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Exmark TT5217KA User's Manual

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1. 47 25 120 0 Model 52 II 52 00 in 132 1 cm 2 10 2 Discharge Right Side 2 10 3 Blade Size Model 36 in 18 00 in 45 7 cm Qty 2 Model 48 in 16 25 in 41 3 cm Qty 3 Model 52 in 18 00 in 45 7 cm Qty 3 2 10 4 of Drive Manual engagement of belt with over center lock Belt tension is adjustable via turnbuckle 2 10 5 Deck Mounting Full floating deck is attached to out front support frame removable for service 2 10 6 Cutting Height Adjusts in 1 2 63 cm increments from 1 5 3 8 cm to 4 1 2 11 4 cm 2 11 DIMENSIONS 2 11 1 Overall Width 36 48 52 46 25 58 25 62 6 Disenarge chute doWI 1475 cm 148 0 cm 159 0 cm Discharge chute up 36 1 48 1 53 0 Transport only 91 7 cm 122 2 cm 134 62 cm 2 11 2 Overall Length 36 48 52 Standard Pistol Grip 77 7 73 7 75 9 Handles 197 cm 187 cm 193 cm ECS Handles 77 0 196 2 11 3 Curb Weight 36 48 Standard Pistol Grip 537 lbs 589 lbs 617 lbs Handles 244 kg 267 kg 280 kg 547 Ibs 599 Ibs 627 lbs Bue Handles 248 kg 272 kg 284 kg Weights will vary slightly depending on engine and electric start options 2 11 4 Height Standard Pistol Grip Handles 42 107 cm all models ECS Handles
2. NOTE After starting the engine and engaging the hydro drive if 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 Adjustment Section 17 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 4 1 2 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 4 1 3 Drive Levers Located on each side of the upper handle assembly directly below the handle grips See Figure 7 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 neutral lock latches are moved into the drive position as shown in Figure 7 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 le
3. 1 4 17 aware of the mower discharge direction and do not point it at anyone 1 4 18 Do NOT operate the mower under the influence of alcohol or drugs 1 4 49 Use care when approaching blind corners shrubs trees or other objects that may obscure vision 1 4 20 If jump starting is required Electric start units only a connect the positive power cable from the positive post on the booster battery to the positive terminal post on the starter solenoid switch this post has the positive battery cable attached to it b connect the negative or ground cable from the negative post on the booster battery to the engine block as far away from the battery as possible C disconnect battery cables in the reverse order after starting MAINTENANCE AND STORAGE 1 5 1 For engine maintenance follow the engine manufacture s recommendations precisely as stated in the engine manual 1 5 2 Disconnect the battery from the negative battery post when the unit will be allowed to sit for more than 30 days without use 1 5 3 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 1 5 4 Keep engine and engine area free from accu
4. This warranty extends only to turf equipment operated under normal conditions and properly serviced and maintained The warranty expressly does not cover i any damage or deterioration due to normal use wear and tear or exposure 1 normal maintenance services such as oil change cleaning lubrication adjustment 1 replacement of service items such as oil lubricants spark plugs or other items subject to normal service replacement 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 specified 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 or Exmark Warranty Company 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 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 acce
5. Voltage Percent Maximum Gharainaintenal Reading Charge Charger Settings ging 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps 1 Hour 12 0 12 2 25 5096 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 096 14 4 volts 2 amps 6 Hours or More 5 2 ADJUSTMENTS 5 2 1 Cutting height and anti scalp roller adjustment A WARNING POTENTIAL HAZARD When the two front support rod hairpins are removed from the mower deck the weight of the tractor section may cause the front frame to rise suddenly WHAT CAN HAPPEN If the unit rises suddenly injury may occur HOW TO AVOID THE HAZARD Securely hold down the front of the unit when the front support rod hairpins are removed a Stop engine and wait for all moving parts to stop b Install hairpin clips in the holes for the desired cutting height See Figure 11 IMPORTANT To maintain correct cutting height and rake check the following for proper adjustment 1 The front and rear hairpins are in the same holes with the proper spacers under the hair pins See Figure 10 2 The tire pressures are set as directed in Section 5 1 11 3 The length of the rear deck support link assemblies are set to 6 89 approximately 6 7 8 from the center of the balljoint to the center of the furthest hole S
6. For Serial Nos 320 000 amp Higher MFG INC Turf Tracer HP with Pistol Grip Handles Turf Tracer HP with ECS Handles TURF TRACER OPERATOR S MANUAL CONGRATULATIONS the purchase of your new Exmark mower Model No This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free Serial No operation Engine Model No If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment Engine Serial No dealer or distributor If you need to order replacement parts from your dealer always Date Purchased give the model number and serial number of your mower as well as the part number description and quantity of the part needed The Serial No plate is located next to the fuel tank on the top left hand side of the fuel tank support For ease of ordering and reference we suggest that you record the information requested in the following identification table Paste Label From Literature Packet Here A WARNING POTENTIAL HAZARD This product is a piece of power equipment WHAT CAN HAPPEN Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD Keep all shields guards and safety devices especially the grass discharge system in place and in proper working c
7. 44 1 112 cm all models 2 11 5 Tread Width to outside of tires 36 35 0 88 9 48 Model 39 4 100 1 cm 100 1 cm C1 m lt o RC 2 12 TORQUE REQUIREMENTS BOLT LOCATION TORQUE Blade Mounting 115 120 ft Ibs Cutter Housing Spindle 75 80 ft Ibs Anti Sealp Roller Bolts reri en saepe pa 40 45 ft Ibs Mower Deck Support Engine Deck Mount 30 35 ft Ibs Engine Mounting Bolts 15 amp 17 HP Kawasaki 15 20 ft lbs 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE UNIT Remove upper handle assembly fuel tank and linkages from the top of the crate 3 2 SERVICE BATTERY Electric start units only WARNING Battery posts terminals and related accessories contain lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling The machine is shipped with a filled lead acid battery 3 2 1 Remove battery cover from the machine DANGER POTENTIAL HAZARD Charging the battery may produce explosive gasses WHAT CAN HAPPEN Battery gasses can explode causing serious injury HOW TO AVOID THE HAZARD Keep sparks flames or cigarettes away from battery Ventilate when charging or using battery an enclosed space Make sure
8. A WARNING Read operator s manual before operating Do operate unless trained to safely operate this machine NOT operate without shields guards and safety devices in place and working Do NOT carry passengers Clear area of debris before mowing KO FRONT OF MOWER STATIONARY ES IDLERS 413093 48 ees Noo We 413327 48 amp 52 Decks PART NO 1 413327 LOCATION Top Center of Cutter Deck Under Center Belt Shield DANGER Before leaving operator s position Lock drive levers in neutral lock position Disengage PTO Shift speed control lever to neutral Engage park brake Shut off engine and remove key before adjusting servicing or cleaning Use extreme caution when operating on slopes Do NOTaperate en slopes greater than 20 Mow across slope NOT up and down Do mow wet slopes area when mowing engine are stopped Thrown objects or blade contact can cause serious injury or death Keep all people and pets out of Avoid alades unless blades and NCAUTION y brake is engaged Hearing protection recommended Do NOT park on slope unless park ECS Handles 15 amp 17 HP Kawasaki Manual Start PART NO 103 1977 LOCATION Co
9. Disengage blade clutch Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s Drain oil while engine is warm from operation Oil drain valve is located on left hand side of engine Place pan under machine to catch oil and open valve with 10mm wrench Allow oil to drain then close valve 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 Check hydraulic oil level Service Interval 40 hr b Stop engine and wait for all moving parts to stop 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 A WARNING POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrate skin and cause injury WHAT CAN HAPPEN Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result HOW TO A
10. 2 5 Pump Drive Belt Tension Adjustment No adjustment necessary 5 2 6 Hydro Drive Linkage Adjustment a Adjust Speed Control Linkage and Neutral Safety Switch 1 Stop engine and wait for all moving parts to stop 2 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 Figure 14 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 linkage Figure 14 until the tabs are positioned correctly 3 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 Figure 13 If necessary move the switch fore and aft 5 16 AS VIEWED FROM THE LEFT SIDE OF UNIT NEUTRAL SAFETY ACTUATING TAB SWITCH IN NEUTRAL POSITION FIGURE 13 NEUTRAL SAFETY SWITCH ADJUSTMENT b Adjust Neutral Control Linkages 34 1 Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground Start the engine and move the throttle ahead to the full throttle position Place the neutral lock latches in the drive position as shown in Figure 7 and move the speed control lever to the mid speed position Note The OPC levers must be held down whenever the
11. 5 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 1 4 15 1 4 16 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 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 Progressively greater care is needed as the slope increases 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 See inside back cover to determine the approximate slope angle of the area to be mowed Stop the blades when crossing surfaces other than grass if mower must be tilted for transportation 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 o
12. 5 16 x 3 4 screws with a 5 16 SAE flat washer and 5 16 lock washer into the threaded holes in the right side of the fuel tank Do not over tighten Place a 5 16 SAE flat washer then a spring over each of the studs and fasten with a 5 16 nyloc nut Tighten 5 16 nyloc nut fully then back off a 1 2 turn This is to allow for normal fuel tank expansion and contraction with changes in temperature and fuel levels Do not over tighten Attach the fuel tank hose to the tank fitting and secure with the clamp provided 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 FUEL TANK SUPPORT FIGURE 1 UPPER HANDLE MOUNTING 14 3 9 Route the throttle cable along the right side of the upper handle under the fuel tank support and position the cable on the left side of the engine Attach throttle cable to engine a Position the throttle control lever located on console 14 6mm from the upper end of the slot b Attach inner wire of the throttle cable to the top hole in the throttle control lever as shown in Figure 2 C Loosen the clamp place the cable behind it and pull on
13. HP Kawasaki Manual start d Make sure the speed control lever is in the true neutral position See section 5 2 6 e Check that the PTO is disengaged and the PTO switch is depressed f Make sure the OPC levers are depressed Electric start only g Check that there is fuel in the tank and that the fuel valve is open 38 h Check that the spark plug wire s are properly connected i Check for loose or faulty wiring connections If it is necessary to disconnect wire connectors Do Not pull on the wires while disconnecting j 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 IMPORTANT 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 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 Engine Service Dealer EN
14. 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 Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 19 DANGER POTENTIAL HAZARD Incertain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN Afire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only in a well ventilated area or refuel outdoors Store gasoline an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoli
15. REGULATOR BATTERY BATTERY Start REGULATOR 9 HYDRAULIC DIAGRAM QqdvA dod 5 Ol In VHGAH HIGH PRESSURE REVERSE 41 3urissatid HOH LIINI dA d HHISSTHIHDIH NIVITHSVO 55 10 WARRANTY Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part manufactured by Exmark and found by us in the exercise of our 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 blade spindle assemblies will be warranted for three years one year parts and labor with an additional two years parts only from date of original retail purchase against defects in materials or workmanship The frame and hydrostatic traction drive system excluding hoses will be warranted for two full years from date of original retail purchase against defects in materials or workmanship We 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 o
16. ROTATE STOP w STATIONARY FRONT OF e IDLER MOWER 413094 e START 413206 36 Decks N WARNING Read operator s manual before operating operate unless trained to safely operate this machine Do NOT operate without shields guards and safety devices in place and working NOT carry passengers Clear area of debris before mowing Before leaving operator s position Lock drive levers in neutral lock position Disengage Shift speed control lever to neutral Engage park brake Shut aff engine and remove key before adjusting servicing or cleaning Use extreme caution when operating on slopes Do NOT operate on slopes greater than 20 Mow across slope NOT up and down mow wet slopes ECS Handles 17 HP Kawasaki Electric Start PART NO 103 1976 LOCATION Console Mw Ro oD PART NO 1 413206 LOCATION Top of Cutter Deck Under Center Belt Shield A DANGER Thrown ch jects or blade contact cause serious injury ar death Keep all people and pets outof area when moving Avoid alades unless blades and engine are stopped y N A CAUTION Hearing protection recommended Do NOT park on slope unless park brake is engaged m RELEASE CN PART NO 103 2103 LOCATION Park Brake Lever 103 1
17. WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the ignition switch and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s WARNING POTENTIAL HAZARD The engine can become very hot WHAT CAN HAPPEN Touching a hot engine can cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before service or making repairs around the engine area Check engine oil level Service Interval See Engine Owner s Manual a Make sure mower is on a level surface Stop engine and wait for all moving parts to stop b Check with engine cool Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick DO NOT screw into place Remove dipstick and check oil level d Ifthe oil level is low add oil as specified in the Engine Owner s Manual to bring the oil level up to the FULL mark on the dipstick DO NOT OVERFILL IMPORTANT DO NOT operate the engine with oil level below the LOW or ADD mark or over the FULL mark Clean engine air cooling system Service Interval See Engine Owner s Manual a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Clean all debris from engine air intake screen and from around engine shrou
18. full throttle position IMPORTANT For electric start models do not crank the engine continuously for more than ten 10 seconds at a time If the engine does not start allow a 60 second starter cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor On a warm engine place the throttle control midway between the Slow and Fast positions NOTE Kawasaki engines generally need to be choked even when warm Stopping Engine Disengage blade drive position speed control lever in neutral lock the drive levers in neutral and engage the park brake Move throttle to the Slow position Allow engine to idle for one minute to allow cool down Turn the key to the Off position Drive Lever Neutral Lock Latch Operation For Standard Pistol Grip Handles 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 7 21 4 3 5 CAUTION POTENTIAL HAZARD Ifthe neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position WHAT CAN HAPPEN drive levers slip into the drive position the unit could lurch forward and cause injury or p
19. in Section 5 1 8 g 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 h Check hydro drive linkage adjustment as stated in Section 5 2 6 5 1 11 Check tire pressures Service Interval Pneumatic air filled Drive Tires 40 hrs Semi pneumatic Caster Tires No maintenance a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s Check air pressure in drive tires recommended tire pressure is 12 16 psi b Inflate tires to pressures stated above Measure circumference of each drive tire Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible 5 1 12 Inspect Belt wear Service Interval 40 hrs a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Remove deck support belt shield to check mower deck drive belt condition C Look under engine deck to check the pump drive and clutching belt condition d Check all idler arms to be sure they pivot freely Disassemble clean and grease pivot bushings if necessary 5 1 13 Inspect PTO Clutching Belt Tension Service Interval Check every 2 hrs for first 8 hrs operation then check every 40 hrs thereafter a Stop engine and wait for all moving parts to stop 29 b Engage PTO lever Look through the round hole in the
20. needed to properly and safely perform the job Only use accessories and attachments approved by Exmark 1 3 2 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended CAUTION POTENTIAL HAZARD This machine produces sound levels in excess of 85 at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine 1 3 8 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals 1 1 3 4 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 A WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide can kill you HOW TO AVOID THE HAZARD Do not engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect DANGER POTENTIAL HAZARD Incertain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN Afire or explosion from gasoline can burn you othe
21. 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 b Fora heavier drive setting relocate the spring anchor link to either the medium or heavy duty positions as shown in Figure 17 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 Medium FIGURE 17 HYDRO PUMP SPRING TENSION SETTING 6 WASTE DISPOSAL 6 1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 37 6 2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is
22. put hands or feet under the mower or mower deck when the PTO is engaged Be sure that all persons are clear of mower deck and discharge area before engaging the PTO Set throttle to midway position Push the PTO engagement arm forward and down to engage blades Accelerate to full throttle to begin mowing See Section 4 1 5 4 3 8 PTO Disengagement Pull upward and back completely on the PTO engagement arm to disengage the blades See Section 4 1 5 4 4 TRANSPORTING WARNING POTENTIAL HAZARD Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous WHAT CAN HAPPEN Theramps could collapse causing the unit to fall which could cause injury HOW TO AVOID THE HAZARD Use proper ramps that are secured to the truck or trailer Keep feet and legs out from under the unit when loading and unloading df necessary use assistance when loading Use a heavy duty trailer to transport the machine Engage neutral lock latches and park brake then 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 23 5 MAINTENANCE amp ADJUSTMENTS 5 1 PERIODIC MAINTENANCE WARNING 5 1 1 5 1 2 POTENTIAL HAZARD If you leave the key in the ignition switch someone could start the engine
23. received by Exmark 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 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 equipment de
24. 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 For Standard Pistol Grip Models Make sure you have not reached the end of the neutral lock 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 wheels stop then go to step 7 SPEED CONTROL CRANK DRIVE LEVER LINKAGE J 7 SPEED HYDRO CONTROL 2 CONTROL LINKAGE LINKAGE NEUTRAL CONTROL LINKAGE ADJUST HERE ROTATE AT APPROX 1 4 TURN INCREMENTS AND RECHECK AS VIEWED FROM THE LEFT LOOSEN SIDE OF UNIT 9 NUT 4 5 6 rA o YOKE FIGURE 14 HYDRO DRIVE LINKAGE ADJUSTMENT Loosen the nut against the neutral control linkage yoke as shown in Figure 14 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 approximately 1 4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1 4 turn 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 After adjust
25. the cable to move the throttle linkage to the full throttle position Tighten the cable clamp screw CHOKE CABLE x CLAMP THROTTLE CABLE THROTTLE CONTROL LEVER FIGURE 2 SPEED CONTROL THROTTLE CABLE HOOK UP 3 10 Connect the blade engagement linkages See Fig 3 Loosen jam nut and remove turnbuckle from lower linkage Screw turnbuckle onto both upper and lower linkages simultaneously Note that threads on upper linkage are left hand See 5 2 2 for linkage adjustment Note The standard pistol grip handles have the drive lever linkage on the outside of the blade engagement lever tab and the hairpin on the inside ECS handles have the drive lever linkage on the inside of the blade engagement lever tab and the hairpin on the outside UPPER BLADE ENGAGEMENT 7 LINKAGE TURNBUCKLE JAMNUT LOWER BLADE ENGAGEMENT LINKAGE FIGURE 3 BLADE ENGAGEMENT LINKAGE 3 11 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 speed control lever from the right hand side and fasten with a hairpin from the bolt bag 15 3 12 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 hairpin from th
26. the park brake switch Fasten the harness to the left hand side of the handle using two large ties from the bolt bag Fasten the harness to the right hand side of the handle using two small ties from the bolt bag On ECS models fasten the harness to the two small holes in the channel under the console using two small ties from the bolt bag For electric start models Route the long unattached portion of the wiring harness up the left handle and under the console Connect the two flag terminals to the OPC switch in any order Connect the connector to the keyswitch Fasten the harness to the left hand side of the handle using two large ties from the bolt bag On ECS models fasten the leads connecting to the OPC switch to the small hole in the channel under the console using a small tie from the bolt bag If machine is shipped without muffler installed install muffler with hardware provided SERVICE ENGINE Refer to Engine Owner s Manual SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil filled to the top of the baffle in the reservoir Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil See Section 5 1 8 GREASE UNIT NOTE UNIT IS NOT GREASED AT THE FACTORY Refer to 5 1 14 for locations and grease amounts Follow pre start instructions as outlined in 4 2
27. tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper and not hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by locking drive levers in neutral and shutting off engine before performing any work on the hydraulic system 1 6 RIDING ATTACHMENTS 1 6 1 1 7 SAFETY 1 7 1 1 7 2 1 7 3 1 7 4 1 7 5 1 7 6 Use only Exmark riding attachments The use of other than Exmark riding attachments may create a hazardous condition resulting in injury SIGNS Keep all safety signs legible Remove all grease dirt and debris from safety signs Safety signs must be replaced if they are missing or illegible When new components are installed be sure that current safety signs are affixed to the replaced components New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower A WARN N G ANTI SCALP ROLLER 3 2 ADJUSTMENT e WARNING ENGINE AND REM
28. transport maintenance and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing WARNING POTENTIAL HAZARD Operating engine parts especially the muffler become extremely hot WHAT CAN HAPPEN Severe burns can occur on contact Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working Keep hands feet hair jewelry or clothing away from rotating parts 1 4 1 1 4 2 1 4 3 Give complete undivided attention to the job at hand Mow only in daylight or good artificial light keeping away from holes and hidden hazards Do Not operate the mower when children or others are in the area When feasible avoid operating the equipment in wet grass 1 4 4 1 4
29. 1 2 12 240 o c A 12 IU 12 2 12 Torque Hequitelmellls o ei cete en on EL oen Le UR OR USC 13 ASSEMBLY INSTRUCTIONS 3 110 3 21 Assembly ree ene p erbe pg te pa dee 13 17 OPERATION INSTRUCTIONS a T E011 1KO Since te d rt itd E 17 19 uino qM P 19 21 4 3 Operation Instructions coca e 21 23 2 4 Transporting 23 MAINTENANCE amp ADJUSTMENTS 5 1 Periodic usce te a tn HEU pt e Pe Ebr Fue beue d xe 24 32 5 2 GUSTING IMG 32 37 WASTE DISPOSAL 6 1 Motor Oil Disposal pee beet tr eq na ced pad etes t 37 TROUBLE SHOOTING 7 1 Mower Tacks Left or Fight e trop oe epe e e E 38 7 2 Mower Cuts Dnevenly sui oed i Pete io te 38 7 3 Engine Will Not enr be e eus 38 39 WIBING BIAGRAM oder de teda ar decidi ons 40 HYDRAULIC 2 2 2 41 LMARBBANDY tab see tins eS aia oben rat 42 43 1 SAFETY 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents Th
30. 2 5 SAFETY INTERLOCK SYSTEM Operator must have speed control lever in neutral PTO disengaged and OPC levers depressed for electric start to start engine Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged 2 6 STEERING 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 7 TRANSMISSION Twin Hydrostatic Drive 2 7 1 Two Hydro Gear BDP 10L series variable displacement high efficiency pumps independently coupled to two high efficiency Parker Ross wheel drive motors 2 7 2 Hydraulic Filter is replaceable cartridge type P N 513211 10 microns 18 psi bypass Summer use above 32 F P N 523541 40 microns 18 psi bypass Winter use below 32 F 2 7 3 Speed Range Forward 0 6 2 mph 10 0 km h Reverse 0 2 2 mph 3 5 km h 2 8 WHEEL DRIVE SYSTEM Drive wheels are direct coupled to Parker Ross wheel drive motors with 1 0 25 4 mm tapered shaft 11 2 9 TIRES 36 Drive 48 amp 52 Drive Front Caster Pneumatic Air Filled Pneumatic Air Filled Semi Pneumatic Size 16 x 6 50 8 16 x 7 50 8 9 x 3 50 4 Quantity 2 2 2 Tread Turf Master Turf Master Smooth Ply Rating 4 4 Pressure 14 psi 97 kPa 14 psi 97 kPa 2 10 DECK 2 10 1 Cutting Width Model 35 25 in 89 5 cm Model 48
31. GINE TROUBLESHOOTING TABLE uA em PLUG FILTER LEVEL SCREEN Dues X X X x x x X X X X _ Seem X x x x x x x eem x X x x x X X x X X X x X x x X _ x x wem X X X x x eem 7 x x x x wm mmm X 39 8 WIRING DIAGRAMS PARK BRAKE SWITCH BLADE SWITCH 0 50 TRANSMISSION SWITCH 0 Tk we 15 amp 17 HP KAWASAKI wo SAFETY INTERLOCK MODULE BLUE ORANGE 4h YELLOW GREEN an RED RED du NT BLACK BLACK s BROWN d CONNECTORS ARE VEWED FROM WIRE END N SWTCH 0 KEY SWITCH N C NORMALLY CLOSED 9 N O NORMALLY OPEN GROUND B ENGINE KILL ENGINE SAFETY INTERLOCK MODULE PLADE SWITCH NEUTRAL SWTCH PARK BRAKE SWITCH OPC SWITCH NO GREEN BLACKMHITE STRIPE GREEN ENGINE BEAK EP BLACK X E ORANGE ORANGE ENGINE SOLENOID VIOLET ow GROUND C LTBLUE WHITE SOLENOID RED RED E ENGINE I SOLENOD Se wor OW REGULATOR ENGINE KILL KEY CIRCUIT START POSITION MAKE CONNECTORS ARE VIEWED FROM WIRE END NORMALLY CLOSED NORMALLY OPEN 40 ENGINE KILL BATTERY
32. LECTION SYSTEM IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED PART NO 1 303508 LOCATION Right Front of Mower Deck Top Surface 303508 T3 Rotate N s ep WARNING V Fe stop Read operator s manual before operating Do NOT cperate unless trained to safely operate DANGER gt tismactin cperate without shields guards and Thrown objects or blade contact 6 safety devices in place and working can cause Serious injury or oe Do NOT carry passengers Keep all people and pete out Clear area of debris before mowing eas ier maii Before leaving operator s position Avoid blades unless blades Lock drive levers in neutral lock position ji Disengage PTO Bil 3 speed conto lever la neutral 28 Engage park brake 2 Shut off engine and remove key before adjusting servicing cr cleaning AN C AU TI ON 1 Use extreme caution when operating on slopes o Mow across slope up and dawn R Hearing protection recommended E N DaNOT iuis slopes o Do NOT park on slope unless park greater fan T brake is engaged DoNOTmow L a wet slopes E NV 20 Ne 03 194 Standard Pistol Grip Handles 15 amp 17 HP Kawasaki Manual Start uc PART NO 103 1974 PART NO 103 1798 LOCATION Console LOCATION RH Side Console Il 103 1 978
33. NG Li Rie PART NO 1 413214 Standard Pistol LOCATION Right Side of Hydro Grip Handles Control Crank Arm CAUTION LOOSE OR DAMAGED BLADE BOLT MAY ALLOW BLADE TO COME OUT FROM UNDER DECK AT HIGH SPEED BLADE BOLT AFTER STRIKING AFOREIGN OBJECT TORQUE BLADE BOLT TO 115 120 FT LBS 156 163N m SEE OPERATOR S MANUAL PART NO 103 1077 LOCATION On Top LH Side of Mower Deck 103 1077 HYDRAULIC OIL USE ONLY MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILL TO TOP OF BAFFLE CAUTION DANGER KEEP HANDS and FEET AWAY HOT ERES V PART NO 1 523522 LOCATION On Top of PART NO 1 403005 Hydraulic Tank LOCATION RH amp LH Corners of Mower Deck PART NO 1 303102 LOCATION Upper Handle PART NO 1 413421 LOCATION Left Rear on Top of Engine Deck DRIVE WHEEL RELEASE o n LAU 7 DO NOT OVER TIGHTEN 603845 PART NO 1 603845 LOCATION Rear Center of Top Surface of Engine Deck CAUTION ALLOW ENGINE TO COOL FOR 2 MINUTES BEFORE REFUELING E303293 PART NO 1 303293 LOCATION On Top RH Side of Fuel Tank A CAUTION MUFFLER AND SHIELDS MAY EXCEED 150 F 746 PART NO 1 513746 LOCATION On Engine Blower Housing Next to Muffler and On Center Belt Cover WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR OR ENTIRE GRASS COL
34. OVE KEY BEFORE MAKING GROUND CLEARANCE Use Only Exmark Riding ADJUSTMENTS SERVICING OR CLEANING DECK I CUTTING HEIGHT N INCHES mm Attachments Use of Other CUTTING HEIGHT ADJUSTMENT Riding Attachments May comp wmv VOS Create a Hazardous Condition 306 INCHES MM FOR MAXIMUM FLOTATION ROLLERS MAY BE Resulting Injury 403143 DECK o POSITIONED LOWER BUT MUST MAINTAIN MINIMUM NS SUPPORTPN 40 OF 1 4 GROUND CLEARANCE NEVER POSITION THE NN ROLLERS TO SUPPORT MOWER DECK eno J PART NO 1 553049 PART NO 1 403143 LOCATION Front of Mower LOCATION Right Side of Rear Deck Top Surface Surface of Engine Deck A WARNING OPEN BELT DRIVE STOP ENGINE BEFORE REACHING UNDERNEATH E303517 i 413421 TENSION INDICATOR CHECK HOURLY FOR THE FIRST 4 HRS CHECK DAILY THEREAFTER ALIGN BOLT WITH TENSION INDICATOR 1 16 PART NO 1 303517 LOCATION Left Side of Rear Surface of Engine Deck aee A WARNING Enn BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN 17 HP Kawasaki Electric Start Only PART NO 1 513747 LOCATION Battery Cover NEUTRAL TRACKI
35. VOID THE HAZARD 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 Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hydraulic system by locking drive levers in neutral and shutting off engine before performing any work on the hydraulic system 27 5 1 10 Change hydraulic system filter Service Interval After First 250 hrs then yearly thereafter Note Use only Exmark Part No 513211 for Summer use above 32 F 0 C or Part No 523541 for Winter use below 32 F 0 C Refer to 2 7 2 for filter specifications a Place unit on a level surface stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Carefully clean area around filter It is important that no dirt or contamination enters the hydraulic system c Unscrew filter to remove and allow oil to drain from reservoir IMPORTANT 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 d Fill reservoir as stated in Section 5 1 8 e Loosen filter 1 2 turn and allow a small amount of oil to leak from the oil filte
36. aler 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 TABLE OF CONTENTS m 1 1 Safety Al rt Symbol ce 1 RAINING eh oen 1 Veo RED ET RE 1 3 1 4 Operation ted ee ted ed expe led Gelder ede 4 6 1 5 Maintenance amp Storage ecrire mcm ete eti meet 6 7 P ding Io Dno et 7 Sale SIUS st cA 7 10 SPECIFICATIONS 2 1 Model 11 11 WU DV SIC Wick aie eunte ee n dut de Sun 11 2 4 Electrical System errem 11 2 5 Safety Interlock System ree eed estrellas c 11 2 6 Steering Brake 0 11 11 2 8 Wheel Drive System em e een e EL qp e p Rd 1
37. ative battery cables NOTE If the positive cable is also disconnected connect the positive red cable to the positive terminal on the battery first then connect the negative black cable to the negative terminal on the battery Reinstall battery cover NOTE If time does not permit charging the battery or if charging equipment is not available connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery Mae S WARNING BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN Remove and open the bolt bag Loosen the 5 16 hardware at the two 2 discharge chute 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 Apply retaining adhesive Fel Pro ProLock Retaining or Retaining or Loctite RC 609 or 680 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
38. being replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified battery reseller 7 TROUBLE SHOOTING 7 1 MOWER TRACKS TO LEFT OR RIGHT a Checkthe drive tire pressure and tire circumference 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 7 2 MOWER CUTS UNEVENLY a Check the drive tire pressure and tire circumference 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 deck support pins Hairpin clips must be in the same hole position on each support pin See Section 5 2 1 Check deck support alignment and check 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 7 3 ENGINE WILL NOT START a Make sure battery has a full charge Electric start only See section 5 1 23 b Check that 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 c Make sure the key switch is in the ON position 15 amp 17
39. conditions it may be necessary to position the anti scalp rollers one or two holes higher than described in c to prevent damage to the rollers and or bolt failure See Figure 11 NOTE When anti scalp rollers are placed in these positions reduced deck flotation will result 5 2 2 PTO Linkage Located between the PTO lever on the left handle and the left rear corner of the engine deck a Stop engine and wait for all moving parts to stop b With PTO engaged adjust the linkage length by loosening the locknut on the turnbuckle and adjusting the turnbuckle so that the bolt on the bellcrank and the indicator arm align with each other within 1 16 See Figure 12 Tighten locknut against turnbuckle 33 Indicator H V4 Align Bolt to BS Indicator within 1 16 Engine Deck FIGURE 12 BLADE ENGAGEMENT LINKAGE 5 2 3 PTO Safety Switch Mounted to a tab on the inside lefthand side of the fuel tank support a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b With PTO disengaged and the bellcrank touching the rear of the slot in the engine deck adjust the PTO safety switch if needed until the bellcrank arm is 5 16 from the switch body sure the bellcrank DOES NOT touch the switch body or damage to the switch could occur d Retighten PTO switch mounting hardware 5 2 4 Engine to Cutter Deck Belt No adjustment necessary 5
40. ding 24 5 1 3 Clean grass build up under deck and check mower blades Service Interval Daily CAUTION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may misfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support a Disengage PTO b Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s c Raise deck and block up using proper safety precautions d Clean out any grass build up from underside of deck and in deck discharge chute Inspect blades and sharpen or replace as required f If blade removal is necessary be careful for the sharp cutting edges of the blades g the blades if they were removed and torque blade bolts to 115 120 ft 16 Be sure the spring disc washer cone is installed toward the bolt head See Figure 8 CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN Aloose or weakened blade bolt could allow blade rotating at a high speed to come out from under the deck causing
41. e bolt bag 3 13 Install drive lever linkages For Standard Pistol Grip Handles Refer to figures 4 and 5 Position speed control lever in neutral Locate two long clevis pins and two hairpin cotters in bolt bag and temporarily install through drive levers and neutral lock latches but not through the drive lever linkages Position drive levers and neutral lock latches in neutral See Figure 16 Identify swivels installed on hydro control arm weldments Thread each drive lever linkage into swivel until hole in upper end of drive lever linkage aligns with clevis pin installed through drive lever and neutral lock latch Remove clevis pins and install first through the drive lever linkages then through the drive levers from the outside then through the neutral lock latches Install hairpin This will give an approximate setting for drive lever linkages you will need to refer to Section 5 2 6 step d to complete the drive lever linkage adjustment NOTE There should NOT be a washer between the neutral lock latch and the hairpin cotter THREADED SWIVEL DRIVE LEVER 9 LINKAGE AS VIEWED FROM THE RIGHT SIDE OF UNIT HYDRO CONTROL ARM WELDMENT FIGURE 4 STANDARD PISTOL GRIP HANDLES DRIVE LINKAGE SWIVEL RIGHT HAND SIDE SHOWN AW DRIVE LEVER LINKAGE DRIVE LEVER FIGURE 5 STANDARD PISTOL GRIP HANDLES DRIVE LEVER LINKAGE TO DRIVE LEVER For ECS handles Refer to figure 6 Position speed control lever in neutral P
42. ed 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 An anti seize compound is used on the following locations a Between engine crankshaft and pump and blade drive sheaves b On clutch arm assembly between bearings and shaft and between lower sheave and shaft Between pump shafts and sheaves Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Check battery charge Electric start units only Service Interval Monthly 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 31 Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage a Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are 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 below for recommended charger settings
43. ee Figure 10 32 LEFT HAND SIDE SHOWN 375 FIGURE 10 CUTTING HEIGHT ADJUSTMENT FOR CUTTING HEIGHTS ABOVE 3 5 SPRING DISC USE THE BOTTOM HOLE CUTTING HEIGHT WASHER THE ROLLERS WILL STILL BE INCHES mm CONE TOWARDS EFFECTIVE AGAINST SCALPING 1 5 38 FRONT LEFT CUTTING HEIGHT 9 20 51 ANTI SCALP BRACKET N INCHES mm O4 2 5 64 SHOWN 1 5 38 amp 2 0 51 O7 3 0 76 rad M 2 5 64 O4 3 5 90 HH 3 0 76 O4 40 102 3 5 90 amp HIGHER 45 114 ANTI SCALP ROLLER MOUNTING BRACKET ANTI SCALP ROLLER DECK BOLT INSTALLATION ANTI SCALP ROLLER SUPPORT CUTTER HEIGHT ADJUSTMENT PIN ADJUSTMENT FIGURE 11 ANTI SCALP ROLLER BOLT INSTALLATION ANTI SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT Adjust anti scalp rollers For Normal Operating Conditions Place rollers in one of the positions shown in Figure 11 Rollers will maintain 3 4 in 19 mm clearance to the ground to minimize gouging and roller wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm minimum clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts and nuts are installed with the spring disc washer between head of the bolt and mounting bracket Torque to 40 45 ft Ibs or loss of roller may result d When operating in extremely rough
44. for all moving parts to stop Remove ignition key or 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 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 Refer to Engine Operators Manual for detailed maintenance regarding the engine 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 16 b Further tighten the nut until the next set of slots line up with the cross hole in the shaft c Replace cotter pin Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners a Pump drive sheave setscrews b Square head setscrews on Hydro pump control arms c OPC lever setscrews d Sheave retaining bolt in end of engine crankshaft Lower Sheave retaining bolt on clutch arm f Shoulder bolts in ends of speed control crank Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining or Retaining Il are used on the following a OPC lever hubs and cross shaft NOTE Care must be us
45. ft 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 position of the neutral lock latches and the speed control lever 4 1 4 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 7 ROTATE BACK FOR NEUTRAL LOCK POSITION ROTATE DOWNWARD FOR NEUTRALLOCKPOSITION LATCH IS IN THE DRIVE POSITION DRIVE LEVER IN NEUTRAL POSITION FULL SPEED NEUTRAL HOLD IN THIS POSITION FORWARD NEUTRAL HOLD DRIVE LEVER IN THIS POSITION FORWARD RELEASE DRIVE LEVER FORWARD RELEASE DRIVE LEVER REVERSE SQUEEZE DRIVE LEVER REVERSE SQUEEZE DRIVE LEVER STANDARD PISTOL GRIP HANDLES ECS HANDLES FIGURE 7 DRIVE LEVER NEUTRAL LOCK LATCH OPERATION 4 1 5 PTO Engagement Located on the left side of the upper handle To engage the blades push the lever forward or away from the operator until the linkage locks over center To disengage the blades pull the lever to the rear or towards the operator 4 1 6 Choke Control Choke is used to aid in starting a cold engine The choke control is located on the front left corner of the fuel tank support and i
46. hen parking on a steep slope the wheels must be chocked or blocked in addition to the brake being engaged The unit must be tied down and brake engaged when transporting Park brake must be disengaged to move speed control out of neutral or engine will kill Fuel Shut Off Valve Installed in the fuel line midway between the tank and the engine 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 rear corner of the hydrostatic pumps Drive wheel release valves are use 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 Manual start units only Located on the right hand side of engine deck below 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 See Section 4 3 2 Tracking Adjustment
47. is symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 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 If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 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 property 1 3 PREPARATION 1 3 1 Evaluate the terrain to determine what accessories and attachments are
48. jack stands high enough to raise the drive wheels off the ground b Check oil level as stated in Section 5 1 8 C Start engine and move throttle control ahead to full throttle position Move the speed control lever to the middle speed position and place the drive levers in the drive position If either drive wheel does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward direction NOTE It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature If the cap is too hot to touch turn off engine The pumps may be damaged if the pump becomes too hot If either drive wheel still does not rotate continue with step d 28 d Thoroughly clean the area around each of the charge pump housings T a CHARGE PUMP CAP FIGURE 9 CHARGE PUMP LOCATION e To prime charge pump loosen two hex socket head capscrews shown in Figure 11 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 housing Retighten capscrews Do this for both pumps Note Hydraulic reservoir can be pressurized to up to 5 psi to speed this process f If either drive wheel still does not rotate stop and repeat Steps d through e above for the respective pump If tires rotate slowly the system may prime after additional running Check oil level as stated
49. left rear corner of the engine deck to inspect blade clutching belt tension Bolt on blade engagement linkage bellcrank and indicator arm should align within 1 16 See Figure 12 Refer to section 5 2 2 for adjustment 5 1 14 Lubrication Service Interval Refer to Chart a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule GREASE LUBRICATION CHART LOCATIONS PUMPS 36 48 52 INTERVAL 1 No 4 Idler Pivot Located Under Engine Deck No 5 Clutch Arm Pivot Located Under Engine Deck No 4 amp 6 Idler Arm Pivots Disassemble and grease once a month 5 lt under a No Load Condition rf C Lubricate pivot points with a spray penetrating lubricant as directed below SPRAY LUBRICANT CHART NO OF SERVICE PIVOT POINT PLACES INTERVAL 1 PTO Lever Weekly 5 1 15 Check spark plugs Service Interval 160 hrs a Stop engine and wait for all moving parts to stop b Remove spark plugs check condition and adjust plug gap or replace with new plugs See Engine Owner s Manual 5 1 16 Remove engine shrouds and clean cooling fins Service Interval See Engine Owner s Manual 30 5 1 17 5 1 18 5 1 19 5 1 20 5 1 21 5 1 22 5 1 23 a Stop engine and wait
50. liarize 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 4 3 2 4 3 3 4 3 4 Refer to Engine Owner s Manual for detailed operating instructions regarding the engine Starting Engine Operator must have PTO disengaged and speed control lever in neutral Lock drive levers in neutral and engage park brake Open fuel shut off valve NOTE Acold 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 Manual start units only a Pull split ring straight out the side of the unit and hook the ring over the lower rear hydro control shield bolt b Start engine Refer to the following guidelines for further starting suggestions To engage pump drive disengage 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 On a cold engine pull out the choke control For a 15 amp 17 HP Kawasaki manual start engine turn key to Run position Pull recoil rope to start engine For a 17HP Kawasaki Electric start engine OPC levers must be depressed turn ignition switch to the start position Release the switch when the engine starts After the engine starts and warms up gradually push down on the choke control and place the throttle control in the
51. ments are made and the wheels stop when the drive levers are in the neutral position tighten the nuts against the yokes c Adjust Hydro Control Linkages 1 Place the speed control lever in the neutral position Note Neutral lock latches should still be unlocked and in the drive position This adjustment is again made with rear of machine on jack stands and engine running at full throttle OPC levers will have to be held down whenever speed control lever is moved out of the neutral position Loosen the front nut on left hydro control linkage as shown in Figure 14 Turn the rear control linkage adjusting nut counter clockwise until wheel rotates forward Turn the rear nut of left control link clockwise 1 4 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 Figure 15 LEFT SIDE SHOWN END VIEW FIGURE 15 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
52. mmercial purposes 43 NOTES 44 SERVICE RECORD Service 45 FOLD ALONG APPROPRIATE LINE E COMPARE SLOPE WITH FOLDED ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC FU i 46 SEE EXMARK S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z HP LAZER Z XP TURF RANGER TURF TRACER TURF TRACER HP METRO METRO HP VIKING HYDRO ULTRA VAC GRASS CATCHER SELF STEERING SULKY MICRO MULCH ACCESSORY WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1997 1998 1999 2000 2001 PART NO 103 1773 EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED IN U S A MFG CO INC
53. mulation 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 1 5 5 Store fuel in a container specifically designed for this purpose in a cool dry place 1 5 6 Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them 1 5 7 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 1 5 8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly 1 5 9 Check all bolts frequently to maintain proper tightness 1 5 10 Keep all guards shields and all safety devices in place and in safe working condition 1 5 11 Frequently check for worn or deteriorating components that could create a hazard 1 5 12 All replacement parts must be the same as or equivalent to the parts supplied as original equipment A WARNING POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrate skin and cause injury WHAT CAN HAPPEN Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are
54. ne expansion and prevent fuel spillage 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 DANGER POTENTIAL HAZARD Incertain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN Astatic charge can ignite gasoline vapors A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container Always place gasoline containers on the ground away from your vehicle before filling Donotfill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete EU 4 2 2 4 2 3 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps Fami
55. neutral occurs check to be sure both springs are properly tightened on the speed control lever under the console especially the rear pivot spring Repeat above adjustments if necessary 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 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 d Drive Lever Linkage Adjustment 1 With rear of machine still on jack stands and engine running at full throttle move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches See Figure 16 If the tire rotates in either direction the length of the drive lever link will need to be adjusted For Standard Pistol Grip Handles 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
56. nsole NAME 1 ROLLER 2 BUSHING vq SPRING WASHER 4 3 8 16 X4 BOLT 5 MOUNT BRACKET 6 FLAT WASHER 7 WHIZLOCK NUT MUST BE GRADE 8 BOLT AND WASHERS MUST 4 BE INSTALLED AS SHOWN ___ IN DIAGRAM TORQUE NUT 1 35 45 FT LBS PART NO 1 323540 Top Surface ENHANCED CONTROL SYSTEM ECS Handles PART NO 103 2242 LOCATION LH Side of Console 10 LOCATION Front of Mower Deck COVER 1 MISSING DO NOT OPERATE THIS UNIT VIFEN NOTIN PLACE PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s ENHANCED CONTROL SYSTEM ECS Handles PART NO 103 2243 LOCATION RH Side of Console 2 SPECIFICATIONS 2 1 MODEL NUMBER Serial Nos 320 000 amp Higher TT3615KA TT4817KA TT5217KA TT3615KAC TT4817KAC TT5217KAC TT4817KAEC TT5217KAEC 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 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 ELECTRICAL SYSTEM Electric start units only 2 4 1 Charging System Flywheel Alternator 2 4 2 Charging Capacity 15 amps 2 4 3 Battery Type BCI Group U1 2 4 4 Battery Voltage 12 Volt Polarity negative ground 2 4 5 Fuses Two 20 amp blade type
57. 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 Exmark Warranty Company or any of their representatives to 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 co
58. ondition Stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop 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 platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer 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 or its distributors and dealers accept no resp
59. onsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 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 X M A R P A T S P L T S applicable 3 If distributor does not have the part s in stock to satisfy 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 arrives in accordance to the program 6 Who pays fo
60. osition drive levers in neutral and engage the neutral lock latches See Figure 16 Drive lever linkages are shipped with upper ball joints installed Thread a 3 8 24 LH jam nut from the bolt bag onto the lower end of each drive lever linkage Identify the lower ball joints installed on hydro control arm weldments Thread lower end of each drive lever linkage into the lower ball joint until hole in upper ball joint aligns with hole in drive lever Install 3 8 16 x 2 hex cap screws and 3 8 16 nyloc nuts from the bolt bag and tighten This will give an approximate setting for drive lever linkages you will need to refer to Section 5 2 6 step d to complete the drive lever linkage adjustment 16 3 14 3 15 3 16 3 17 3 18 3 19 3 20 SPEED CONTROL LEVERINNEUTRAL 2 DRIVE LEVERS 3 8 16 X2 HEX CAP SCREW RIGHT HAND x SIDE SHOWN 3 8 16 NYLOC NUT DRIVE LEVER eee N 241 JAM NUT HYDRO CONTROL ARM WELDMENT LOWER BALL JOINT FIGURE 6 ECS HANDLES DRIVE LEVER LINKAGE INSTALLATION Connect wiring harness For recoil start models Route the long unattached portion of the wiring harness up the left handle and under the console Connect the connector on the end of the shorter lead to the keyswitch Connect the two flag terminals that are in the longer lead to the OPC switch in any order Continue routing this lead down the right side of the handle and connect the connector on the end of it to
61. r 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 f Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground Run machine to allow any other air to be purged from the hydraulic system and recheck the oil level g If either drive wheel does not rotate or both of the charge pumps located on the top of the main pump as shown in Figure 9 may have lost their prime Refer to Section 5 1 10 h 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 Hydraulic system air purge procedure Air must be purged from the hydraulic system when any hydraulic components including the 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 9 Air in other parts of the hydraulic system will be purged through normal operation once the charge pumps are primed a Stop engine and wait for all moving parts to stop Raise the rear of the machine up onto
62. r in any speed but neutral and electric blade clutch disengaged starter MUST NOT crank Try to start with OPC levers depressed speed control lever in neutral and electric blade clutch engaged starter MUST NOT crank 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 IMPORTANT It is essential that all Operator Safety Mechanisms be in place and in proper operating condition prior to mowing Check for loose hardware Service Interval Daily b Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service pre cleaner element and air cleaner Service Interval See Engine Owner s Manual 26 5 1 7 5 1 8 Change engine oil Service Interval See Engine Owner s Manual NOTE Change oil after first five 5 hours of operation Follow engine manufacturer s recommendations for future oil changes b f 9
63. r over speed the engine Operating an engine at excessive speed may increase the hazard of personal injury Place speed control levers in neutral lock position disengage PTO and engage park brake before starting engine Start the engine carefully with feet well away from blades Keep hands feet and clothing away from rotating parts while the mower is being operated Stop the engine and wait for all moving parts to stop Remove plug wire s or remove ignition key e Before checking cleaning or working on the mower e After striking a foreign object inspect the mower for damage and make repairs before restarting and operating the mower Stop the engine and wait for all moving parts to stop e Before clearing blockages e Whenever you leave the mower e Before removing the grass catcher e Before refueling Before making height adjustments Before stopping the engine return the throttle control to the idle position for about One minute to allow the engine to cool down 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 This mower was designed for one operator only Keep all others away from mower during operation Do Not mow without the grass deflector or entire grass collection system in place and in proper working condition T 1 5
64. r 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 Dealers and applies only to orders submitted on this program Monday through Thursday Parts Plus service is available only in the 48 contiguous United States 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 quality all Exmark Parts Plus orders must be
65. r 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 We are 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 This warranty may not be assigned or transferred without the prior express written consent of Exmark and Exmark Warranty Company The warranty period commences upon the date of the original retail purchase The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period The warranty shall extend to the expense of repair or replacement as determined by us of the defective part including labor The warranty shall not extend to the expense of delivering the mower to the dealer for warranty work nor the expense of returning it back to the owner after repair or replacement Our 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
66. rive levers Slowly and carefully release the drive levers Drive Wheel Engagement Turning With drive levers locked 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 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 22 4 3 6 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 PTO Engagement DANGER POTENTIAL HAZARD Therotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT
67. roperty damage HOW TO AVOID THE HAZARD Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of each latch 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 carefully release the drive levers For ECS Handles 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 inner thumb lobe of the neutral lock latches and push downward moving them under the drive levers Release drive levers See Figure 7 CAUTION POTENTIAL HAZARD Ifthe neutral lock latches not completely engaged the drive levers could unexpectedly slip into the forward drive position WHAT CAN HAPPEN lf the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage HOW TO AVOID THE HAZARD sure the drive levers are past the roller and securely seated at the bottom of the neutral lock latches To place the drive levers in the drive position slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches and push forward moving them out from under the d
68. rs and cause property damage HOW TO AVOID THE HAZARD NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark e Refuel only in a well ventilated area or refuel outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage 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 DANGER POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN static charge can ignite gasoline vapors A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container Always place gasoline containers on the ground away from your vehicle before filling Do gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any sta
69. s activated by pulling the control outward Once the engine has started move the choke control to the off position and move the throttle to the medium or full throttle position 18 4 1 9 4 1 10 4 1 11 4 1 12 4 1 13 4 1 14 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 Off Run Switch 15 amp 17 HP Kawasaki Manual Start only Located on the console Turn key to the Run position to allow the engine to be started Turn key to the Off position to shut engine off Ignition Switch 17 HP Kawasaki Electric Start only Located on the control console The ignition switch starts and stops the engine The switch has three positions OFF 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 When engine starts release key Operator must have speed control lever in neutral and blade engagement lever fully disengaged to start engine Park Brake Lever Located on the right side of the unit above the hydraulic tank The brake lever engages the park brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake W
70. serious injury or property damage HOW TO AVOID THE HAZARD Replace the blade bolt after striking a foreign object Use only Exmark replacement parts PN 103 1026 blade bolt and PN 1 513208 spring disc washer DO lubricate the threads of the bolt or spindle before assembly Torque the blade bolt to 115 120 ft 16 g Remove jack stands or equivalent support and lower deck to ground 25 5 1 4 5 1 6 DO NOT USE WRENCH HERE FOR BLADE INSTALLATION MAINTAIN 75 85 ft Ibs ON THIS NUT p 2 CONE TOWARDS BOLT HEAD TORQUE 115 120 ft Ibs USE 1 WRENCH HERE TO HOLD SPINDLE FOR BLADE REPLACEMENT FIGURE 8 BLADE BOLT INSTALLATION Check safety interlock system Service Interval Daily a 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 hands are removed from the handles the mower engine MUST stop For Electric Start Units Only Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and electric blade clutch disengaged Try to start the engine with OPC levers disengaged speed control lever in neutral and electric blade clutch disengaged starter MUST NOT crank Try to start with OPC levers depressed speed control leve
71. ssories 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 42 As a condition to this warranty customer shall have read the operator s manual and shall have completed and returned to Exmark Warranty Company within the prescribed time the Exmark warranty registration The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we 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
72. the linkage several turns if the tire is rotating fairly fast But as the adjustment gets closer adjust the linkage in 1 2 turn increments Release and re engage neutral lock latch checking that the tire stops Continue this process until the tire is at a dead stop Replace the hairpin back into each clevis pin For ECS Handles Adjust the linkage length by loosening the jam nuts at both ends of the linkage and rotating the linkage in the ball joints Lengthen the linkage if the tire is turning in reverse and shorten the linkage if the tire is creeping forward Tighten the jam nuts at both ends Release and re engage the neutral lock latch checking that the tire stops Continue this process until the tire is at a dead stop 36 4 STANDARD PISTOL GRIP HANDLES FIGURE 16 DRIVE LEVER AND LATCH IN NEUTRAL POSITION 3 Make this adjustment for both sides e Tracking Adjustment 1 Stop engine and wait for all moving parts to stop Raise the rear of the machine remove jack stands and carefully lower the machine to the ground Check the drive tire pressure and tire circumference See 5 1 11 2 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 7 Hydro Pump Spring Tension Setting a For medium or heavy duty drive conditions such as
73. tic charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete A WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks or hot engine exhaust components WHAT CAN HAPPEN Explosion and fire may occur resulting in property damage personal injury and or death HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer to prevent build up of gasoline vapors especially at floor level Never refuel equipment inside an enclosed trailer Be sure all fuel tanks and gasoline storage containers have proper caps installed to prevent spillage and minimize vapor escaping into the trailer Do not place any equipment that is leaking gasoline in an enclosed trailer 1 4 OPERATION Although hazard control and accident prevention are partially 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
74. venting path of battery is always open once battery is filled with acid 3 2 2 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are 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 below for recommended charger settings Voltage Percent Maximum Reading Charge Charger Settings Charging Alera 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 7596 16 volts 7 amps 1 Hour 12 0 12 2 25 5096 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 0 14 4 volts 2 amps 6 Hours or More 13 3 3 3 4 3 5 3 6 3 7 3 8 CAUTION POTENTIAL HAZARD If the ignition is in the position there is potential for sparks and engagement of components WHAT CAN HAPPEN Sparks could cause an explosion or moving parts could accidentally engage causing personal injury HOW TO AVOID THE HAZARD sure ignition switch is in the OFF position before charging the battery 3 2 3 Connect the neg

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