Exmark M216KASPC User's Manual
Contents
1. 2 m 7282 Figure 21 1 Screw 2 Cover 3 Paperair filter 4 Remove the cover and clean it thoroughly Fig 21 16 5 Remove the paper air filter and discard it as required Fig 22 3 ES 2 Sam m 7281 Figure 22 1 Paper air filter 2 Foam pre cleaner Important Do not try to clean a paper filter 6 Remove the foam pre cleaner and wash it with a mild detergent and water then blot it dry Fig 21 7 Saturate the pre cleaner with clean engine oil then squeeze it do not twist to remove the excess oil 8 Install the foam pre cleaner 9 Install the new paper air filter 10 Install the cover and secure it with the screw Changing the Engine Oil Change the oil after the first 8 operating hours and than after every 50 operating hours or every season more frequently in dusty or dirty conditions 1 Run the engine to warm the engine oil Note Warm oil flows better and carries more contaminants 4 Oil may be hot after engine has been run and contact with hot oil can cause severe personal injury A Warning Avoid contacting the hot engine oil when you drain it 2 Stop the engine and wait for all moving parts to stop 3 Disconnect the wire from the spark plug Fig 9 4 Place a suitable drain pan beside the right side of the lawn mower 5 Remove the dipstick by2. 26 This spark ignition system complies with Canadian ICES 002 Ce systeme d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Specifications Model Number M216KASPC Engine Kawasaki 6 0 hp OHV 3300 RPM No load Fuel System Capacity Fuel filter 4 0 qt 3 8 L Non replaceable in tank Transmission 3 speeds forward Speed range First 1 8 mph 2 9 km h Second 2 7 mph 4 3 km h Third 3 8 mph 6 1 km h Cutting Width 2 in 53 cm Cutting Height Adjusts in 1 2 in 1 3 cm increments from 75 in 1 9 cm to 3 25 in 8 3 cm Grass Catcher Capacity 2 5 Bu 88 L Weight with bag 115 Ib 52 2 kg All Rights Reserved Printed in the USA Introduction Read this manual carefully to learn how to operate and maintain your product properly The information in this manual can help you and others avoid injury and product damage Although Exmark designs and produces safe products you are responsible for operating the product properly and safely This manual identi
3. 2 i W 3 _ 1 E 7277 DM Figure 6 1 Dipstick 3 Add 2 Full Note When the crankcase is empty pour about 3 4 of the crankcase capacity of oil in the crankcase then follow the procedure in this section To add oil 1 Move the lawn mower to a level surface 2 Clean around the dipstick Fig 6 3 Remove the dipstick by rotating the cap counterclockwise and pulling it out 4 Wipe the dipstick clean with a clean cloth 5 Insert the dipstick into the filler neck then remove it Note To ensure an accurate oil level reading you must fully install the dipstick 6 Read the oil level on the dipstick Fig 6 7 If the oil level reading is below the Add mark on the dipstick slowly pour only enough oil into the filler hole to raise the oil level to the Full mark on the dipstick El TC Do not overfill the crankcase with oil and run the engine engine damage will result Drain the excess oil until the oil level on the dipstick reads Full 8 Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight Filling the Fuel Tank with Gasoline For best results use clean fresh lead free gasoline with an octane rating of 87 or higher To ensure freshness purchase only the quantity of gasoline that you expect to use in 30 days Using unleaded gasoline results in fewer combustion deposits and longer engine life Important Do not add oil to the gasoline Do no
4. Elbow fitting 5 Slide the end of the fuel line onto the elbow fitting Fig 3 6 Secure the fuel line in place with the fuel line clamp Fig 3 Installing the Discharge Tunnel Plug 1 Open the discharge door by pulling forward on the handle and moving it rearward Fig 4 Hold the discharge door handle to prevent the spring loaded door from closing while you insert the plug BY acp i EL i m 1914 Figure 4 1 Discharge door handle 2 Plug rotated clockwise 2 Since the plug is slightly wider than the discharge tunnel opening rotate the plug clockwise slightly while inserting it Fig 4 Note Ensure that the arrow on the plug decal points upward 3 Push the plug all the way in until the spring clip on the bottom of the plug clicks into place locking the plug securely into the discharge tunnel Fig 5 m 1915 Figure 5 1 Springclip 4 Release the discharge door handle to lock the top of the plug Before Starting Filling the Crankcase with Oil Initially fill the crankcase with 30 ounces 0 88 liters of oil Use only high quality SAE 30 or SAE 10W30 weight detergent oil that has the American Petroleum Institute API service classification SF SG SH or SJ Oil Capacity With Oil Filter 30 ounces 0 88 L Without Oil Filter 24 ounces 0 70 L Before each use ensure that the oil level is between the Add and Full marks on the dipstick Fig 6 Ma E NSA
5. Fig 9 3 Using an oil can add about one tablespoon of oil to the crankcase through the spark plug hole 4 Slowly rotate the engine several times using the starter rope to distribute the oil 5 Install the spark plug but do not connect the wire to the spark plug General Information l Clean the lawn mower housing Refer to Cleaning the Underside of the Lawn Mower Housing on page 15 2 Clean any dirt and chaff from the cylinder cylinder head fins and blower housing 3 Remove grass clippings dirt and grime from the external parts of the engine the shrouding and the top of the lawn mower housing 4 Clean the BBC shield refer to Cleaning Blade Brake Clutch Shield on page 18 5 Check the condition of the blade Refer to Maintaining the Blade on page 17 6 Service the air filter refer to Servicing the Air Filter on page 16 7 Lubricate the pivot arms refer to Lubricating the Pivot Arms on page 16 8 Tighten all nuts bolts and screws 9 Touch up all rusted or chipped paint surfaces with paint available from an Authorized Service Dealer Removing the Lawn Mower from Storage 1 Check and tighten all fasteners 2 Remove the spark plug and spin the engine rapidly using the starter to blow excess oil from the cylinder 3 Clean the spark plug or replace it if it 1s cracked broken or if the electrodes are worn 4 Install the spark plug and torque it to 17 ft lb 23 N m 5 Perform any n
6. HAZARD e This product is a piece of power equipment WHAT CAN HAPPEN e 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 condition Before adjusting servicing or performing maintenance stop the engine and wait for all moving parts to stop then remove the spark plug wire or remove the key If the mower deck becomes clogged stop the engine and wait for all moving parts to stop then remove the spark plug wire or remove the key before cleaning the blockage Keep hands feet and clothing away from power driven parts Keep off the mower unless the seat platform is provided Keep others off the mower WARNING POTENTIAL HAZARD e Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN e Failure to use caution may Cause serious injury or illness HOW TO AVOID THE HAZARD e Avoid prolonged breathing of vapors e Keep face away from nozzle and gasoline tank container opening e Keep gasoline away from eyes and skin e Never siphon gasoline by mouth Exmark reserves the right to make changes to add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers
7. Neutral position when you use the lawn mower for trimming and whenever you leave the lawn mower Using the Discharge Tunnel Plug 1 Stop the engine and wait for all moving parts to stop 2 Insert the plug refer to Installing the Discharge Tunnel Plug on page 7 3 To remove the plug move the discharge door handle rearward and lift up the spring clip on the bottom of the plug When the plug is unlocked pull it out of the discharge tunnel Note When grass is thick and lush clippings may collect on and around the discharge tunnel plug This may make removing the plug difficult Clean the plug thoroughly after each use Checking the Blade Brake Clutch Check the blade brake clutch BBC system before each use to ensure that it is operating properly Normal Test 1 Stop the engine and wait for all moving parts to stop 2 Move the lawn mower onto a paved surface in a non windy area 3 Set all four wheels in to the 2 1 2 in 64 mm cutting height setting Fig 16 Set the ground speed selector to the Neutral position gt 5 Take half sheet of newspaper and crumple it into a ball small enough to go under the deck about three inches or 76 mm in diameter as shown in Figure 12 Figure 12 1 5in 12 7 cm 6 Place the ball of newspaper five inches 12 7 cm in front of the lawn mower Fig 12 7 Start the engine with the blade control bail down to its lowest position Fig 13 m 508
8. and turn the lawn mower off if children enter the area e Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision e Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property e See the manufacturer s instructions for proper operation and installation of accessories Use only the accessories that are approved by the manufacturer Preparation e Thoroughly inspect the area where you will use the lawn mower and remove all stones sticks wires bones and other foreign objects e While mowing always wear substantial footwear and long trousers Do not operate the lawn mower when barefoot or wearing open sandals Always wear safety goggles or safety glasses with side shields when operating the lawn mower Warning Gasoline is highly flammable Take the following precautions Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the engine Never remove the cap of the fuel tank or add gasoline while the engine is running or when the engine is hot If gasoline is spilled do not attempt to start the engine Move the lawn mower away from the area of spillage to avoid creating any source of ignition until the gasoline vapors have dissipated Replace all fuel tank and container caps securely
9. are more than 5 inches 12 7 cm of leaves on the lawn set the front cutting height 1 or 2 notches higher than the rear cutting height This makes it easier to feed the leaves under the lawn mower deck Slow down your mowing speed if the lawn mower does not cut the leaves finely enough If you mow over oak leaves you can add lime to the grass in the spring to reduce the acidity of the oak leaves Maintenance Note Determine the left and right sides of the machine from the normal operating position Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure e Check the engine oil level e Check the stopping time of the blade brake The blade must stop within 3 seconds of releasing the bail if it does not contact an Authorized Service Each Use Dealer for repair e Remove grass clippings and dirt from under the housing e Clean the discharge tunnel and the discharge tunnel plug e Check the blade and the engine mounting fasteners Tighten them if they are 5 Hours Doe e Clean the foam pre cleaner of the air cleaner e Change the engine oil without the oil filter 1 e Sharpen or replace the blade maintain it more frequently if the edge dulls quickly in rough or in sandy conditions 50 Hours e Clean the blade brake clutch shield e Check for leaks in the fuel system and or a deteriorating fuel hose Replace parts if necessary e Remove grass clippings and debris from under the belt cover e Lu
10. brake clutch mechanism 1 Install the empty grass bag on the discharge tunnel 2 Start the engine 3 Push the blade control bail Fig 13 down to its lowest position 4 Move the blade control bail to the right and then lift it to about one inch 2 5 cm below the handle The bag should begin to inflate indicating that the blade is engaged and rotating 5 Release the blade control bail If the bag does not immediately deflate it indicates that the blade is still rotating The blade brake clutch mechanism may be deteriorating and if ignored could result in an unsafe operating condition Have the lawn mower inspected and serviced by an Authorized Service Dealer Adjusting the Cutting Height Each wheel is adjusted individually with a wheel height adjustment lever Cutting heights are 1 inch 25 mm 1 1 2 inches 38 mm 2 inches 51 mm 2 1 2 inches 64 mm 3 inches 76 mm and 3 1 2 inches 89 mm Adjusting the cutting height levers could bring your hands into contact with a moving blade and result in serious injury e Stop the engine and wait for all movement to stop before adjusting the cutting height e Do not put your fingers under the housing when adjusting the cutting height 1 Pull the wheel height adjustment lever toward the wheel Fig 16 and move it to the desired setting m 225 Figure 16 1 Wheel height adjustment lever 2 Release the wheel height adjustment lever and seat it se
11. 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 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 Contents PEC MICAUONG Introduction Rone dae vola General Lawn Mower Safety Exmark Lawn Mower Safety Safety and Instruction Decals Assembly cee eae Installing Handle Installing the Fuel Tank and the Fuel Line Installing the Discharge Tunnel Plug Before os se ok th be E Hs E AR EN Ea Filling the Crankcase with Oil Filling the Fuel Tank with Gasoline Operation CONTOR goto ence 39 152 9293 9 29 99 9999 Starting Stopping the Operating the Blade and the Self Propel Drive Using the Discharge Tunnel Plug Checking the Blade Brake Clutch Adjusting the Cutting Height Using the G
12. rotating the cap counterclockwise and pulling it out Fig 6 6 Raise the left side of the lawn mower to drain the oil into the drain pan Note You can also remove the oil from the crankcase using an oil extractor 7 Lower the left side of the lawn mower 8 Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight 9 Recycle the used oil according to local codes 10 Fill the crankcase to the Full line on the dipstick with fresh oil Refer to the Filling the Crankcase with Oil on page 7 11 Wipe up any spilled oil 12 Connect the wire to the spark plug Maintaining the Blade Always mow with a sharp blade A sharp blade cuts cleanly and without tearing or shredding the grass blades 1 Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug Fig 9 3 Drain the gasoline from the fuel tank refer to Emptying the Fuel Tank and Cleaning the Fuel Filter on page 19 4 Tip the lawn mower onto its right side Fig 23 796 Figure 23 1 Blade 3 Anti scalp cup 2 Blade nuts 4 Accelerator 17 Inspecting the Blade Carefully examine the blade for sharpness and wear especially where the flat and the curved parts meet Fig 24A Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade check the blade before using the lawn mower If you notice a slot or wear Figs 24B an
13. stop 2 Disconnect the wire from the spark plug Fig 9 3 Remove the cap screw the wheel spacer and the locknut mounting the wheel to the pivot arm Fig 37 Figure 37 1 Locknuts 6 Plastic cover rear wheels 2 Wheelspacer only 3 Bearing hub assembly 7 Lug 4 Bearing spacer Bearing 2 5 Wheel half 9 Cap screw 4 Separate the wheel halves from the tire by removing 4 cap screws and 4 locknuts Fig 37 Note If you remove the bearings from the bearing hub assembly remove them by pressing on the bearing spacer Fig 37 Assembling the Wheels 1 Position the tire onto one wheel half aligning the lugs on each Fig 37 2 Place the bearing hub assembly into the center hole of the wheel half Ensure that the legs of the hub are positioned over the flange of the hole Fig 37 3 Place the other wheel half onto the bearing hub assembly aligning the wheel and the tire lugs and the mounting holes Fig 37 4 Using 2 fully threaded screws or bolts 1 4 20 x 1 50 in and non locking nuts loosely secure the wheel halves together Mount the screws or bolts in the opposing holes Fig 37 5 Check the alignment of all parts and tighten the screws alternating from side to side for a uniform fit until the wheel halves are drawn together Fig 37 6 Install the 2 cap screws and 2 locknuts previously removed in the remaining holes in the wheel halves and tighten Remove the 2 long screws or bolts a
14. the lawn mower strikes an object or starts to vibrate immediately stop the engine disconnect the wire from the spark plug and examine the lawn mower for damage Maintain a sharp blade throughout the cutting season Periodically file down nicks on the blade Replace the blade when necessary with an original Exmark replacement blade Mow only dry grass or leaves Wet grass and leaves tend to clump on the yard and can cause the lawn mower to plug or the engine to stall Wet grass or leaves can cause serious injury if you slip and contact the blade A Warning Mow only in dry conditions Clean the underside of the lawn mower deck after each mowing See Cleaning the Underside of the Lawn Mower Housing on page 15 Keep the engine in good running condition Set the engine speed to the fastest position for the best cutting results Operating a lawn mower with its engine running at a speed greater than the factory setting can cause the lawn mower to throw a part of the blade Warning or engine into the operator s or bystander s area and result in serious personal injury or death e Do not change the engine speed setting e f you suspect the engine speed is faster than normal contact an Authorized Service Dealer Clean the air filter frequently Mulching stirs up more clippings and dust which clogs the air filter and reduces engine performance Cutting Grass Grass grows at different rates at different times of t
15. 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 Ifthe 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 Ifthe 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 qualify all Exmark Parts Plus orders must be rec
16. 5 Figure 13 10 8 Move the blade control bail to the right and then lift it up to about one inch 2 5 cm below the handle refer to position A in Figure 14 Note The fan like noise indicates that the lawn mower blade is turning m 5085 Figure 14 1 Tin 2 5 cm 9 Release the blade control bail refer to position B in Figure 15 You should hear a bang The blade should stop in three seconds m 5085 Figure 15 10 Immediately push the lawn mower over the newspaper ball 11 Stop the engine and wait for all moving parts to stop 12 Walk around the lawn mower to check for the newspaper ball If the ball did not go under the deck repeat steps 6 through 11 13 Pull the lawn mower away from the newspaper If the newspaper ball unravels or is shredded the blade has not properly stopped resulting in an unsafe operating condition Contact an Authorized Service Dealer Danger If the blade brake clutch system is inoperative the blade will continue to rotate when you release the blade control bail Contact with the blade could occur causing serious injury e Check the BBC operation before each use e Never use a BBC equipped lawn mower with an inoperative safety system e Take your lawn mower to an Authorized Service Dealer for repair if the safety system fails to operate properly Test Using the Grass Bag You can use the grass bag to perform an additional test to check the blade
17. ING SULKY MICRO MULCH ACCESSORY Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 2004 FORM NO 3350 478 EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ANK ALL RIGHTS RESERVED PRINTED IN U S A MFG CO INC
18. If you must drain the fuel from the fuel tank do it outdoors Replace faulty mufflers Before using always visually inspect the blades blade bolts and cutter assembly for wear or damage Replace worn or damaged blades and bolts in sets to preserve balance On multibladed lawn mowers use care as rotating one blade can cause the other blades to rotate Operation Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect Mow only in daylight or in good artificial light Always be sure of your footing on slopes Walk never run Keep a firm hold on the handle For wheeled rotary lawn mowers mow across the face of slopes never up and down Exercise extreme caution when changing the direction on slopes Do not mow excessively steep slopes Use extreme caution when reversing or pulling the lawn mower toward you Before and while moving backward look behind and down for small children e Stop the blade s if you must tilt the lawn mower for transportation when crossing surfaces other than grass and when transporting the lawn mower to and from the area to be mowed e Never operate the lawn mower with damaged missing guards or shields or without safety devices such as deflectors and grass catchers in place e Do not change the speed settings on the engine e Disengage all blade and drive clutches before starting the engine e Start the engine carefully according to
19. M216KASPC For Serial Nos 440 000 amp Higher 1 er a LL CA C METRO 21 CONGRATULATIONS on the purchase of your new Exmark mower This product has been carefully designed and manufactured to give a maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the part number description and quantity of the part needed The Serial No plate is located on the top of the mower deck on the right hand corner of the machine For ease of ordering and reference we suggest that you record the information requested in the following identification table Place Model No and Serial No Label Here Included in Literature Pack Engine Model No and Spec No Code or Fill in Below Engine Serial No E No Model No Date Purchased Serial No Part No 3350 478 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 WARNING POTENTIAL
20. accept no responsibility 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 17 If dealer does not have in stock for 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 line items or less 2 Distributor ships part s to dealer or customer as requested by dealer same day overnight UPS Distributor bills dealer for part and freight charges where applicable A TS PLUS 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 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 arrive in accordance to the program 6 Who pays for
21. ace any decal that is damaged or lost REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND DO NOT ALLOW OPERATION OF THIS MACHINE BY UNTRAINED PERSONNEL KEEP SAFETY DEVICES IN PLACE AND WORKING 104 8582 104 8582 N 74 1970 JN P 74 1970 1 Transmission speeds 2 Neutral A WARNING ROTATING BLADE OR THROWN OBJECTS CAN SERIOUSLY INJURE DO NOT OPERATE WITHOUT PLUG OR OTHER ATTACHMENT LOCKED IN PLACE 76 2110 lt gt GS e X201Nn R 43 8480 HOURS OF OPERATION THROWN OBJECTS AND BLADE CONTACT MAY GREASE GEAR BOX INPUT SHAFT RESULT IF DOOR IS NOT COMPLETELY CLOSED TWO PUMPS EVERY 100 HOURS e THROWN OBJECTS AND BLADE CONTACT CAN OF OPERATION SEE OPERATOR S SERIOUSLY INJURE MANUAL 52 2620 OPERATE ONLY IF DOOR IS COMPLETELY CLOSED OR ATTACHMENT IS LOCKED IN PLACE CLEAR DISCHARGE WITH ENGINE STOPPED BY MOVING DOOR HANDLE BACK AND FORTH s NIN 93 7398 Stay away from rotating blade 68 7410 BLADE STOF TD ETOF WXE THROTTLE TO OFF 100 3282 HEARING PROTECTION RECOMMENHDED EIL 104 1329 Assembly ie the Fuel Tank and the Note Determine the left and right sides of the machine from the normal operating position 1 Start the two self tapping screws into the bottom of the fuel tank and then remove the screws Fig 2 Installing the Handle i 3 1 Mount t
22. allow objects to be thrown Frequently check the components and replace them with the manufacturer s recommended parts when necessary e Lawn mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them e Do not change the speed settings on the engine e f you must drain the fuel from the fuel tank do it outdoors e To ensure the best performance and safety purchase only genuine Exmark replacement parts and accessories e Maintain or replace safety and instruction decals when necessary Exmark Lawn Mower Safety The following list contains safety information specific to Exmark products or other safety information that you must know that is not included in the ANSI OPEI standard This product is capable of amputating hands and feet and of throwing objects Always follow all safety instructions to avoid serious injury or death Use this product only for cutting and mulching grass or when equipped with a grass bagger for catching cut grass e Stop the lawn mower if anyone enters the area e Do not operate the lawn mower without either the grass catcher or the guard in place e Do not touch the lawn mower or attachment parts which may be hot from operation Allow the lawn mower to cool down before attempting to maintain adjust or service it Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Repl
23. anty adjustments on engines This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance e Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Depart
24. bricate the pivot arms e Adjust the self propel drive system e Inspect the spark plug and replace it if necessary e Clean the cooling system remove grass clippings debris or dirt from the engine air cooling fins and starter Clean the system more frequently in dirty or 100 Hours high chaff conditions e Lubricate the gear case e Adjust the blade brake cable e Service the wheels e Replace the paper air filter Replace it more frequently in dusty operating e Empty the fuel tank before repairs as directed or before storage 1Change the engine oil after the first 8 operating hours Important Refer to your engine operator s manual for additional maintenance procedures Caution If you leave the wire on the spark plug someone could accidently start the engine and seriously injure you or other bystanders Disconnect the wire from the spark plug before you do any maintenance Set the wire aside so that it does not accidently contact the spark plug 14 Checking the Engine Oil Level Before you use the lawn mower make sure that the oil level is between the Add and the Full marks as shown on the dipstick Fig 6 If the oil level is below the Add mark and oil Refer to Filling the Crankcase with Oil on page 7 Checking the Blade Brake Clutch Refer to Checking the Blade Brake Clutch on page 10 Cleaning the Underside of the Lawn Mower Housing To ensure the best performance keep the underside of the
25. cable if necessary Clean the debris from under the belt cover Limited Warranty Exmark Turf Equipment Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part manufactured by Exmark and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship This warranty applies to Exmark turf equipment sold in the US or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Products Warranty Period e All Products except as noted below 1 year 90 days for rental use e Peerless 5 speed transmission 1 year extended beyond manufacturer s warranty of 90 days e Frame Hydrostatic Traction System Electric Clutch and Exmark supplied Mufflers 2 years e Blade Spindle Assy and Deck Jackshaft Assy 3 years 1 year parts and labor with additional 2 years parts only e Belts and Tires 90 days e Battery Refer to the battery manufacturer s warranty in the literature packet e Engine Warranty is covered by engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are not authorized to handle warr
26. curely in the notch 3 Adjust all the wheels to the same cutting height setting Using the Grass Bag Occasionally you may wish to use the grass bag for bagging extra long grass lush grass or leaves Installing the Grass Bag 1 Stop the engine and wait for all moving parts to stop 2 Ensure that the discharge door handle is fully forward and that the pin is engaged in the catch Fig 17 m 1912 Figure 17 1 Bag frame on retaining post Pin engaged in catch 3 Handle fully forward Discharge door closed N 3 Slide the hole in the bag frame onto the retaining post on the discharge tunnel Fig 17 D o Pull the discharge door handle forward until the pin clears the catch and move the handle rearward until the pin locks in the bag notch Fig 18 m 1913 Figure 18 1 Pinlocked in bag notch Note The discharge door in the lawn mower housing is NOW open Set the rear of the bag frame onto the bag support rod 12 Mowing with the Grass Bag A A A worn grass bag could allow small stones and other similar debris to be thrown in the operator s or bystander s direction and result in serious personal injury or death to the operator or bystanders Warning Check the grass bag frequently If it is damaged install a new Exmark replacement bag Cut the grass until the bag 1s full Important Do not overfill the bag Removing the Grass Bag 1 Stop the engine and wait for a
27. d 24C replace the blade refer to Removing the Blade on page 17 Figure 24 3 Wear 4 Slot formed 1 Sail 2 Flat part of blade Note For the best performance install a new blade before the cutting season begins During the year file down any small nicks to maintain the cutting edge A worn or damaged blade can break and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death e nspect the blade periodically for wear or damage e Replace a worn or damaged blade Removing the Blade l Grasp the end of the blade using a rag or a thickly padded glove 2 Remove the blade nuts the anti scalp cup the accelerator and the blade Fig 23 Sharpening the Blade File the top side of the blade to maintain its original cutting angle Fig 25A and inner cutting edge radius Fig 25B The blade will remain balanced if you remove the same amount of material from both cutting edges A B 2 153 m 4783 Figure 25 1 Sharpen at this angle only 2 Maintain the original radius here Balancing the Blade 1 Check the balance of the blade by placing the center hole of the blade over a nail or screwdriver shank clamped horizontally in a vise Fig 26 1007 Figure 26 Note You can also check the balance using a commercially manufactured blade balancer 2 If either end of the blade rotates downward file that end not
28. e the throttle control to the Off position 2 Disconnect the wire from the spark plug if you do not use the lawn mower or if you leave it unattended Operating the Blade and the Self Propel Drive 1 Have the blade control bail in the A position Fig 11 m 3769 Figure 11 2 Slide the blade control bail to the right and raise it to the B position to engage the blade Fig 11 3 Squeeze the blade control bail against the handle to the C position to drive Fig 11 Note To disengage the traction drive but keep the blade engaged gradually release the blade control bail to the B position To self propel with the blade disengaged squeeze the blade control bail against handle to the C position without sliding the blade control bail to the right The lawn mower has 3 ground speeds 1 is slow 2 is medium and 3 is fast The ground speed control is located at the rear of the belt cover Fig 10 Note You can vary the ground speed by increasing or decreasing the distance between the control bar and the handle Lower the control bar to slow the lawn mower when making a turn or if the lawn mower is moving too fast for you If you lower the control bar too far the lawn mower stops self propelling Squeeze the control bar closer to the handle to increase the ground speed When you hold the control bar tight against the handle the lawn mower Self propels at the maximum ground speed Move the ground speed control to the
29. e wheel drive control knob on the rear of the gear box 1 Close the door in the lawn mower housing and remove the grass bag 2 Rotate the control knob clockwise 1 9 turn if the lawn mower does not self propel If the lawn mower creeps forward rotate the knob 1 9 turn counterclockwise to loosen the belt Fig 30 m 228 Figure 30 1 Control knob 3 Slowly pull the lawn mower backward while you gradually move the control bar toward the handle Note The adjustment is correct when the rear wheels stop turning and the control bar is about one inch 2 5 cm from the handle Fig 31 WA m 513 Figure 31 1 One inch 2 5 cm Servicing the Spark Plug Check the spark plug after every 100 operating hours Use an NGK BPRSES spark plug or equivalent 1 Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug Fig 9 3 Clean around the spark plug 4 Remove the spark plug from the cylinder head ETC Replace a cracked fouled or dirty spark plug Do not clean the electrodes because grit entering the cylinder can damage the engine 5 Set the gap on the plug to 0 030 in 0 76 mm Fig 32 ILOS ISSCC OCEN 000000006000 EERROR m 110 Figure 32 1 0 030 in 0 76 mm 6 Install the spark plug and the gasket seal 7 Torque the plug to 17 ft lb 23 N m 8 Connect the wire to the spark plug Changin
30. eeded maintenance procedures refer to Maintenance on page 14 6 Fill the fuel in the fuel tank with fresh gasoline 7 Check the engine oil level 8 Connect the wire to the spark plug Accessories You may purchase the following accessory from an Authorized Service Dealer Side Discharge Kit You can install the side discharge kit in seconds It is rear mounted in place of the grass bag It disperses clippings while trimming on both sides Fig 38 de N An AA we 1 2047 Figure 38 1 Side discharge chute Troubleshooting Exmark designed and built your lawn mower for trouble free operation Check the following components and items carefully and refer to Maintenance on page 14 for more information If a problem continues contact an Authorized Service Dealer Possible Causes Corrective Action Engine does not start Engine starts hard or loses power Engine runs rough 1 The fuel tank is empty or the fuel system contains stale fuel The throttle lever is not in the Choke position The wire is not connected to the spark plug The spark plug is pitted fouled or the gap is incorrect The fuel tank contains stale fuel The fuel cap vent hole is plugged The air filter element is dirty and is restricting the air flow The underside of the lawn mower deck contains clippings and debris The spark plug is pitted fouled or the gap is
31. eived by Exmark by 3 00 p m central time Orders must be six 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 Exmark Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air ship ment 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 dealer or
32. erty damage Warning Avoid fuel spills by emptying the fuel tank as directed never siphon 5 Remove the two blade nuts the anti scalp cup the accelerator and the blade Fig 27 Figure 27 3 Tab and bolt 1 Tabs and nuts 2 BBC shield 6 Loosen the tabs that secure the BBC shield to the deck by loosening the nuts or the bolts on the tabs Fig 27 Rotate the tabs 180 to move them out of the way 7 Remove the BBC shield and brush or blow all the debris from under the shield and around the BBC system 18 8 Install the BBC shield Rotate the tabs 180 back into position Tighten the nuts or the bolts on tabs to secure the BBC shield to the deck 9 Install the blade the accelerator the anti scalp cup and the two blade nuts 10 Turn the lawn mower upright 11 Connect the wire to the spark plug Emptying the Fuel Tank and Cleaning the Fuel Filter The fuel filter screen element is located inside the fuel tank Clean the fuel filter element every 100 operating hours 1 Stop the engine and wait for it to cool down Important Drain gasoline from a cold engine only 2 Disconnect the wire from the spark plug Fig 9 3 Close the fuel valve Fig 3 4 Disconnect the fuel line Fig 33 by loosening the tube clamp at the carburetor 5 Open the fuel valve by turning the lever to the open position Fig 7 6 Drain the gasoline completely from the tank and fuel line into a
33. fies potential hazards and has special safety messages that help you and others avoid personal injury and even death Danger Warning and Caution are signal words used to identify the level of hazard However regardless of the hazard be extremely careful Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions This manual uses two other words to highlight information calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safety This lawn mower meets or exceeds the CPSC blade safety requirements for walk behind rotary lawn mowers and the B71 4 specifications of the American National Standards Institute in effect at the time of production Exmark designed and tested this lawn mower to offer reasonably safe service however failure to comply with the following instructions may result in personal injury Warning Engine exhaust contains carbon monoxide odorless deadly poison that can kill you Do not run the engine indoors or in an enclosed area To ensure maximum safety and best performance and to gain knowledge of the product it is essential that
34. g the Oil Filter Replace the oil filter Fig 33 after every 100 operating hours or yearly whichever comes first m 7284 Figure 33 2 Fuel line 1 Oil filter 1 Run the engine to warm the oil Warning Oil may be hot after the engine has been run and contact with hot oil can cause sever personal injury Avoid contacting the hot engine oil when you drain it 2 Stop the engine and wait for all moving parts to stop 3 Disconnect the wire from the spark plug Fig 9 4 Drain the engine oil refer to Changing the Engine Oil on page 16 5 Place a rag under the oil filter to catch any oil that may leak out as you remove the filter 6 Remove the oil filter 7 Use your finger to coat the gasket on the new filter with clean engine oil Fig 34 Figure 34 1 Gasket 8 Install the new filter and hand tighten it 2 3 turn only 9 Fill the crankcase to the Full line on the dipstick with fresh oil Refer to Filling the Crankcase with Oil on page 7 10 Connect the wire to the spark plug 11 Run the engine for about 3 minutes 12 Stop the engine wait for all moving parts to stop and check for oil leakage around the filter 13 Add oil to compensate for the oil in the oil filter Refer to Checking the Engine Oil Level on page 15 14 Recycle the used oil filter according to local codes Lubricating the Gear Case After every 100 operating hours grease the gear ca
35. he year In the summer heat it is best to cut grass at the 2 inch 51 mm 2 1 2 inch 64 mm or 3 inch 76 mm cutting height settings Cut only about a third of the grass blade at a time Do not cut below the 2 inch 51 mm setting unless the grass is sparse or it is late fall when grass growth begins to slow down When cutting grass over 6 inches 15 cm tall first mow at the highest cutting height setting and walk slower then mow again at a lower setting for the best lawn appearance If the grass is too long and the leaves clump on top of the lawn the lawn mower may plug and cause the engine to stall Alternate the mowing direction This helps disperse the clippings over the lawn for even fertilization If the finished lawn appearance is unsatisfactory try one or more of the following Sharpen the blade Walk at a slower pace while mowing Raise the cutting height on your lawn mower Cut the grass more frequently Overlap cutting swaths instead of cutting a full swath with each pass Set the cutting height on the front wheels one notch lower than the rear wheels For example set the front wheels at 2 inches 51 mm and the rear wheels at 2 1 2 inches 64 mm Cutting Leaves 13 After cutting the lawn ensure that half of the lawn shows through the cut leaf cover You may need to make more than one pass over the leaves For light leaf coverage set all the wheels at the same cutting height setting If there
36. he handle to the outside of the lawn mower housing using the bottom hole with 2 cap screws 5 16 18 1 1 4 in washers and thin nylon insert locknuts 2 2 Secure the handle latches to the handle with 2 cap screws 5 16 18 x 1 1 2 in washers and nylon insert locknuts Fig 1 Jl 5 S 177 LAN isi 530 3 Figure 2 1 Tank base 4 Fuel tank 2 Fuel tank bracket 5 Self tapping screw 2 3 Plastic clips m 534 2 Hook the plastic clips on the front of the fuel tank onto the fuel tank bracket Fig 2 Figure 1 1 Handle latch 2 3 Cap locknut 2 3 Secure the fuel tank to the tank base with the two 2 Bag support rod 4 Handle self tapping screws Fig 2 Do not overtighten the Screws 4 Remove the red cap from the end of the fuel line and from the end of the elbow fitting on the fuel tank Fig 3 Note You can adjust the handle height for comfortable operation Stand behind the handle to determine the height To adjust the handle height position the cap screws and the locknuts that secure the handle latches to the handle into the other mounting holes in the latches 3 Slide the bag support rod through the bottom mounting holes in the handle and secure each end with a cap locknut Fig 1 4 Use a cable tie to secure the control cables to the left handle below the bag support rod m 7283 Figure 3 1 Fuelline 3 Fuel valve 2
37. ibrates excessively Uneven cutting pattern Discharge chute plugs Lawn mower does not self propel The blade is bent or is out of balance The blade mounting bolt is loose The underside of the lawn mower deck contains clippings and debris The engine mounting bolts are loose All four wheels are not at the same height The blade is dull You are mowing in the same pattern repeatedly The underside of the lawn mower deck contains clippings and debris The throttle lever is not in the Fast position 2 he cutting height is too low 3 You are mowing too fast 4 The grass is wet The underside of the lawn mower deck contains clippings and debris The self propel drive cable is out of adjustment or is damaged There is debris under the belt cover 25 Balance the blade If the blade is bent replace it Tighten the blade mounting bolt Clean the underside of the lawn mower deck Tighten the engine mounting bolts Place all four wheels at the same height Sharpen and balance the blade Change the mowing pattern Clean the underside of the lawn mower deck Move the throttle lever to the Fast position 2 Raise the cutting height 3 Slow down 4 Allow the grass to dry before mowing Clean the underside of the lawn mower deck Adjust the self propel drive cable Replace the
38. incorrect The engine oil level is low or the oil is dirty The wire is not connected to the spark plug The spark plug is pitted fouled or the gap is incorrect The throttle lever is not in the Fast position The air filter element is dirty and is restricting the air flow 24 Drain and or fill the fuel tank with fresh gasoline If the problem persists contact an Authorized Service Dealer Move the throttle lever to the Choke position Connect the wire to the spark plug Check the spark plug and adjust the gap if necessary Replace the spark plug if it is pitted fouled or cracked Drain and fill the fuel tank with fresh gasoline Clean the fuel cap vent hole or replace the fuel cap Clean the air filter pre cleaner and or replace the paper air filter Clean the underside of the lawn mower deck Check the spark plug and adjust the gap if necessary Replace the spark plug if it is pitted fouled or cracked Check the engine oil Change the oil if it is dirty or add oil if it is low Connect the wire to the spark plug Check the spark plug and adjust the gap if necessary Replace the spark plug if it is pitted fouled or cracked Move the throttle lever to the Fast position Clean the air filter pre cleaner and or replace the paper air filter Possible Causes Corrective Action Lawn mower or engine v
39. instructions and with feet well away from the blade s e Do not start the engine when standing in front of the discharge chute e Do not put your hands or feet near or under rotating parts Keep clear of the discharge opening at all times e Never pick up or carry a lawn mower while the engine is running e Stop the engine and disconnect the spark plug wire before clearing blockages or unclogging the chute before checking cleaning or working on the lawn mower after striking a foreign object Inspect the lawn mower for damage and make repairs before starting and operating the lawn mower and if the lawn mower starts to vibrate abnormally check it immediately e Stop the engine whenever you leave the lawn mower and before refuelling e Reduce the throttle setting during engine run out and if the engine has a shutoff valve turn the fuel off after mowing e Stop the blade s when crossing gravel drives walks or roads e Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher e Do not operate the lawn mower while under the influence of alcohol or drugs e Ifthe lawn mower should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble Slopes are a major factor related to slip and fall accidents which can result in a severe injury If you feel uneasy on a slope do n
40. lawn mower housing clean Fig 19 796 Figure 19 Washing Method 1 Position the lawn mower on a flat concrete or asphalt surface near a garden hose 2 Start the engine 3 Hold the running garden hose at handle level and direct the water to flow on the ground just in front of the right rear tire Fig 20 1093 Figure 20 1 Rear right wheel 15 4 Engage the blade Note The blade will draw in water and wash out clippings Let the water run until you no longer see clippings being washed out from under the housing 5 Disengage the blade stop the engine and wait for all moving parts to stop 6 Turn off the water 7 Start the lawn mower engage the blade and let the lawn mower run for a few minutes to dry out its components Scraping Method If washing does not remove all debris from under the lawn mower scrape it clean 1 Disconnect the wire from the spark plug Fig 9 2 Drain the fuel from the fuel tank Refer to Emptying the Fuel Tank and Cleaning the Fuel Filter on page 19 A A Tipping the lawn mower may cause the fuel to leak from the carburetor or the fuel tank Gasoline is extremely flammable highly explosive and under certain conditions can cause personal injury or property damage Warning Avoid fuel spills by running the engine dry or by removing the gasoline with a hand pump never siphon 3 Tip the lawn mower onto its right side Fig 19 4 Rem
41. ll moving parts to stop 2 Raise the discharge door handle and move it forward to engage the pin with the catch Fig 17 3 Grasp the handles at the front and the rear of the bag and lift the bag off the lawn mower 4 Gradually tip the bag forward to empty the clippings 5 To install the bag refer to Installing the Grass Bag on page 12 If the discharge door does not close completely the lawn mower could throw objects causing serious personal injury or death If you cannot close the door because the grass clippings clog the discharge area stop the engine and gently move the discharge door handle back and forth until you can close the door completely If you still cannot close the door remove the obstruction with a stick not your hand The lawn mower can throw grass clippings and other objects through an open discharge tunnel Objects thrown with enough force could cause serious personal injury or death to the operator or bystander Never open the door on the discharge tunnel when the engine is running Operating Tips Review the safety instructions and read this manual carefully before operating the lawn mower Clear the area of sticks stones wire branches and other debris that the blade could hit and throw Keep everyone especially children and pets away from the area of operation Avoid striking trees walls curbs or other solid objects Never deliberately mow over any object If
42. ment The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense As a condition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions 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 e Expenses related to gasoline oil or lubricants e 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 e Rental of like o
43. n approved fuel container 7 Remove the fuel tank from the mower 8 Close the fuel valve 9 Poura small amount of fuel in the fuel tank move the fuel around in the tank and pour it out into an approved fuel container 10 Install the fuel tank and fuel line refer to Installing the Fuel Tank and the Fuel Line on page 6 Cleaning under the Belt Cover Keep the area under the belt cover free of debris l Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug Fig 9 3 Remove the bolts that secure the belt cover Fig 28 to the lawn mower housing Figure 28 1 Belt cover 4 Lift off the cover and brush out all the debris around the belt area 5 Install the belt cover 6 Connect the wire to the spark plug Lubricating the Pivot Arms After every 50 operating hours or when the season ends lubricate the pivot arms 1 Move the rear wheel cutting height levers to the center setting 2 Wipe the grease fittings with a clean rag Fig 29 m 232 Figure 29 1 Grease fitting 3 Install a grease gun onto the fitting and gently apply 2 or 3 pumps of 2 multi purpose lithium base grease Fig 29 Note Excessive grease pressure may damage the seals 19 Adjusting the Self propel Drive If the lawn mower does not self propel or has a tendency to creep forward when the control bar is more than 1 1 2 inches 3 8 cm from the handle adjust th
44. nd replace them with 2 cap screws and 2 locknuts Fig 37 7 Install the wheel to the pivot arm with the cap screws a spacer and a locknut Ensure that the spacer is positioned between the wheel hub and the pivot arm Fig 37 8 Connect the wire to the spark plug Storage To prepare the lawn mower for off season storage perform the recommended maintenance procedures Refer to Maintenance on page 14 Store the lawn mower in a cool clean dry place Cover the lawn mower to keep it clean and protected 22 Preparing the Fuel System Warning Gasoline can vaporize if you store it over long periods of time and explode if it comes into contact with an open flame e Do not store gasoline over long periods of time e Do not store the lawn mower with gasoline in the fuel tank or the carburetor in an enclosure with an open flame For example a furnace or a water heater pilot light e Allow the engine to cool before storing it in any enclosure Empty the fuel tank when mowing the last time before storing the lawn mower 1 Run the lawn mower until the engine stops from running out of fuel 2 Prime the engine and start it again 3 Allow the engine to run until it stops When you can no longer start the engine it is sufficiently dry Preparing the Engine 1 While the engine is still warm change the oil from the crankcase Refer to Changing the Engine Oil on page 16 2 Remove the spark plug
45. ot mow it e Watch for holes ruts or bumps Tall grass can hide obstacles e Do not mow near drop offs ditches or embankments You could lose your footing or balance e Do not mow on wet grass Reduced footing could cause slipping Maintenance and Storage e Keep all nuts bolts especially blade attachment bolts and screws tight to ensure that the lawn mower is in safe working condition e Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark e Allow the engine to cool before storing the lawn mower in any enclosure e To reduce the fire hazard keep the engine muffler battery compartment and gasoline storage area free of grass leaves or excessive grease e Check the grass catcher frequently for wear or deterioration e Replace worn or damaged parts e Use extra care when handling gasoline gasoline vapors are explosive e Never tamper with safety devices Check their proper operation regularly e Keep the lawn mower free of grass leaves or other debris buildup Clean up any oil or fuel spills e Stop and inspect the lawn mower if you strike an object Repair the lawn mower if necessary before starting the engine e Never attempt to make wheel height adjustments while the engine is running Safety and Instruction Decals e Grass catcher components are subject to wear damage and deterioration which could expose moving parts or
46. ove the dirt and grass clippings with a hardwood scraper Avoid burrs and sharp edges 5 Turn the lawn mower upright 6 Fill the fuel tank 7 Connect the wire to the spark plug Cleaning the Discharge Tunnel and Plug Remove the plug from the discharge tunnel and clean it after each use Always be sure that the discharge tunnel door closes securely when you release the handle If the debris prevents the discharge door from closing securely clean the inside of the discharge tunnel and the door thoroughly Grass clippings and other objects can be thrown from an open discharge tunnel and cause serious injury or kill the operator or bystanders Warning Never start or operate the lawn mower unless one of the following is true The discharge tunnel plug is locked securely in the discharge tunnel The grass bag is locked in place The optional side discharge chute is locked in place The discharge tunnel door is locked in place Servicing the Air Filter Clean the foam pre cleaner every 25 operating hours Replace the paper air filter once every season or every 300 operating hours replace it more frequently in dusty conditions Do not operate the engine without the air filter assembly extreme engine damage will occur l Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug Fig 9 3 Remove the screw that secures the air cleaner cover Fig 21
47. ow the loss of any static charge When practical remove gasoline powered equipment from the truck or trailer and refuel the equipment with its wheels on the round If this is not possible then refuel such equipment on a truck or trailer from a portable container not from a gasoline dispenser nozzle If you must use a gasoline dispenser nozzle keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Use a fuel stabilizer conditioner regularly during operation and storage A stabilizer conditioner cleans the engine during operation and prevents gum like varnish deposits from forming in the engine during periods of storage Important Do not use fuel additives other than a fuel stabilizer conditioner Do not use fuel stabilizers with an alcohol base such as ethanol methanol or isopropanol 1 Clean around the fuel tank cap Fig 7 G 4 eo m 7279a Figure 7 1 Oil fill Dipstick 2 Fuel tank cap 3 Air cleaner 4 Starter handle 2 Remove the cap from the tank 3 Fill the fuel tank with unleaded gasoline to within 1 4 to 1 2 inch 6 to 13 mm from the top of the tank Do not fill into the filler neck Important Do not fill the tank more than 1 4 inch 6 mm from the top of the tank because the gasoline must have room to expand 4 Install the fuel tank cap and wipe up any spilled ga
48. r similar replacement equipment during the period of any warranty repair or replacement work e Any telephone or telegram charges or travel charges e Loss or damage to person or property other than that covered by the terms of this warranty e Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment which is the subject of this warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Rev 8 1 2003 SERVICE RECORD Description Work Done Service Done By SEE EXMARK S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z HP LAZER Z XP LAZER Z CT TURF RANGER TURF TRACER TURF TRACER HP VIKING HYDRO METRO METRO HP ULTRA VAC ULTRA VAC QDS GRASS CATCHER SELF STEER
49. rass Operating Tips Maintenant oe ty EE Recommended Maintenance Schedule Checking the Engine Oil Level Checking the Blade Brake Clutch Cleaning the Underside of the Lawn Mower Housing Cleaning the Discharge Tunnel and Plug Servicing the Air Filter Changing the Engine Oil Maintaining the Blade Cleaning the Blade Brake Clutch Shield Emptying the Fuel Tank and Cleaning the Pie Fier Pr Cleaning under the Belt Cover Lubricating the Pivot Arms Adjusting the Self propel Drive Servicing the Spark Plug Changing the Oil Filter Lubricating the Gear Case Adjusting the Blade Brake Cable Servicing the Wheels ro t ve OOOO NINN 0 gt 10 10 10 11 12 13 14 14 15 15 Page wc oo pwd 22 Preparing the Fuel System 22 Preparing the Engine 4 er 23 General Information 23 Removing the Lawn Mower from Storage 23 do day ad qd eae Sous 23 Troubleshooting 24 Limited Warranty Exmark Turf Equipment
50. se 1 Remove the grass bag 2 Install a grease gun onto the fitting through the belt cover opening Fig 35 2 1 ENL Figure 35 1 Belt cover 2 Grease fitting 3 Gently apply one to 2 pumps of 2 multi purpose lithium base grease 4 Install the grass bag Adjusting the Blade Brake Cable Whenever you install a new blade brake cable assembly or replace the blade brake belt adjust the blade brake cable a Warning Overtightening the blade brake cable can cause the blade brake to fail to stop a rotating blade when you release the blade control bail A rotating blade can cause serious personal injury e Check the blade brake each time you adjust the brake cable to ensure that the brake stops the blade in three seconds or less If the blade does not stop rotating in three seconds or less bring the lawn mower to an Authorized Service Dealer for repair 1 Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug Fig 9 3 Loosen the cable clamp screw until the cable conduit slides Fig 36 a 1 3 278 Figure 36 A 1 Spring 3 Cable conduit 2 Cable clamp screw 4 Pull the cable to remove the slack but do not put tension on the spring 5 Tighten the screw to lock the adjustment in place 6 Connect the wire to the spark plug Servicing the Wheels Removing the Wheels 1 Stop the engine and wait for all moving parts to
51. soline Operation Note Determine the left and right sides of the machine from the normal operating position Each time before you mow make sure that the self propel drive and the blade control bail operate properly When you release the blade control bail the blade and self propel drive should stop If they do not contact an Authorized Service Dealer This machine produces sound levels in excess of 854 at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Controls The blade control bail and throttle control are on the upper handle as shown in Figure 8 222 Figure 8 1 Blade control bail 2 Throttle control Starting the Engine 1 Connect the wire to the spark plug Fig 9 Figure 9 1 Spark plug wire 2 Open the fuel valve Fig 3 3 Move the throttle control to the D Choke position Fig 8 4 Move the ground speed control to the N Neutral position Fig 10 224 Figure 10 Ground speed control 5 Pull the starter handle Fig 7 lightly until you feel resistance then pull it sharply Allow the rope to return slowly 6 Regulate the throttle and the ground speed control as desired when the engine starts Note If the engine fails to start after 3 pulls repeat steps 3 through 6 Stopping the Engine 1 Release the blade control bail and mov
52. t use methanol gasoline containing methanol gasohol containing more than 10 ethanol premium gasoline or white gas Using these fuels can damage the engine s fuel system Important Do not use gasoline that has been stored since the last mowing season or longer In certain conditions gasoline is extremely flammable and highly explosive A fire or explosion from gasoline can burn you and others and can damage property e Fill the fuel tank outdoors in an open area and when the engine is cold Wipe up any gasoline that spills Do not fill the fuel tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 in 6 to 13 mm below the bottom of the filler neck This empty space in the tank allows the gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where a spark may ignite the gasoline fumes Store gasoline in an approved fuel container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline When fueling under certain circumstances a static charge can develop igniting the gasoline A fire or explosion from gasoline can burn you and others and damage property e Always place gasoline containers on the ground and away from your vehicle before filling Do not fill 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 sl
53. the cutting edge or the end near the cutting edge The blade is properly balanced when neither end drops Installing the Blade 1 Install a sharp balanced Exmark blade the blade accelerator the anti scalp cup and the blade nuts Fig 23 2 Torque the blade nuts to 15 to 27 ft lb 20 to 37 N m A A Operating the lawn mower without the accelerator in place can cause the blade to flex Warning bend or break resulting in serious injury or death to the operator or bystanders Do not operate the lawn mower without the accelerator 3 Return the lawn mower to its upright position 4 Connect the wire to the spark plug Cleaning the Blade Brake Clutch Shield Clean the BBC blade brake clutch shield at the end of each mowing season to ensure the best performance and to prevent parts from degrading Clean the BBC shield when you sharpen the blade because you need to remove the blade in order to remove the BBC shield 1 Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug Fig 9 3 Drain the gasoline from the fuel tank refer to Emptying the Fuel Tank and Cleaning the Fuel Filter on page 19 4 Tip the lawn mower onto its right side air filter up A A Tipping the lawn mower may cause the fuel to leak from the carburetor or the fuel tank Gasoline is extremely flammable highly explosive and under certain conditions can cause personal injury or prop
54. you and any other operator of the lawn mower read and understand the contents of this manual before the engine is ever started A This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Improperly using or maintaining this lawn mower could result in injury or death To reduce this potential comply with the following safety instructions General Lawn Mower Safety This lawn mower is capable of amputating hands and feet and of throwing objects Failure to observe the following safety instructions could result in serious injury or death Training e Read this operator s manual carefully Be thoroughly familiar with the controls and the proper use of the lawn mower before starting it e Never allow children to operate the lawn mower Local regulations may restrict the age of the operator e Never allow adults unfamiliar with these instructions to operate the lawn mower e Never mow while people especially children or pets are nearby Stop the lawn mower if anyone enters the area e Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the lawn mower and the mowing activity Never assume that children will remain where you last saw them e Keep children out of the mowing area and under the watchful care of a responsible adult e Be alert
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