Exmark Viking Hydro User's Manual
Contents
1. a b Stop engine and remove spark plug wire s Clean all debris from engine air intake screen and from around engine shrouding 5 1 3 Clean grass build up under deck and check mower blades Service Interval Daily a b c d e A CAUTION When it is necessary to raise the deck or mower for service or maintenance DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Disengage blade clutch Stop engine and remove spark plug wire s Raise deck and block up using proper safety precautions Clean out any grass build up from underside of deck and in deck discharge chute Inspect blades and sharpen or replace as required 20 f If blade removal is necessary be careful for the sharp cutting edges of the blades g Re install the blades if they were removed and torque blade bolts to 75 80 ft lbs Be sure the spring disk washer cone is installed toward the bolt head See Figure 7 h Remove jack stands or equivalent support and lower deck to ground FOR REFERENCE ONLY CONE TOWARDS BOLT HEAD TORQUE TO 75 80 ft Ibs FIG 7 BLADE BOLT INSTALLATION 5 1 4 Check safety interlock system Service Interval Daily a b c For your safety your Exmark mower is equipped with Operator Presence Controls OPC When either the mower blades are engaged or the speed control lever is not in neutral and both han2. warrants on the terms and conditions herein that it will repair replace or adjust any part manufactured by Exmark and found by Exmark in the exercise of its reasonable discretion to be defective in factory material or workmanship This warranty is limited to one year from the date of original retail purchase 90 days for rental use for any Exmark mower that is used for commercial or any other income producing purpose The hydrostatic traction drive system will be warranted for two full years from date of original retail purchase against defects in materials or workmanship excluding hoses Exmark Mfg will extend the Peerless 5 speed transmission manufacturer s warranty from 90 days to one year Belts and tires are warranted for 90 days against defects in materials or workmanship The engine warranty is covered by its respective engine manufacturer Please refer to the engine manufacturers warranty statement that is included in the literature packet Exmark is not authorized to handle warranty adjustments on engines Engine warranties should be referred to the nearest authorized service outlet of the engine manufacturer This warranty extends only to the original retail purchaser of the equipment The warranty may not be assigned or transferred without the prior express written consent of Exmark The warranty commences upon the date of the original retail purchase The Exmark turf equipment including any defective part must be returned t
3. 1 SAFETY ALERT SYMBOL THIS SAFETY ALERT SYMBOL A IS USED BOTH IN THIS MANUAL AND ON THE MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE FOLLOWED TO AVOID ACCIDENTS THIS SYMBOL MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The safety alert symbol appears above information which alerts you of unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION When used with the word DANGER IT DENOTES THAT AN EXTREME HAZARD EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN When used with the word WARNING IT DENOTES THAT A HAZARD EXISTS WHICH CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT TAKEN When used with the word CAUTION IT DENOTES A REMINDER OF SAFETY PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH COULD RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment 1 2 3 Never allow children teenagers or people unfamiliar with these instructions to use the mower 1 2 4 Avoid mowing while people especially children or pets are nearby Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their p
4. 36 4g 52 Overall Length 78 44 ld TO a 198 1 cm 189 7 cm 191 3 cm 2 10 3 Curb Weight 36 48 5250 Curb Weight 433 lbs 478 lbs 506 lbs 196 kg 217 kg 229 kg Weights will vary slightly depending on engine option 2 10 4 Overall Height 43 2 109 7 cm all units 2 10 5 Tread Width to outside of tires 36 Model 35 6 90 4 cm 48 Model 39 6 100 6 cm 52 Model 39 6 100 6 cm 2 11 TORQUE REQUIREMENTS BOLT LOCATION TORQUE Blade Cutter Housing Spindle Bolt 75 80 ft lbs Caster Bracket MOUNES 30 35 ft lbs Cutter Deck Engine Deck Mount 30 35 ft lbs Engine Mounting Bolts Briggs amp Stratton 15 20 ft lbs Kohler amp Kawasakl 25 30 ft lbs 3 ASSEMBLY INSTRUCTIONS 3 1 Uncrate unit leaving it on the pallet place upper handle assembly fuel tank and drive linkages at the rear of the machine Place casters at the front of unit Place a length of 4 x 4 block between the front of the cutter deck and the pallet Remove the bolt bag from the top of the fuel tank support Loosen the 5 16 hardware at the two 2 discharge deflector hinge points so that the deflector is snug but can be moved up and down freely Refer to Parts Manual to help you identify and locate parts and their proper position Install casters to front of deck using appropriate hardware from the bolt
5. Adjustment Section 14 4 OPERATION INSTRUCTIONS 4 1 Controls 4 1 1 Operator Presence Control OPC Levers Located on the upper handle assembly directly above the handle grips When these levers are depressed the OPC system senses that the operator is in the normal operator s position When the levers are released the OPC system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the blade clutch is engaged Speed Control Lever Located in middle of control console it controls the maximum forward speed and is infinitely variable from neutral 0 mph to 6 2 mph Drive Levers Located on each side of the upper handle assembly directly below the handle grips See Figure 6 These levers individually control the speed and direction of each drive wheel When the speed control lever is moved out of the neutral position and the lock latches are moved into the drive position as shown in Figure 6 and the drive levers are released the drive wheels are engaged in the forward direction Squeezing the left hand and or right hand lever causes the left hand and or right hand drive wheel respectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the positi
6. Engine Service Dealer ENGINE TROUBLESHOOTING TABLE FAULTY srac INCORRECT DIRTY IMPRO PROBLEM de SPARK orn AIR ave PLUG React LEVEL SCREEN Hard atartiag ull EX E ROA AAN E pl te erratically Knocks or knocks or pinga SE a Cs ee EE Dn EA a A a overheats e ae High fuel consumption 38 7 WIRING DIAGRAM B amp S VAN GUARD TRANSMISSION SWITCH FROM SAFETY INTERLOCK MODULE YELLO SWITCH XO RED BLACK BROWN OPC SWITCH CONNECTORS ARE VIEWED FROM WIRE END N C NORMALLY CLOSED ENGINE N O NORMALLY OPEN XILL KEY GROUND SWITCH ENGINE KAWASAKI TRANSMISSION SWITCH NO uv mows CYL ad FROM SAFETY INTERLOCK MODULE ORANG GREEN BLACK aa Fm gp c SWITCH 3 L ENGINE KEL rey pan CONNECTORS ARE VIEWED FROM WIRE END N C NORMALLY CLOSED ENGINE N O NORMALLY OPEN GROUND TRANSMISSION SWITCH RQ 3 tr nw sos Cr J una O BLADE gt a gt 0 ENGINE KILL Zes INE oo ENGINE GROUND CONNECTORS ARE VIEWED FROM WIRE END N C NORMALLY CLOSED N O NORMALLY OPEN 39 HYDRAULIC DIAGRAM 8 CY VMYOJ 3SY3IA38Y JYNASSIYA HOIH JYNSSIYUA HOIH ANVL INANVECAH dYVWMYJOY3 431713 JYNASSIYA HOIH 3SYIA3Y JYNASSIYA HOIH 40 9 WARRANTY Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg Co Inc Exmark
7. SETTING 6 TROUBLE SHOOTING 6 1 MOWER TRACKS TO LEFT OR RIGHT a Check the drive tire pressures and circumferences See 5 1 11 b Turn knob on the right hydro control linkage in the direction that the mower needs to be adjusted to Turn the knob in 1 4 turn increments until the mower tracks correctly 6 2 MOWER CUTS UNEVENLY a Check the drive tire pressures and circumferences See 5 1 11 A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation b Check blade spacers they must be equal on each blade c Check caster mounting brackets to be sure all bolts are tight d Check blades tip to tip for straightness They should be within 3 16 or one blade width from being in line 6 3 BLADES DO NOT STOP WHEN DISENGAGED a Check belt guides under rear deck to make sure they are properly set See Section 5 2 8 and check the blade engagement adjustment See Section 5 2 4 36 6 4 ENGINE WILL NOT START a Check that the choke is in the ON position for a cold engine or in the OFF position for a warm engine See 4 3 2 NOTE Kawasaki engines may need to be choked even when warm b Make sure the key switch is in the ON position B amp S engine only c Make sure transmission is in true neutral position See 5 2 10 d Check that the blades are disengaged and the blade switch is depressed e Check that there is fu
8. and CASTER HEIGHT ADJUSTMENT Refer to the following chart to properly adjust desired cutting height 28 CUTTING HEIGHT ADJUSTMENT i to 4 1 4 NUMBER OF 1 4 BLADE SPACERS BELOW SPINDLE NO OF SPACERS POSITION BELOW CASTER FIG 9 1 2 3 16 T gt ner uz ze a O OCN ie 2 sz EE me Ee Sa ss E MC RENO saree rir rr BEA parra ANCONS ac rwe tun rye 17e r mel Ed REE HE RE a al AXLE P o p ol Rp N e a ETE mes oar a ses 2 ore 3 382 3 s as pes faa ae DEZA aa i L Ese EE EET ee ae EZ c es EXE EE 5797 3 0 a Css pa e Tee IMPORTANT To achieve the highest quality of cut blades should be level with the ground or tipped slightly down at the front SPRING DISC WASHER CONE TOWARDS BOLT HEAD FRONT LEFT ANTI SCALP BRACKET SHOWN TORQUE TO 40 45 ft ibs FIG 10 ANTI SCALP ROLLER ADJUSTMENT 52 MODELS ONLY 5 2 3 Anti scalp Roller Adjustment 52 models only For maximum deck flotation rollers should maintain 1 4 1 2 in clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts are tight or loss of roller may result See Figure 10 29 5 2 2 2 6 Blade engagement Linkage Located between the blade engagement bellcrank and blade engagement assist arm beneath the front left hand corner of the engine deck a Stop engine and remove spark plug wire s b With
9. bag Thread each drive linkage into the threaded swivel See Figure 4 Connect the upper end of each drive linkage to the drive levers Fasten with a long clevis pin and cotter pin from bolt bag Be sure the clevis pin is first inserted through the drive linkage and then through the drive lever from the outside before installing the hairpin cotter See Figure 5 E 3 16 RIGHT HAND SIDE SHOWN DRIVE LINKAGE FIG 5 DRIVE LINKAGE TO DRIVE LEVER Route the long unattached wiring harness lead up the left hand side of the handle and connect the two terminals in any order to the operator presence control switch terminals underneath the control console Fasten the lead to the handle with two large wire ties from bolt bag one at the upper end of the handle next to the console amd one at the very lower end of the handle where it attaches to the fuel tank support If machine is shipped without muffler installed install muffler with hardware provided Service Engine Refer to Engine Owner s Manual GREASE UNIT NOTE UNIT IS NOT GREASED AT THE FACTORY Refer to 5 1 13 for locations and grease amounts Follow pre start instructions as outlined in 4 2 NOTE After starting the engine and engaging the hydro drive and either of the drive wheels acts sluggish or will not rotate at all stop engine and refer to Section 5 1 10 on the Hydraulic System Air Purge procedure Perform any needed adjustments as outlined in the
10. down Loss of control and or loss of operator s footing could result in a fall with an arm or leg getting under the mower or engine deck and sustaining serious injury Drive slower on slopes DO NOT operate on slopes greater than 20 degrees Watch for ditches holes rocks dips and rises which can cause erratic handlebar movement and loss of footing Keep away from drop offs and steep banks Avoid sudden starts Look down and behind you before and while moving backwards DO NOT mow slopes when grass is wet slippery conditions create hazardous footing affect steering and reduce traction and braking The operator is responsible for safe operation on slopes Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Never operate the mower with defective guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Do Not change the engine governor settings or over speed the engine Operating an engine at excessive speed may increase the hazard of personal injury Place transmission in neutral disengage blade drive before starting engine Start the engine carefully with feet well away from the blades Keep hands feet and clothing away from rotating parts while the mower is being operated 2 1 4 11 Stop the engine and remove plug wire s or ignition key e Before checking cleaning or working
11. or cardboard NOT HANDS to search for leaks e Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result 5 1 9 Change hydraulic system filter Service Interval After First 250 hrs then each yearly thereafter a b c d f g Place unit on a level surface stop engine and remove spark plug wire s Carefully clean area around filter It is important that no dirt or contamination enters the hydraulic system Unscrew filter to remove and allow oil to drain from reservoir Before re installing new filter fill it completely with Mobil 1 15W 50 and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter Do not tighten yet Use only Exmark filter element Part No 513211 Fill reservoir as stated in Section 5 1 8 Loosen filter 1 2 turn and allow a small amount of oil te leak from the oil filter this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir Turn filter clockwise until rubber seal contacts the filter adapter Then tighten the filter an additional 2 3 to 3 4 turn Run machine to allow any other air to be purged from the hydraulic system and recheck the oil level If either drive wh
12. or replace with new plugs See Engine Owner s Manual 5 1 15 Remove engine shrouds and clean cooling fins Service Interval See Engine Owner s Manual a Stop engine and remove spark plug wire s b Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling c Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating 5 1 16 Change fuel filter Service Interval As Required a A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary 5 1 17 Refer to Engine Operators Manual for detailed maintenance regarding the engine 5 1 18 Wheel hub slotted nut torque specification When tightening the slotted nut on the wheel motor tapered shaft a Torque the slotted nut to 100 ft lbs b Further tighten the nut until the next set of slots line up with the cross hole in the shaft c Replace cotter pin d To aid in wheel hub removal it is recommended that an antisieze compound is used on the tapered shaft of the wheel motor 26 5 1 19 Thread locking adhesives such as Loctite 242 or 5 1 20 5 1 21 Fel Pro Pro Lock Nut Type are used on the following fasteners a All belt drive pulley setscrews b Square head setscrews on Hydro pump control arm c OPC lever setscrews d Sh
13. For Serial Nos 130 000 amp Higher e MFG CO INC VIKING HYDRO Operators Manual Part No 850435 A WARNING FAILURE TO FOLLOW CAUTIOUS OPERATING PRACTICES CAN RESULT IN SERIOUS OPERATOR INJURY A CAUTION Keep all shields guards and safety devices especially grass discharge system in place and in proper working condition Stop engine and remove spark plug wire s or remove key before adjusting servicing or preforming maintenance When mower deck becomes clogged stop engine and remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat or platform is provided 6 Keep others off mower 4 HEALTH WARNING GASOLINE Harmful or fatal if swallowed Long term exposure to vapors has caused cancer In laboratory animals 4 WARNING The engine exhaust from this product contains chemicals known to the State i Avoid prolonged breathing of vapors Keep face away from nozzle and gas tankicontainer opening Keep away from eyes and skin Never siphon by mouth Failure to use caution may cause serious injury or illness Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no re
14. NT i 5 16 WHIZLOCK NUT TENSION ROD e L D FOR BELT AR x e REFERENCE ONLY ON Gs Eros WR FIG 12 CUTTER DECK BELT ADJUSTMENT For the 14 and 15 hp engines proper belt tension will reguire about 10 lbs side pull on belt halfway between pulleys to deflect belt 1 2 For the 16 hp engines proper belt tension will reguire about 12 lbs of pull to deflect belt 1 2 See Figure 12 Point A 5 2 7 Secondary Belt 48 and 52 units only a b Stop engine and remove spark plug wire s The secondary drive belt is adjusted via the belt tension rod See Figure 12 The 5 16 nylock adjustment nut is located at the rear right corner of engine deck Proper belt tension for the secondary belt will require about 10 lbs side pull on belt halfway between pulleys to deflect belt 1 2 See Point B Figure 12 5 2 8 Belt Guide Adjustment a b c d Stop engine and remove spark plug wire s Engage the blade drive belt Check belt guide clearance on the mower deck The four welded belt guides on the mower deck should be located 1 8 from belt Adjust if necessary Check belt guides under the engine deck for proper adjustment See Figures 13 and 14 Adjust as necessary The disengaged belt should not drag or fali off pulley when guides are properly adjusted NOTE Belt guides are not installed on the same bolts on the 36 model as on the 48 and 52 models 31 1 1 4 CLEA
15. No 543631 Part No 323151 LOCATION Upper Handle Console LOCATION On Top Rear Right Hand A WARNING Surface of Mower Deck OPEN BELT DRIVE Part No AWARNING STOP ENGINE BEFORE REACHING UNDERNEATH 203517 DO KOT OPERATE WITHOUT DISCHARGE DEFLECTOR OR ENTIRE GRASS COLLECTION SYSTEM IX PLACE DO KOT REMOVE GRASS CATCHER UNTIL BLADES RAVE STOPPED Part No 303508 LOCATION Left Side of Rear Surface on Engine Deck A CAUTION t Arab A HYR O TG E CLEAR AACA OF PEOPLE PEYS Hed Stine x Keep FL an Yn n so S RAWSS OUT PAON MACHINE WHE Macrame r Mes gai Ents e USE EXTREME CAUTION VEN OPERATING ON SLOPES HOY ACROSS SLOPE NEVER LP AD DON DO NOT OPERATE ON SLOPES GREATER THAN 20 e_YATOH ER DITOES POLES ROCKS RISES OIPS lt KES AWAY FROM GROP IFES AMO STEEP BANG e LOK BEHIND YOU BEFORE SACKING DRIVE SLIVER ON SLOPES _ EXCOUTE TURNS SLINY DO NOT KY WET SLOPES VION ovat ae D ISENS AGED E Teams gron woes RE ASEO PLASE LEFT Ane mont DAVE LEVERS WIC MEUTRAL LOCK POSITION USING MEUTAAL LOCK Latent 9 QUPORE LEAVING OPLAATOR S POETON Smt T AST ION al META AL E DISENGAGE PLAST SUT oN CAT MAM ALL Sout AWS GUARDS Bi P AC be snot Sei MOWER DESK wets ets AVOID SIDIEN STARTS Part No a Grass CATENE A OR DISEMARSE DEFLECTOR 32 3232 PS mon Pane PAAK A ADE ats wets wom LOCATION Upper Handle Console e KEEP ALL PEPE
16. QUT OF AREA WEN MOWING e THROWN SELECTS OR BLADE CONTACT CAN CALSE SERIOS INORY OR DEATH AN ENCLOSED AREA BETES PRILLE CARSON MDG WHICH TS AN Part No MRES DELY POISN J 323525 aisaia TRACKING LIOR m gt LOCATION Right Side of Hydro Control Crank Arm LOCATION Upper Handle Console Di AL 52 KY AND 48 YIK 5 SP0 WY Part No LOCATION 36 DECK Part No LOCATION 48 4 52 403139 DECKS 2 SPECIFICATIONS 2 1 MODEL NUMBER VH3614KA VH3615KC VH4814KA VH4815KC VH5216BV 2 2 ENGINE 2 2 1 Engine Specifications See your Engine Owner s Manual 2 2 2 3600 RPM No Load 2 3 FUEL SYSTEM 2 3 1 Capacity 5 0 gal 18 9 L 2 3 2 Type of Fuel Regular unleaded gasoline 87 octane or higher In countries using the research method it should be a 90 octane minimum 2 3 3 Fuel Filter Replaceable in line 2 3 4 Fuel Shut Off Valve 1 4 turn 2 4 SAFETY INTERLOCK SYSTEM Operator must have transmission in neutral and blade clutch disengaged to start engine Release of OPC levers will cause the engine to stop if hydro transmission is not in neutral and or blade clutch is engaged 2 5 STEERING BRAKE CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning 2 6 TRANSMISSION Twin Hydrostatic Drive 2 6 1 Two Hydro Gear Sundstrand BDP 10L series variable displacement
17. RANCE 1 1 4 CLEARANCE CENTER OF SLOT yd x ga CLEARANCE 777 Wh CLEARANCE END OF SLOT FIG 13 FIG 14 BELT GUIDE LOCATION BELT GUIDE LOCATION 48 amp 52 36 MOWER DECK Under Rear Deck Under Rear Deck 5 2 9 Pump Drive Belt Tension Adjustment No adjustment necessary 5 2 10 Hydro Drive Linkage Adjustment Adjust Speed Control Linkage and neutral safety switch a 1 Move the speed control lever located on the console to the full forward position and check the orientation of the tabs on the ends of the speed control crank fig 16 These tabs should be pointing straight down at the 6 o clock position or slightly forward Adjust the threaded yoke at the bottom of the speed control link until the tabs are positioned correctly 2 Pull the speed control lever back to neutral Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is about 5 16 between the tab and the switch See fig 15 If necessary move the switch fore and aft 5 16 AS VIEWED FROM THE LEFT SIDE OF UNIT NEUTRAL ACTUATING SAFETY ACT SWITCH FIG 15 NEUTRAL SAFETY SWITCH ADJUSTMENT b Adjust Neutral Control Linkages 1 Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground 2326 2 NEUTRAL CONTROL LINKAGE AS VIEWED FROM THE LEFT SIDE OF UNIT 4 6 Start the engine and move the throt
18. TION e Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system A CAUTION Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result ACAUTION Keep body and hands away from pin holes or nozzles that eject hydraulic fluid fluid under high pressure Use paper or cardboard NOT HANDS to search for leaks CAUTION Safely relieve all pressure in the hydraulic system before disconnecting lines or before performing any work on the hydraulic system 1 6 RIDING ATTACHMENTS 1 6 1 Use only Exmark riding attachments The use of other than Exmark riding attachments may create a hazardous condition resulting in injury SAFETY SIGNS i 1 7 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs 1 7 2 Safety signs must be replaced if they are missing or illegible 1 7 3 When new components are installed be sure that current safety signs are affixed to the replaced components 1 7 4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc 1 7 5 Safety signs may be affixed by peeling off
19. alve NOTE A cold weather starting kit has been added for ease of starting in either cold weather or when the unit has not been run for a period of time To use cold start kit a Place shifter in neutral position b Pull split ring straight out the side of the unit and hook the ring over the lower front hydro control shield bolt c Start engine Refer to the following guidelines for further starting suggestions To engage pump drive unhook cold start kit a Pull chain straight out from the side of the unit until the split ring can be removed from the bolt SLOWLY release tension on chain For Kohler and Kawasaki engines On a cold engine place the throttle in the full forward Choke position Pull recoil rope to start engine With a cold engine gradually return choke to the full throttle position after the engine starts and warms up NOTE Kawasaki engines generally need to be choked even when warm On a warm engine place the throttle control midway between the Slow and Fast positions 17 sd 3 3 For B amp S engines Turn key to the Run position On a cold engine place the throttle in the full forward position and pull the choke control on the engine fully outward to the engaged position Pull recoil rope to start engine With a cold engine gradually return choke to the full throttle position after the engine starts and warms up On a warm engine place the throttle control midwa
20. and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing 1 5 MAINTENANCE AND STORAGE Le 5 1 10 11 For engine maintenance follow the engine manufacture s recommendations precisely as stated in the engine manual If carburetor adjustment is necessary stand to one side and keep feet and hands clear while making adjustments Keep engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Store fuel in a container specifically designed for this purpose in a cool dry place Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly Check all bolts frequently to maintain proper tightness Keep all guards shields and all safety devices in place and in safe working condition Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as or equivalent to the parts supplied as original equipment A CAU
21. bag eight 3 8 x 3 4 bolts and eight 3 8 whizlock nuts tightening the lower four bolts first then the top four Apply threadlocker Fel Pro Nut Type or Loctite Threadlocker 242 on the two threaded studs from the bolt bag and install into the two left holes underneath fuel tank Install the fuel tank on top of the fuel tank support with the studs going through the slots in the support Install two 5 16 x 3 4 screws with a flatwasher and lockwasher into the threaded holes in the right side of the fuel tank Do not over tighten Place a 1 4 flatwasher then a spring over each of the studs and fasten with a 5 16 nyloc nut Tighten to where there is a small gap between the coils of the springs Do not over tighten 10 3 8 Attach the fuel tank hose to the tank fitting and secure with the clamp provided Make sure that fuel hose is not between engine and throttle plate on engine 3 9 Position the lower end of the handle assembly on the outside of the upper rear section of the fuel tank amp handle support Install four 3 8 16 x 1 bolts with four spring disk washers against the head of each bolt from the outside in Secure using four 3 8 whizlock nuts on the inside of each handle support and tighten until the spring disk washers are flat See Figure 1 UPPER HANDLE UPPER HANDLE MOUNTING TAB FRONT OF UNIT FIG 1 UPPER HANDLE MOUNTING 3 10 Route the throttle cable along the right side of the upper handle under th
22. blade drive engaged adjust the linkage length to obtain 1 8 to 3 16 clearance between the lower end of the bellcrank and the axle support gusset See Figure 11 VIEWED BELLCRANK FROM RIGHT SIDE OF UNIT SWITCH IS LOCATED BENEATH THE ENGINE DECK BLADE 1 3 TO 3 16 SAFETY SWITCH CLEARANCE FIG 11 BLADE ENGAGEMENT LINKAGE Blade Safety Switch a Stop engine and remove spark plug wire s b With blades disengaged and the bellcrank touching the rear of the slot in the engine deck adjust the blade safety switch mounting bracket if needed until the bellcrank depresses the plunger by 1 4 c Be sure the bellcrank DOES NOT touch the switch body or damage to the switch could occur d Retighten switch blade mounting bracket Engine to Cutter Deck Belt a Stop engine and remove spark plug wire s b Check belt guides under rear engine and front mower deck to see that they are properly set See Section 5 2 8 c Belt must be tight enough so it does not slip during heavy loads while cutting grass Over tensioning will reduce belt and spindle bearing life To adjust belt tension loosen the 5 16 whizlock nut on turnbuckle and rotate the turn buckle rotate turnbuckle toward rear of mower to tighten and toward front of mower to loosen belt tension See Figure 12 Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation Adjust as necessary 30 ADJUSTME
23. cified in the operator s manual or other operational instructions provided by Exmark vi repair or replacement arising as a result of any operation from turf equipment that has been altered or modified so as to in the determination of Exmark adversely affect the operation performance or durability of the equipment or that has altered modified or affected the turf equipment so as to change the intended use of the product vii repair or replacement necessitated by use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf 41 equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark viii repairs or replacements resulting from parts or accessories which have adversely affected the operation performance or durability of the turf equipment or ix damage or defects due to or arising out of repair of turf equipment by person or persons other than an authorized Exmark service dealer or the installation of parts other than genuine Exmark or Exmark recommended parts As a condition to this warranty customer shall have read the operator s manual and shall have returned to Exmark within the prescribed time the enclosed warranty registration card The sole liability of Exmark with respect to this warranty shall be repair and replacement as set forth herein Exmark shall have no liability for any other cost loss or damage including but
24. ds are removed from the handles the mower engine MUST stop Check OPC circuits Clear the area Run engine at one third throttle then with drive levers and neutral lock latches in neutral lock position move the speed control lever out of neutral and release OPC levers engine MUST stop Again run engine at one third throttle move the speed control lever to neutral engage blade clutch and release OPC levers engine MUST stop If machine does not pass any of these tests DO NOT operate Contact your authorized EXMARK SERVICE DEALER A CAUTION e It is essential that all Operator Safety Mechanisms be connected and in proper operating condition prior to the use of the mower 21 A CAUTION e When checking starting problems be sure to keep body hands and clothes away from areas where moving parts can suddenly engage 5 1 5 Check for loose hardware Service Interval Daily a b Stop erigine and remove spark plug wire s Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating 5 1 6 Service pre cleaner element and air cleaner Service Interval See Engine Owner s Manual 5 1 7 Change engine oil Service Interval See Engine Owner s Manual NOTE Change oil after first five 5 hours of operation Follow a b c a e f g engine manufacturers recommendations for future oil changes Disengage blade clutch S
25. e fuel tank support and position the cable on the left side of the engine Kaw amp Kohler or to the right side of engine B amp S Attach throttle cable to engine For Kohler and Kawasaki engines with positive detents in throttle cable for the full throttle and idle positions a Position the throttle control lever on console in the full throttle but not choke position You will feel a detent when the throttle lever is approximately 3 4 from the upper end of the slot this is full throttle position b Loosen clamp on engine control plate See Figures 2 amp 3 Attach inner wire of the throttle cable to the control plate lever and position cable clamp do not tighten clamp Choke Link Clamp Control Cable Control Alignment Holes Choke Adjusting Screw Control Plate Lever Kill Switch Adjusting Screw Control Plate Kill Switch FIG 2 KOHLER SPEED CONTROL THROTTLE CABLE HOOK UP 11 Control Alignment Holes c d e For a b Link Control Cable Choke Adjusting Screw Control Plate Lever FIG 3 Control Plate KAWASAKI SPEED CONTROL THROTTLE CABLE HOOK UP Pull cable upward until alignment holes in control plate lever and control plate line up For Kawasaki a 15 64 6 mm drill bit can be inserted through these two holes to align them For Kohler use a 19 64 drill bit Once the holes are aligned tighten clamp onto throttle cable Be sure the choke adjusting screw just c
26. eel does not rotate one or both of the charge pumps located on the top of the main pump as shown in Figure 8 may have lost their prime Refer to Section 5 1 10 DO NOT change hydraulic system oil except what can be drained when changing filter unless it is felt that oil has been contaminated Changing oil unnecessarily could damage the hydraulic system by introducing contaminates into the system 22y 5 1 10 Hydraulic system air purge procedure Air must be purged from the hydraulic system when any hydraulic components including oil filter are removed or any of the hydraulic lines are disconnected The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump See Figure 8 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed a Stop engine Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground b Check oil level as stated in Section 5 1 8 c Thoroughly clean the area around each of the charge pump housings LOOSEN 1 1 2 TURNS ONLY CHARGE PUMP FIG 8 CHARGE PUMP LOCATION d To prime charge pump loosen two hex socket head capscrews shown in Figure 8 1 1 2 turns only Make sure engine is not running Lift charge pump housing upward and wait for a steady flow of oil to flow out from under ho
27. el in the tank and that the fuel valve is open f Check that the spark plug wire s are properly connected g Check for loose or faulty wiring connections If it is necessary to disconnect wire connectors Do Not pull on the wires while disconnecting h Check for corrosion at all wiring connections Even minor corrosion may cause a faulty connection Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect A CAUTION It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use NOTE After carefully checking the above steps attempt to start the engine If it does not start contact your authorized Exmark service dealer ENGINE TROUBLESHOOTING A CAUTION e When checking starting problems be sure to keep body hands and clothes away from areas where moving parts can suddenly engage caution When performing maintenance servicing or repairing the unit allow the engine ample time to cool down Serious burns can result from hot metal 237 When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures such as valves governor etc Have this work done by your
28. ent Push forward and down completely on the engagement knob to disengage the blades 4 4 TRANSPORTING Use a heavy duty trailer to transport the machine Engage neutral lock latches and block wheels Securely fasten the machine to the trailer with straps chains cables or ropes Use a safety chain and be sure that the trailer has all necessary lighting and marking as required by law 19 5 MAINTENANCE amp ADJUSTMENTS CAUTION Disengage blade clutch shut off engine and remove spark plug wire s before servicing cleaning or making adjustments The engine can become very hot Always allow the engine to cool before servicing or making repairs around the engine area 5 1 PERIODIC MAINTENANCE 5 1 1 Check engine oil level Service Interval See Engine Owner s Manual a b c a Make sure engine is stopped and on a level surface Check with engine cool Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick DO NOT screw into place for Kohler and Kawasaki engines DO screw into place for B S engines Remove dipstick and check oil level If the oil level is low add oil as specified in the Engine Owner s Manual to bring the oil level up to the F mark on the dipstick DO NOT OVERFILL IMPORTANT DO NOT operate the engine with oil level below the L mark or over the F mark 5 1 2 Clean engine air cooling system Service Interval See Engine Owner s Manual
29. indle shaft The highest quality cut can be achieved with all four spacers between the blade and the spindle shaft If the mulching kit is installed the highest quality cut can be obtained with 3 spacers between the blade and spindle minimum is 1 for a good cut If you need to cut higher or lower than what the spacers will allow it will be necessary to adjust the rear axle height and caster position See Section 5 2 2 below 27 5 2 2 Axle height and caster spacer position Desired cutting height range can be obtained by adjusting the rear axle and placing caster spacers above or below the caster arm See Figure 9 To adjust rear axle a Stop engine and remove spark plug wire s b Raise the rear of the machine up onto jack stands and remove the drive wheels Axcavtion e When it is necessary to raise the deck or mower for service or maintenance DO NOT rely solely on mechanical or hydraulic jacks for support Use adeguate jack stands or eguivalent support c Loosen but do not remove the top two bolts on each hydraulic motor mounting bracket DO NOT remove See Figure 9 d Remove the bottom sets of hardware for each bracket e Reposition the mounting bracket to the desired height and reinstall the bottom hardware f Tighten all hardware and remount drive wheels AXLE CASTER ADJUSTMENT ADJUSTMENT 4 ea 1 2 SPACERS LOOSEN BUT 1 ea 3 16 SPACER DO NOT REMOVE CASTER SUPPORT FIG 9 AXLE
30. ing With drive levers located in neutral shift speed control lever to desired forward speed Slowly squeeze and hold both drive levers in the neutral position and move both neutral lock latches from the neutral lock position Do Not squeeze both drive levers all the way back this will cause the drive wheels to be engaged in the reverse direction For straight ahead motion smoothly release both drive levers to engage drive wheels Squeeze the right hand drive lever to turn right and the left hand drive lever to turn left 18 To make a zero turn squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed To back up squeeze both drive levers into the reverse position For smooth operation of this machine avoid quick jerky movements of the drive levers Move the drive levers smoothly and deliberately 4 3 6 To Stop Squeeze drive levers back to the neutral position Move neutral lock latches into the neutral lock position and release drive levers Move the speed control lever to the neutral position 4 3 7 Blade Engagement Be sure that all persons are clear of mower deck and discharge area before engaging the blades Set throttle to midway position Pull the blade engagement knob up and rearward to engage blades Accelerate to full throttle to begin mowing See Section 4 1 5 4 3 8 Blade Disengagem
31. nd Kohler engines secure fuel line to throttle control cable with a small wire tie approximately 2 ahead of filter to keep fuel line away from hydraulic lines to prevent vapor lock 3 11 Install the blade engagement linkage to the bell crank on Us 12 FROM THE RIGHT 13 14 15 the front left hand side of the engine deck Insert rod through the hole from the outside and fasten with cotter hairpin from bolt bag Note the sguare swivel at the end of the hydro control arm linkage Place the stud end of the swivel into the hole on the end of the short crank arm located at the end of the speed control crank top rear of fuel tank support Install a 1 4 washer and fasten with a 3 32 x 1 2 cotter pin from bolt bag Repeat on opposite side of unit See Figure 4 HYDRO CONTROL CRANK ARM LINKAGE DRIVE LEVER AS VIEWED LINKAGE SIDE OF UNIT THREADED SWIVEL FIG 4 HYDRO CONTROL LINKAGE SWIVEL amp DRIVE LINKAGE SWIVEL Install the speed control rod assembly linkage with the yoke installed on one end into the end of the speed control lever located underneath the center of the console Insert the end of the linkage opposite the yoke into the end of the lever from the right hand si e and fasten with a hair pin from bolt bag Connect the lower end of the speed control linkage to the speed control crank located at the top rear of the fuel tank support Secure with clevis pin and hair pin from bolt
32. ndary 48 amp 52 decks belt condition c Look under engine deck to check the pump drive belt condition d Check all idler arms to be sure they pivot freely Disassemble clean and grease pivot bushings if necessary 5 1 13 Lubrication Service Interval Refer to Chart a Stop engine and remove spark plug wire s b Lubricate fittings with one to two pumps of SAE No 2 multi purpose gun grease see recommended lubricants following the lubrication chart Refer to the following chart for fitting locations and lubrication schedule GREASE LUBRICATION CHART FITTING INITIAL ED SERVICE LOCATIONS PUMPS 36 INTERVAL 6 Pump Control Bearings 2 Under severe cutting conditions two pumps of grease twice weekly may be more beneficial 25 Recommended SAE No 2 Greases Pennzoil 705 Pennzoil 707L Pennzoil TTM 302 Mobil Grease CM P Mobilith SHC220 Mobil Grease Special Mobilith SHC460 Available at Mobil Stations Ronex MP Available at Exxon Stations Shell Alvania 2 Available at Shell Stations Super Lube M EP 2 or Super Stay M 2 Available at Conoco Stations c Lubricate pivot points with a spray penetrating lubricant as directed below SPRAY LUBRICANT CHART NO OF PLACES SERVICE POINT PIVOT EM 36 48 52 INTERVAL 1 Blade Engagement Upper Bellcrank 2 2 2 Weekly 5 1 14 Check spark plugs Service Interval 100 hrs a Remove spark plugs check condition and adjust plug gap
33. not limited to any incidental or consequential loss or damage In particular Exmark shall have no liability or responsibility for i expenses relating to gasoline oil or lubricants ii loss cost or expense relating to transportation or delivery of turf equipment from the location of owner or location where used by owner to or from any authorized Exmark service dealer iii travel time overtime after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer iv rental of like or similar replacement equipment during the period of any warranty repair or replacement work v any telephone or telegram charges or travel charges vi loss or damage to person or property other than that covered by the terms of this warranty vii any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty or viii attorney s fees There are no representations or warranties which have been authorized and provided to the buyer of the turf equipment other than as set forth in this warranty Any and all statements or representations made by any seller of this equipment including those set forth in any sales literature or made orally by any sales representative are superseded by the terms of this warranty Any affirmation of fact or promise made by Exmark or any of its representatives t
34. o the buyer which relates to the goods that are the subject of this warranty shall not be regarded as part of the basis of the bargain and shall not be deemed to create any express warranty that such goods shall conform to the affirmation or promise THERE ARE NO UNDERSTANDINGS AGREEMENTS REPRESENTATIONS OR WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY REGARDING THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NOT SPECIFIED HEREIN RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY This warranty applies to all Exmark turf equipment sold in the United States and Canada and intended to be used for commercial purposes 42 SEE EXMARK S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z EXPLORER TURF RANGER TURF TRACER HYDRO TURF TRACER HP VIKING 5 SPEED VIKING HYDRO METRO SELF STEERING SULKY GRASS CATCHER MICRO MULCHING ACCESSORY EXMARK MFG CO INC PART NO 850435 INDUSTRIAL PARK BOX 808 402 223 4010 BEATRICE NE 68310 FAX 402 223 4154 ALL RIGHTS RESERVED PRINTED IN U S A a MFG CO INC
35. o an authorized Exmark service dealer within the warranty period The warranty shall extend to cost to repair or replace as determined by Exmark the defective part including labor The expense of delivering the mower to the dealer for warranty work and the expense of returning it back to the owner after repair or replacement will be paid for by the owner Exmark s responsibility in respect to claims is limited to making the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower Proof of purchase may be required by the dealer to substantiate any warranty claim All warranty work must be performed by an authorized Exmark service dealer This warranty extends only to turf equipment operated under normal conditions and properly serviced and maintained The warranty expressly does not cover i any defects damage or deterioration due to normal use wear and tear or exposure ii normal maintenance services such as oil change cleaning lubrication adjustment iii replacement of service items such as oil lubricants spark plugs belts rubber hoses or other items subject to normal service replacement iv damage or defects arising out of or relating to misuse neglect alteration negligence or accident v repair or replacement arising from operation of or use of the turf equipment which is not in accordance with operating instructions as spe
36. on of the neutral lock levers and the speed control lever Neutral Lock Latch Located directly above the drive levers These latches allow the operator to lock the drive levers in a neutral position where neither of the drive wheels are engaged in either a forward or reverse direction See Figure 6 ROTATE BACK FOR NEUTRAL LOCK POSITION LATCH IS IN THE DRIVE POSITION NEUTRAL X FULL SPEED a NEUTRAL HOLD IN THIS POSITION FORWARD FORWARD RELEASE DRIVE LEVER REVERSE SOUEEZE DRIVE LEVER FIG 6 DRIVE LEVER NEUTRAL LOCK LATCH OPERATION 15 eis Ts eds 10 11 Blade Engagement The push pull blade engagement knob is located on the left side of the control console To engage the blades the knob must be pulled toward the operator until the turnbuckle attached to the blade engagement idler locks over center To disengage the blades push the knob down until the bellcrank front left on engine deck contacts the end of the slot in the deck Choke Control Choke is used to aid in starting a cold engine On the B amp S engine the choke control is located on the left hand front corner of the engine and is activated by pulling the control outward On Kawasaki and Kohler engines the choke is part of the throttle control lever and is activated by moving the throttle control to the full forward position Once the engine has started move the choke control to the off position and move the th
37. on the mower e After striking a foreign object inspect the mower for damage and make repairs before restarting and operating the mower 1 4 12 Stop the engine e Before clearing blockages e Whenever you leave the mower e Before removing the grass catcher e Before refueling e Before making height adjustments 1 4 13 Before stopping the engine return the throttle control to the idle position for 30 seconds to allow the engine to cool down 1 4 14 The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel when e The machine will not be used for a few days e During transport to and from the job e When parking inside a building 1 4 15 This mower was designed for one operator only Keep all others away from mower during operation 1 4 16 Do Not mow without the grass deflector or entire grass collection system in place and in proper working condition AADANGER DO NOT operate the engine in a small confined area where dangerous carbon monoxide fumes can collect ACAUTION e Failure to follow safety instructions and cautious operating practices can result in serious injury ACAUTION Although hazard control and accident prevention partially are dependent upon the design and configuration of the equipment these factors are also dependent upon the awareness concern prudence and proper training of the personnel involved in the operation transport maintenance
38. ontacts the choke lever when the throttle control is in the full throttle position Choke link should not move when throttle control is moved to the full throttle position Choke must be completely closed when throttle lever is moved to the full forward CHOKE position This step needs to be done after the unit has been assembled and the engine has been started Refer to Section 4 Operation Instructions Check the engine STOP position by moving throttle control fully to the rear Note There is a detent toward the end of the slot in the console for IDLE the STOP lower position is rearward from this detent For Kohler if the engine continues to run in the STOP position turn kill switch adjusting screw inward until engine stops then give it an additional 1 2 to 3 4 turn to assure it will always function properly Kawasaki kill switch is not adjustable B amp S Vanguard Engines Position the throttle control lever on console 1 8 from the upper end of the slot Route the throttle cable along the right side of the upper handle under the fuel tank support and position the cable on the right side of the engine between the oil fill tube and engine Attach the inner wire to the appropriate throttle control lever on the engine Loosen the cable clamp on the engine place the cable behind it and pull up on the cable to move the throttle linkage to the full throttle position Tighten the cable clamp screw L 19 On Kaw a
39. oulder bolts in ends of speed control crank e Shoulder bolts connecting Hydro control linkages to hydro pump control arms Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining II are used on the following a OPC lever hubs and cross shaft NOTE Care must be used not to bond the bearing next to each OPC hub to the cross shaft which could cause binding of the OPC levers and erratic operation b Transmission drive pulley on the engine PTO shaft An anti seize compound is used on the blade drive pulley hub located on the engine PTO shaft this allows for ease of removal of the pulley It also used on tapered shaft of wheel hub mounts Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 5 2 ADJUSTMENTS 5 2 1 A CAUTION Disengage blade clutch shut off engine and remove spark plug wire s before servicing cleaning or making adjustments Blade Spacers Blades may be adjusted for cutting height by using the four 1 4 spacers found on the blade spindle bolts factory setting is two above and two below This allows a 1 range in 1 4 increments of cutting height in any axle position The same number of blade spacers must be used on all blades to achieve a level cut two above and two below one above and three below etc For the best cut and discharge a minimum of two spacers should be placed between the blade and sp
40. pumps independently coupled to two high efficiency Ross wheel drive motors 2 6 2 Speed Range Forward 0 6 2 mph 10 0 km h Reverse 0 2 2 mph 3 5 km h 2 7 WHEEL DRIVE SYSTEM Drive wheels are direct coupled to Ross wheel drive motors with 1 0 25 4 mm tapered shaft 2 8 TIRES Drive Front Caster Size wate oss 16 x 6 50 8 9 x 3 50 4 Quantity P GG GG AG UR 2 Tread Turfsaver Smooth Ply Rating amp ER O 4 Pressure 14 psi 97 kPa 22 psi 152 kPa 2 9 DECK 2 9 1 Cutting Width Model 36 in 35 38 in 89 9 cm Model 48 imn L he aW eee 47 63 in 121 0 cm Model 52 in 52 00 in 132 1 cm 2 9 2 Discharge Right Side 2 9 3 Blade Size Model 36 in 18 00 in 45 7 cm Qty Model 48 in 16 25 in 41 3 cm Qty Model 52 in 18 00 in 45 7 cm Qty 2 9 4 Type of Drive Manual engagement of belt with over center lock Belt tension is adjustable via turnbuckie The 48 and 52 units have an additional belt also adjustable 2 9 5 Deck Mounting Bolted directly to the engine deck 2 9 6 Cutting Height Adjusts in 1 4 63 cm increments from 1 2 5 cm to 4 1 4 10 8 cm 2 10 DIMENSIONS 2 10 1 Overall Width 36 Discharge chute down 46 1 117 1 cm 4 Discharge chute up Transport only cm 48 52 58 1 62 7 147 6 cm 159 26 cm 48 4 0 122 9 cm s cm 2 10 2 Overall Length
41. re engage neutral lock latch checking that the tire stops Continue these process until the tire is at a dead stop FIG 18 DRIVE LEVER AND LATCH IN NEUTRAL POSITION 4 Replace the hairpin back into each clevis pin 5 Make this adjustment for both sides Tracking Adjustment Stop engine Raise the rear of the machine remove jack stands and carefully lower the machine to the ground Check the drive tire pressures and tire circumferences See 5 1 11 Run the unit and observe the tracking on a level smooth hard surface such as concrete or asphalt If the unit tracks to one side or the other turn the quick track knob Turn the knob right to Steer right turn the knob left to steer left 5 2 11 Hydro Pump Spring Tension Setting a b For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling For a heavier drive setting relocate the spring anchor links to either the medium or heavy duty positions as 35 shown in Figure 19 The spring anchor links are attached to the upper rear corner of the hydro drive shields on the left and right hand sides of the machine Note In the medium or heavy duty positions the drive lever forces at the upper handle will also be increased Retaining Bolt Standard Medium Heavy Duty Spring FIG 19 HYDRO PUMP SPRING TENSION
42. ring Repeat above adjustments if necessary w Place the speed control lever in neutral Adjust the right side linkage by turning the quick track knob counter clockwise until the tire begins to rotate forward Begin to retighten the knob clockwise about 1 4 turn at a time stopping to move the speed control forward and back to neutral Recheck the drive wheel rotation to see if further adjustment is necessary 4 The spring that keeps tension on the knob should normally not need adjustment However if adjustment is needed adjust to where length of spring is about 1 between the washers Adjust spring length by turning nut at front of spring a Drive Lever Linkage Adjustment 1 With rear of machine still on jack stands and engine running at full throttle move the speed control lever 34 e to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches See fig 18 If the tire rotates in either direction the length of the drive lever link will need to be adjusted 3 Adjust the linkage length by releasing the drive lever and removing clevis pin and rotating the linkage in the lower swivel Lengthen the linkage if the tire is turning in reverse and shorten the linkage if the tire is creeping forward Rotate the linkage several turns if the tire is rotating fairly fast But as the adjustment gets closer adjust the linkage in 1 2 turns Release and
43. rive lever is in the neutral position tighten the nut against the yoke c Adjust Hydro Control Linkages 1 Place the speed control lever in the neutral position This adjustment is again made with rear of machine on jack stands and engine running at full 233 throttle OPC levers will have to be held down whenever speed control levers are moved out of the neutral position 2 Loosen the front nut on left hydro control linkage as shown in Figure 16 Turn the rear control linkage adjusting nut counter clockwise until wheel rotates forward Turn the rear nut of left control linkage clockwise 1 6 of a turn at a time stopping to move the speed control forward and back to neutral until left wheel stops rotating forward Turn the rear nut an additional 1 2 turn and tighten the front nut making sure not to put a bind on the linkage Make sure flat part of linkage is perpendicular to pin part of swivel See Fig 17 LEFT SIDE SHOWN END VIEW FIG 17 HYDRO CONTROL LINK SWIVEL ADJUSTMENT After adjusting the left hydro control linkage move the speed control lever to the mid speed position and then back to the neutral position Recheck the left drive wheel rotation to see if further adjustment is necessary be sure the speed control lever is in the neutral position If inconsistent neutral occurs check to be sure both springs are properly tightened on the speed control lever under the console especially the rear pivot sp
44. rk by 3 00 p m central time Orders must be six 6 line items or less Exclusions from the Exmark Parts Plus Program are Any wholegood or accessory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions Due to UPS restrictions aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air Exmark Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program iii CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation OPERATOR S MANUAL This manual contains assembly operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipmen
45. roperty 1 3 PREPARATION 1 3 1 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended 1 3 2 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals 1 3 3 Thoroughly inspect the area where the equipment is to be used and remove all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders 1 4 OPERATION WARNING Fuel is Highly Flammable DO NOT smoke while refueling Refuel only in a well ventilated area or refuel outdoors s Store fuel in containers specifically designed for this purpose e Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot e If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source Of ignition until fuel vapors have dissipated Give complete undivided attention to the job at hand Mow only in daylight or good artificial light Do Not operate the mower when children or others are in the area When feasible avoid operating the equipment in wet grass Use EXTREME caution when mowing and or turning on slopes as loss of traction and or control could occur Mow across slopes with walk behind mowers never up and
46. rottle to the medium or full throttle position Throttle Control Located on the control console s right side The throttle is used to control engine speed Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed All Kohler and Kawasaki units are equipped with throttle kill as a standard feature Moving the throttle to the full rear Stop position will shut off the engine B amp S units use a key switch to shut off engine Off Run Switch B amp S only Located on the front left corner of the fuel tank support Turn key to the Run position to allow the engine to be started Turn key to the Off position to shut engine off Fuel Shut Off Valve Located along the fuel line The fuel shut off valve is used to shut off the flow of fuel when parking inside a building during transportation to and from the job sites and when the machine will not be used for a few days Rotate valve 1 4 turn clockwise to shut fuel off Rotate valve 1 4 turn counter clockwise to turn fuel on Drive Wheel Release Valves Located on the top corner of the hydrostatic pumps Drive wheel release valves are used to release the hydro static drive system to allow the machine to be moved by hand without the engine running Turn valves one half turn counterclockwise to release the drive system Turn clockwise to reset the drive system Do Not over tighten Cold Start Kit Located on the righ
47. s Y waste eee ed Y Se See S 8 2 2 Engine Au eS ig BAS San YN AS ashe av a A ears 8 2 3 Puel System su a bu oh baa See Wd RAO dda eee ee 8 2 4 Safety Interlock System HY MC 8 2 5 Steering Brake Control ooooooooooomomo mom onmo 8 2 6 Transmission lt AN y 8 2 7 Wheel Drive System i A ss OE SO du tee Wie ee wie are 8 28 Tires ue RO O Mele 23 NN a by 8 29 DECK s oet i A E u gee Y A ete eral gigs DAN eae FU e tige s 9 2 10 DIMENSIONS yeh cee a GA GROG eye a aqa Y do Cau AGO BT 9 2 11 Torque ReguirementS rr 10 ASSEMBLY INSTRUCTIONS 3 1 t6 3 23 Assembly a A AO 10 14 OPERATION INSTRUCTIONS BST COMET OVS 00 iu i Gw a Ga gave Blade wre aac ates ANA 15 17 42 Pre Starb o eie orto eB eerie Wye ae dd a a 17 4 3 Operation Instructions 17 19 44 cTransporting es a is o A a e ae ies we Se LD MAINTENANCE ADJUSTMENTS 5 1 Periodic Maintenance o ooooooooooooooo mos 20 27 5 2 AQJUSEMENES soro u usa a a e 27 36 TROUBLE SHOOTING 6 1 Mower Tacks Left or Right oo oooooooooooooomoo oo 36 6 2 Mower Cuts Unevenly 2 cc cece cee eee eee eee 36 6 3 Blades Do Not Stop When Disengaged 36 6 4 Engine Will Not Start 37 38 WIRING DIAGRAM io ciao ea e 39 HYDRAULIC DIAGRAM 40 WARRANTY iii a tate es en eae eee 41 42 1 SAFETY 1
48. sponsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication of California to cause cancer birth defects or other reproductive harm EXMARK PARTS PLUS PROGRAM EFFECTIVE DATE September 1 1995 Program If your Exmark dealer does not have the Exmark part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed How the Program Works 1 if dealer does not have part in stock for a down unit at the time of request by customer the dealer contacts his distributor by 1 00 p m local time and requests Exmark Parts Plus shipment of six 6 line items or less 2 Distributor ships part s to dealer or customer as requested by dealer same day overnight UPS Distributor bills dealer for part and freight charges where applicable 3 If distributor does not have the part s in stock to satisfy ws Exmark Parts Plus order he contacts Exmark by 3 00 p m central time with an Exmark Parts Plus order of six 6 line items or less 4 If order is received by 3 00 p m central time Exmark ships part s direct to dealer or customer as requested by distributor same day overnight UPS Exmark bills the distributor for parts and shipping charges where applicable 5 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arri
49. t dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the quantity part number and description of the part needed The serial number plate of the tractor is located on the top front engine frame on the right hand side of the machine We suggest you record the numbers below for ready reference Model NO PASTE LABEL FROM OR LITERATURE PACKET HERE Date Purchased Purchased From w TABLE OF CONTENTS SAFETY eres cern eee 6 PAGE iLi Safety Alert Symbol scrisori neide eda See sankhu asa kuma Ua 1 12 raining NN 1 13 Pr paration usus yuy gsc o is ave eo a Sener oi oh bole 1 1 4 Operati Nn a AI er ee pam ce ee ae 2 3 1 5 Maintenance amp Storage o oo ooooooococo omo omo ooo 4 5 1 6 Riding Attachments e aa 5 17 Safety SIGNS is ia AE 5 7 SPECIFICATIONS 2 1 Model Number ss iii ig cece Site
50. t hand side of engine deck below and slightly ahead of the hydro control shield The cold start kit is used to ease the starting of the unit in cold weather or when the unit has not been operated for a period of time The cold start kit moves the idler pulley away from the pump belt releasing the tension on the belt which allows the engine to turn over with less resistance 16 4 1 12 Tracking Adjustment Knob Located on the right hand side of the rear of the fuel tank support Can be adjusted so that machine will track straight ahead with drive levers released 4 2 Pre Start 4 2 1 Fill fuel tank For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Regular grade leaded gasoline may also be used however combustion chamber and cylinder head will require more frequent service See Engine Owner s Manual Do not add oil to gasoline Do not overfill fuel tank Leave room for fuel to expand 4 2 2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps 4 2 3 Familiarize yourself with the controls and operation of unit See Controls section 4 1 and Operating Instructions section 4 3 4 3 OPERATING INSTRUCTIONS 4 3 1 Refer to Engine Owner s Manual for detailed operating instructions regarding the engine 4 3 2 Starting Engine Operator must have blade drive disengaged and transmission in neutral Open fuel shut off v
51. the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles 1 7 6 Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower Part No 513746 A CAUTION MUFFLER AND SHIELDS MAY EXCEED 150 F 313746 LOCATION On Engine Blower Housing Next to Muffler Part No DRIVE WHEEL RELEASE 603845 DO NOT OVER TIGHTEN LEDO ACAUTION ALLOW ENGINE TO COOL FOR 2 MINUTES BEFORE REFUELING Part No 303293 LOCATION On Top Right Side of Fuel Tank Part No NEUTRAL 303102 LOCK 4 LOCATION Upper Handle Part No 403120 Part No 323141 LOCATION Upper Handle Console Part No 403143 HYDRAULIC OL RESERVOR USE ONLY MOBIL 1 SAE 1SW 50 SYNTHETIC ENGINE OL Part No 513890 FEL TO TOP OF BAFFLE LOCATION On Top of Hydraulic Tank Part No 403005 LOCATION Front Corner s of Mower Deck Kawasaki and Kohler LOCATION On Switch Bracket at Front Left of Fuel Tank Support 16 hp B amp S only m CN O LOCATION Upper Handle Part No 613169 tx AWARNING Use Only Exmark Riding Attachments Use of Other Riding Attachments May Create a Hazardous Condition Resulting in Injury one LOCATION Rear Surface on Engine Deck 322151 O MI AAODI THROTTLE Briggs Straton Part
52. tle ahead to the full throttle position Place the neutral lock levers in the drive position as shown in Figure 6 and move the speed control lever to the mid speed position Note The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill Squeeze the respective drive lever until an increased resistance is felt this is where neutral should be Make sure you have not reached the end of the thumb latch slot If you have shorten the drive lever linkage If the wheel turns while holding the drive lever in neutral the neutral control linkages need to be adjusted If wheel stop then go to step 7 SPEED CONTROL DRIVE LEVER CRANK LINKAGE FG SPEED HYDRO CONTROL CONTROL LINKAGE LINKAGE FIG 16 HYDRO DRIVE LINKAGE ADJUSTMENT Loosen the nut against the neutral control linkage yoke as shown in Figure 16 Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring neutral position Turn the adjusting bolt clockwise if the wheel is turning in reverse or turn the bolt counter clockwise if the wheel is turning forward Release the drive lever to the forward drive position and squeeze back into the neutral position Check to see if the wheel stops If not repeat the above adjustment procedure Make this adjustment on both sides 7 After adjustments are made and the wheel stops when the d
53. top engine and remove spark plug wire s Drain oil while engine is warm from operation Remove the oil drain plug from the right hand side of the engine Allow oil to drain then replace drain plug Replace the oil filter as per Engine Owner s Manual Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn Clean around oil fill cap and remove cap Fill to the specified capacity and replace cap Use oil as specified in Engine Owners Manual Do not overfill Start the engine and check for leaks Stop engine and recheck oil levels 5 1 8 Check hydraulic oil level Service Interval 25 hr a b Stop engine Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use Mobil 1 15W 50 synthetic motor oil Ad caution e Safely relieve all pressure in the hydraulic system before disconnecting lines or before performing any work on the hydraulic system 22 A CAUTION e Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system A CAUTION Keep body and hands away from pin holes or nozzles that eject hydraulic fluid under high pressure Use paper
54. using Retighten capscrews Do this for both pumps Note Hydraulic reservoir can be pressurized to up to 5 psi to speed this process e Start engine and move throttle control ahead to full throttle position Move the speed control lever to the full speed position and place the drive levers in the drive position If either drive wheel still does not rotate stop and repeat steps d through e above for the respective pump If wheels rotate slowly the system may prime after additional running f Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position Check oil level as stated in Section 5 1 8 24 Caster Pivots 5 Idler Pivot Pump Drive Cutter Deck Idler Pivots g Check hydro drive linkage adjustment as stated in Section 5 2 10 5 1 11 Check tire pressures Service Interval 25 hrs a Stop engine and remove spark plug wire s Check air pressure in tires recommended tire pressure is rear 12 to 16 psi pneumatic casters 22 psi b Inflate tires to pressures stated above Measure circumference of each drive tire Adjust tire pressures within above range to try to make the circumferences match as closely as possible NOTE Front caster tires have permanent tire sealant installed 5 1 12 Inspect Belt wear Service Interval 25 hrs a Stop engine and remove spark plug wire s b Remove cutter deck belt shield to check mower primary and seco
55. ve in accordance to the program 6 Who pays for the part and freight if it fails to arrive overnight in accordance to the program A Under any circumstance the customer does not pay B If the part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following restrictions apply The Exmark Parts Plus Program is available only through participating Exmark I Dealers and applies only to orders submitted on this program Monday through Thursday UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exma
56. y between the Slow and Fast positions DO NOT choke B amp S when warm NOTE It is helpful to have the left and right neutral lock latches applied when starting the engine See Controls Section 4 1 Stopping Engine Disengage blade drive shift transmission to neutral and lock the drive levers in neutral Move throttle to the Slow position Allow engine to idle for 30 seconds to allow cool down For Kawasaki and Kohler engines after cool down time move throttle lever to the full rear Stop position For B amp S engines After cool down time turn key to the Off position Drive Lever Neutral Lock Latch Operation To lock the drive levers in neutral squeeze the drive levers back to the neutral position Do Not squeeze the drive levers all the way back as this will cause the drive wheels to go into full reverse direction Place thumbs on the upper portion of the neutral lock latches and move them to the rear Release drive levers See Figure 6 A CAUTION e Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of each latch if not the drive levers could unexpectedly slip into the forward drive position To place the drive levers in the drive position firmly hold the drive levers place thumbs on the upper portion of the neutral lock latches and move them forward to release drive levers Slowly and smoothly release the drive levers Drive Wheel Engagement Turn
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