/4inchcapscrewsand
1/2-13inchhexangelocknutsfromthetwo
bracketsateachendoftheupperrollbartubeand
retainforlateruse(Figure1).
©2013—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4501-768Rev.A
PrintedintheUSA.
AllRightsReserved
*4501-768*A
6.Removethefour1/4inchlagscrewsholdingthe
wheelhubbracketstothecratebottomanddiscard.
Figure1
1.1/2-13x3/41/4inch
Capscrew
3.Upperrollbartube
2.1/2-13inchhexangelock
nuts
7.Raisetherearoftheunitapproximately10–12inches
andsupportitwithjackstandsorequivalentsupport.
CAUTION
Raisingtherearoftheunitforassemblyrelying
solelyonmechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulicjacks
maynotbeenoughsupportormaymalfunction
allowingtheunittofall,whichcouldcause
injury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstandsor
equivalentsupport
8.Locatetheleftandrightlowerrollbartubes.
9.Alignlowerrollbartubesalongrearengineframe
(Figure2).
10.Looselyinstalllowerrollbarhardware(four3/8-16
x1inchcapscrews,fourspringdiscwashersand
four3/8-16inchwhizlocknuts)tothetubesoneach
side(
Figure2).
Note:Besurethespringdiscwasherconeis
installedtowardstheheadofthecapscrew.
Figure2
1.3/8-16x1inchcapscrews
3.Wheelnuts
2.Springdiscwasher(cone
towardscapscrewhead)
4.3/8-16inchwhizlocknuts
Figure3
1.1/4-20inchnylocnut
5.Upperrollbartube
2.1/2-13inchhexangelock
nuts
6.Latchpinassembly
3.Applyoiltoinsidesurface
ofearshapedholes
7.1/2-13x31/4inch
capscrew
4.Bumper
11.Locatethelatchpinassemblies(pinandhairpin
connectedwithalanyard).
12.Inserta1/2-13x31/4inchcapscrew(removedin
step5)intothebenttabwasheronthelanyardof
eachpinassembly(Figure3).
Note:Makesurethebenttabinthewasheris
towardstheheadofthebolt.
2
13.Lightlyoiltheinsidesurfacesoftheear-shaped
platesattheupperendofthelowerrollbartubes
(Figure3).
14.Locatetheupperu-shapedsectionoftherollbar.
Installtheupperrollbarsectionusingthetwo1/2-13
x31/4inchcapscrewsandtwo1/2-13inchhex
angelocknuts(removedinstep
5).Donotover
tighten.Makesureupperrollbarcanpivotfreely.
Note:Makesurethecapscrewandnutsareinstalled
withthenuttotheinsideoftherollbar.
Note:Makesurethetabonthelanyardwasheris
installedasshownandpointstowardthefrontof
theunit.
15.Raisetherollbarintotheuprightpositionandsecure
withthelatchpinassembliesoneachside.Install
latchpinfromoutersurfaceofrollbarassemblyand
securewiththehairpintotheinside.
16.Torquealllowerrollbarhardwareattachedtothe
machineframeto30-35ft-lb.(41-47N-m).
InstallingtheAirCleanerGuard
1.LocatetheblackU-shapedGuard,twoU-bolts,and
four3/8-16inchNylocnuts.
2.PositiontheGuardovertheAirIntakeCapand
looselyinstallfasteninghardwareontorighthand
RollBartubeasshownin
Figure4.
3.EnsurethattheGuardiscenteredovertheAirIntake
Capandtightenthefour3/8-16inchnylocnuts.
Figure4
1.3/8-16inchnylocnut3.Guard
2.3/8-16x1inchU-Bolt
4.Airintakecap
InstallingtheDriveWheels
1.Removethe1/2-20inchdrivewheelnuts(installed
onstudsofdrivemotors;Figure2)andretainfor
wheelmounting.Removeanddiscardshipping
bracketsmountedonwheelhubs.
2.Mountdrivewheelswiththevalvestemtothe
outsideoftheunit.Secureusingfour1/2-20inch
wheelnutsremovedinstep1.
3.Torqueto95ft-lb(128N-m).
CheckingTirePressure
1.Checkthetirepressureinthedrivetires.Proper
inationfordrivetiresis10psi(69kPa).
2.Adjustifnecessary.
ServicingtheBattery
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Note:Themachineisshippedwithalledleadacid
battery.
DANGER
Chargingorjumpstartingthebatterymayproduce
explosivegases.Batterygasescanexplodecausing
seriousinjury.
•Keepsparks,ames,orcigarettesawayfrom
battery.
•Ventilatewhenchargingorusingbatteryinan
enclosedspace.
•Makesureventingpathofbatteryisalwaysopen
oncebatteryislledwithacid.
•Alwaysshieldeyesandfacefrombattery.
3
DANGER
Batteryelectrolytecontainssulfuricacid,whichis
poisonousandcancausesevereburns.Swallowing
electrolytecanbefatalorifittouchesskincan
causesevereburns.
•Wearsafetyglassestoshieldeyes,andrubber
glovestoprotectskinandclothingwhen
handlingelectrolyte.
•DoNotswallowelectrolyte.
•Intheeventofanaccident,ushwithwaterand
calladoctorimmediately.
1.Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebattery
inthetablebelowandchargethebatteryforthe
recommendedtimeintervaltobringthechargeup
toafullchargeof12.6voltsorgreater.
Important:Makesurethenegativebattery
cableisdisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6or
greater
100%
16volts/7
amps
NoCharging
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
11.7orless
0%
14.4volts/2
amps
6Hoursor
More
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosionor
movingpartscouldaccidentallyengagecausing
personalinjury.
Besureignitionswitchisinthe“OFF”position
beforechargingthebattery.
2.Connectthenegativebatterycable.
Note:Ifthepositivecableisalsodisconnected,
connectthepositive(red)cabletothepositive
batteryterminalrst,thenthenegative(black)cable
tothenegativebatteryterminal.Slipinsulatorboot
overthepositiveterminal.
Note:Iftimedoesnotpermitchargingthebattery,
orifchargingequipmentisnotavailable,connect
thenegativebatterycablesandrunthevehicle
continuouslyfor20to30minutestosufciently
chargethebattery.
InstallingtheSideBumpers
(RearDischargeUnitsOnly)
Mountthesidebumpersinthetopholeswhenoperating
inheightofcutshigherthan21/2inches(64mm)and
inthecenterholeswhenoperatinginheightofcuts
lowerthan21/2inches(64mm).
1.Raisethedecktothe5inch(12.7cm)heightposition
(alsotransportposition).
2.Removethebumpersfromthesidesofthecrate.
Figure5
1.Carriagebolt
3.Nylocnut
2.Bumper
3.Moveeachbumpertothedesiredpositionand
securewiththree3/8–16x21/4inchcarriagebolts
and3/8inchnylocnuts.
PositioningtheDischargeChute
(SideDischargeUnits)
Loosenthetwo3/8inchnylocnutsattachingthe
dischargechute.Lowerthedischargechuteinto
position.Retightenthenylocnutsuntilthechuteissnug
butcanpivotfreely.
4
InstallingtheDischargeTunnel
(RearDischargeUnits)
1.Removethenut,lockwasher,andbushingfromeach
strutbolt.DoNotremovethestrutbolts.
Figure6
72InchDeckShown
1.Strutbolt
5.Nut
2.Dischargetunneltab6.Frametube
3.Bushing7.Notch
4.Lockwasher
2.Removethedischargetunnelfromthesidesofthe
crate.
3.Placethedischargetunnelontopofthereardeck
ange.Makesurethetunnelgoesintothenotches
oneachsideofthedeck.
4.Pullthestrutboltsoutward,fromtheframetube,
justfarenoughtopositionthedischargetunneltab.
5.Pushtheboltsbackthroughtheframetubeand
dischargetunnel.Reinstallthebushing,lockwasher,
andnut.
Figure7
1.60Inchunit5.Bushing
2.72Inchunit6.Lockwasher
3.Strutbolt
7.Nut
4.Strut
ServicingtheEngine
Theengineisshippedwithoil;checkoillevelandif
necessarylltotheappropriatelevel.Exmark4-Cycle
PremiumEngineOilisrecommended.Refertothe
EngineOwner’sManualforanacceptablealternative.
ServicingtheEngineCoolant
Themachineisshippedlledwithenginecoolant.
WARNING
Dischargeofhotpressurizedcoolantortouching
hotradiatorandsurroundingpartscancausesevere
burns.
•Donotremovetheradiatorcapwhentheengine
ishot.Alwaysallowtheenginetocoolatleast15
minutesoruntiltheradiatorcapiscoolenough
totouchwithoutburningyourhandbefore
removingtheradiatorcap.
•Donottouchradiatorandsurroundingparts
thatarehot.
CAUTION
Enginecoolantistoxic.Swallowingenginecoolant
cancausepoisoning.
•Donotswallowenginecoolant.
•Keepoutofreachfromchildrenandpets.
5
Withcoolengine,checkthatcoolantlevelisuptothe
indicatorlineontheoverowbottle.Ifnot,add50/50
coolantmixtooverowbottletobringthelevelupto
theindicatorline.Alsocheckcoolantlevelinradiator.
Fillitashighaspossiblewith50/50coolantmix.
Note:UnitsshouldonlybelledwithDexCool©
extendedlifecoolant,whichcanbeidentiedbyits
orangecolor.
ServicingtheHydraulicOil
Themachineisshippedwithhydraulicoilinthe
reservoir.
1.Runthemachineforapproximately15minutesto
allowanyextraairtopurgeoutofthehydraulic
system.
2.Checkhydraulicreservoirandifnecessaryllthe
reservoirtotheappropriatelevelwithExmark
PremiumHydrooil.
3.Replacehydraulicreservoircapandtightenuntil
snug.DoNotovertighten.
Note:Thebafeislabeled“HOT”and“COLD”.
Theoillevelvarieswiththetemperatureoftheoil.
The“HOT”levelshowsthelevelofoilwhenitisat
225°F(107°C).The“COLD”levelshowsthelevelof
theoilwhenitisat75°F(24°C).Filltotheappropriate
leveldependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C).Filltohalfway
betweenthe“HOT”and“COLD”levels.Iftheoilisat
roomtemperature(about75°F(24°C)),llonlytothe
“COLD”level.
FillingOuttheProduct
Registration
Fillouttheonlinewarrantyregistrationformandplace
keysintoliteraturepack.
6
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