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Exmark LZ27KC604 User's Manual

1. WINA 0907948 108402 HLIM 038079 38V ADEE HII 04501 S3HOLIMS 108402 NOLLOW TI 18115 E avaa 10HLN09 1081802 2 deg NOLON HT NOLLOW HH Dp 00 38IM Q3M3IA SHOLO3NNOO 3 d ALON 2 2 rh 5 8 8377 F 232 F 8 8 2 F F 8 F m TR S I 8 1HVLS Atx OLI9NVYO LNO HOLMS XOVI8 INid 01398780 NI HOLIMS 320 39 VW LINDHID NOLLISOd N3389 YA 1349 WOLOSNNOO X NONI ann jue ATWNIWYAL ame pA gs EEE Old V TVNIWY3L aionziog FL gt T yovrasonvuo 390 US dui res 8 TWNIWHAL 39Nvu0 0 o S WNINWHAL ameyo y NY 0c a34 39NVHO 1 3505 E E HOLIMS Old H3L3W un OH 0c E 13701A 39 80 3504 HOLIMS Av 130 1 36 X TvNIWH3L NL NOILIN9I 1916 S TYNIWHAL HOLIMS 014 INI9N3 YILIN YNOH TVNIINH3L 1370 9 TVNIINH3L YOLVIN93Y 39 1 0 V TWNIWYSL up 2471 SNOLLO3NNOO 1 1 8 ee H LIMS NOLLINDI X i zm ota HOLIMS AndNIFINGON 7081802 FINGON Moin 1135 ANTIC 1 38 MBA 1135 19 35 NI HOLVHIdO HLIM 099019 SI HOLIMS 122 305 30010 INON A730 1935 G006132 43 Schemat
2. Figure 9 For cutting heights above 3 5 inches 90 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller mounting bracket 2 Cutting height 7 For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 4 mm clearance to the ground Do Not adjust the rollers to support the deck Be sure the whizlock nuts are installed with the spring disc washer between the head of the nut and the mounting bracket Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure that PTO is disengaged Torque the 3 8 16 whizlock nut to 30 35 ft lb 41 47 N m Figure 10 Torque the 3 8 nyloc nut to 30 35 ft lb 41 47 N m 22 Operation G006758 Figure 10 1 Spring disc washer cone towards nut Front right anti scalp bracket shown 3 3 8 nyloc torque to 30 35 ft lb 41 47 N m 3 8 16 whizlock nut torque to 30 35 ft lb 41 47 N m 4 Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain A CAUTION This unit does not have proper turn signals lights reflective
3. 103 5881 CHECK SERVICE REFERENCE AID gt GREASE LUBE POINTS AT INTERVALS SHOWN CHECK HYDRAULIC FLUID AT INTERVAL SHOWN USE ONLY MOBIL 1 15W 50 SYNTHETIC MOTOR OIL 2 SEE ENGINE OPERATOR S MANUAL FOR SERVICING ENGINE 3 CHECKTIRE PRESSURE IN PNEUMATIC TIRES 13 PSI AT INTERVAL SHOWN SEE OPERATORS MANUAL FOR ADDITIONAL DETAILS YEARLY lt UNDER ENGINE DECK 40 HOURS p YEARLY TNI YEARLY YEARLY 40 HOURS 40 HOURS dos st 103 6319 13 avoid loss of control and possibility of rollover N A WARNING A V i TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked position and use seat belt THERE IS NO ROLL OVER PROTECTION WHEN THE ROLL BAR IS DOWN Lower the roll bar only when absolutely necessary Do not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Read and follow slope operation instructions and warnings 107 2102 107 2102 A WARNING Operating on wet grass or steep slopes can cause sliding and loss of control than 15 Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning Do NOT operate near drop offs or near water NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden tur
4. Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer Battery Engine Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are not authorized to handle warranty 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 Pickup and delivery charges to and from any authorized Exmark Service Dealer beyond first warrantable service Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments 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 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 There are no other express warranties except for engine and special emission system coverage stated elsewhere herein or included with the product All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must
5. Note When changing the cutting height positions always come to a complete stop and disengage the PTO G006118 Figure 8 Lever in transport and 5 inch 12 7 cm cutting height position Insert the height adjustment pin into the hole corresponding to the desired cutting height and install the hairpin cotter pin See the decal on the side of the deck lift plate for cut heights Move the deck height lever out of the transport position or 5 inch 12 7 cm cutting height and down onto the height adjustment pin to mow at selected height Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure that PTO is disengaged Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed 1 Stop the machine and move the motion control levers outward to the neutral locked position Disengage the PTO 3 Engage the park brake Stop the engine remove the key and wait for all moving parts to stop After adjusting the height of cut adjust the anti scalp rollers by removing the nyloc nut bushing spring disc washer and whizlock nut 6 Place the rollers in one of the positions shown Figure 9 Rollers will maintain 3 4 inch 19 mm clearance to the ground to minimize gouging and roller wear or damage 1 2 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm ODO
6. SLOW and FAST positions 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine A CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop 20 Operation When levers are centered in the T slot the drive system is in the neutral position With levers moved out in the T slot the drive system is in the neutral lock position Figure 6 2 6006147 6 1 Handles Out Neutral 5 Neutral Lock 2 Handles In Neutral 6 Reverse 3 Front of Unit 7 Neutral Lock 4 Forward Driving Forward 1 Release the parking brake 2 Move the motion control levers inward to the center to the neutral unlocked position To move f
7. Roll Over Protection System ROPS Snow Blade Sun Shade Trash Container Turf Striper Ultra Vac Collection System Ultra Vac Quick Disposal System Walk Behind Accessories Grass Catcher Micro mulch System Steerable Sulky Sulky Hitch Kit Turf Striper Standon Check Us Out On The Web www exmark com 2007 Exmark Mfg Co Inc Part No 4500 246 Rev A 402 223 6300 Br Beatrice NE 68310 Fax 402 223 5489 Rights Reserved Printed in the USA
8. often in dry or dirty cutting height position Lift the front of unit conditions and support unit using jack stands or equivalent support A CAUTION Excessive debris around the engine cooling ait intake and inside of the pump drive belt compartment and damaged or missing A CAUTION Raising the mower deck for service or maintenance relying solely on mechanical ot hydraulic jacks could be dangerous The rubber baffles can cause the engine and mechanical or hydraulic jacks may not be hydraulic system to overheat which can create a fire hazard enough support or may malfunction allowing the unit to fall which could cause injury Clean all debris from inside of pump drive belt compartment daily Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Clean out any grass build up from underside of 2 Clean all debris from rotating engine air intake deck and in discharge chute screen and from around engine shrouding 3 Clean all debris from inside of pump drive belt Waste Di spos al compartment 4 Inspect rubber engine baffles for proper fit Motor Oil Disposal Replace if necessary Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified Remove Engine Shrouds and recycling center or according to your state a
9. Pivots Drive Belt Idler Arm 5 83 4 3 12 5 Brake 1 2 200 Houts Number 6 Mule Drive Belt Idler Arm Located Brackets Under Engine Frame 1 1 Yearly Number 7 Pump Dtive Belt Idler Arm Located Drive Belt Under Engine Frame Idler Arm ET 7 S 3 Lubricate front caster pivots once a year Remove Dui hex plug Thread grease zerk hole and pump with grease until it oozes out around top Idler Arm 2 bearing Remove grease zerk thread plug 1 s 40 Hours in Place cap back on Rear Struts See step for special lubrication instructions on Lubricate Caster Wheel Hubs the front caster pivots and the Lubricate Caster Wheel Hubs section for special lubrication Service Interval Yearly instructions on the front casters wheel hubs 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 9 9006115 2 Figure 13 1 Seal guard 2 Spacer nut with wrench flats 2 Remove caster wheel from caster forks 3 Remove seal guards from the wheel hub 30 Maintenance 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from the wheel assembly 5 Pry out seals and inspect bearings for wear or damage and replace if necessary 6 Pack the bearings wi
10. Type BCI Group U1 Battery Voltage 12 Volt e Polarity Negative Ground e Fuses Two 20 amp blade type Safety Interlock System e PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine Itis not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers ate moved from neutral lock position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levers are adjustable to two heights Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the position of the levers relative to each other Moving motion control levers outward in slots locks the drive system in neutral PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades Parking Brake Lever Engages parking brake Deck Height Adjustment Lever Sets cutting height to desired position Deck Lift Assist Lever Foot pedal that assists in raising the deck Seat Type Standard seat with high back foam padded internal suspension and armrests Optional seat accessories Custom ride suspension system to enhance Standard Seat D
11. add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2007 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 Contact us at www Exmark com Printed in the USA All Rights Reserved EXMARK PARTS PLUS PROGRAM EXMARK PARTS PLUS EFFECTIVE DATE September 1 1995 Program If your Exmark dealer does not have the Exmark part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed How the Program Works 1 If dealer does not have part in stock for a down unit at the time of request by customer the dealer contacts his distributor by 1 00 p m local time and requests Exmark Parts Plus shipment of six 6 line items or less 2 Distributor ships part s to dealer or customer as requested by dealer same day overnight UPS Distributor bills dealer for part and freight charges where applicable 3 If distributor does not have the part s in stock to satisfy 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
12. at one third throttle with brake disengaged move levers in and raise off seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever in engine must initiate shutdown Repeat again moving the right lever in then moving both levers in engine must initiate shutdown whether operator is on seat or not Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check Rollover Protections Systems Roll Bar Pins Service Interval Before each use or daily Make sure latch pin and hair pin are fully installed and lanyard is in good condition Check Seat Belt Service Interval Before each use or daily Visually inspect seat belt for wear cuts and proper operation of retractor and buckle Replace before operating if damaged Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service Air Cleaner Service Interval Every 50 hours Service the air cleaner May need m
13. be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service 45 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 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or 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 read the operator s manual You must also 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 General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement of defective components 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 lia
14. drain the machine indoors or inside an enclosed trailer Do Not fill the fuel tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 inch 6 13 mm below the bottom of the filler neck This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark 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 If fuel is spilled Do Not attempt to start others and cause property damage Always place gasoline containers on the ground 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 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 If a 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 the engine Move
15. forward or backward turns the wheel on the same side forward or in reverse Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position into the T slot locks them in the neutral position Figure 6 Choke Control Located on right fuel tank The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the ON position Throttle Control Located on right fuel tank The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle Brake Lever Located on left side of unit just to the front of the console The brake lever engages a parking 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 The unit must be tied down and brake engaged when transporting Ignition Switch Located on right fuel tank The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwis
16. markings or a slow moving vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not drive a unit on a public street or roadway A WARNING Loading a unit on a trailer or truck increases the possibility of backward tip over Backward tip over could cause serious injury or death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit If individual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward Having a full width ramp provides a sutface for the frame mem
17. prior to mower use 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 of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running Engine looses power PTO is engaged Parking brake is not Drive levers are not in neutral lock position Battery does not have a full charge Electrical connections are corroded loose or faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed Oil level in the crankcase is low The throttle and choke are not in the correct position Dirt in fuel filter Dirt water or stale fuel is in the fuel system Air cleaner is dirty Seat switch is not properly adjusted Electrical connections are corroded loose or faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Engine load is excessive Air cleaner is dirty Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Vent hole in
18. rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position Tighten lock nut Repeat on opposite side of unit 36 _ G006127 F p HIE Eu E 6 5 4 Figure 19 1 Turn bolt here 4 Yoke 2 Levercenteredinnotch 5 Loosen here 3 End of slot 6 Reverse indicator Motion Control Linkage Adjustment A WARNING Engine must be running and drive wheels must be turning so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces A CAUTION Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Maintenance 1 2 This adjustment must be made with the drive wheels turning First raise the frame and block up so that drive wheels can rotate freely Remove the electrical connection from the seat safety switch located directly to the left of the seat switch assembly beside the hydraulic oil reservoir Tempor
19. running Unhook seat latch and tilt seat up to gain access to pumps With a 7 16 inch wrench turn both valves one turn counterclockwise to release drive system Turn clockwise to reset system Do Not overtighten Do Not tow machine PTO Engagement Switch Located on right fuel tank Switch must be pulled out to the ROTATE position to engage the blades Switch is pushed in to the STOP position to stop the blades Pre Start Fill fuel tanks For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Regular grade leaded gasoline may also be used however combustion chamber and cylinder head will require more frequent service See Engine Owner s Manual Do Not add oil to gasoline Do Not overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 inch 13 mm below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Raise the Rollover Protection System ROPS Important Lower the roll bar only when absolutely necessary 1 Remove the hairpin cotter pins and remove the two roll bar pins Figure 5 Raise the roll bar to the upright position and install the two pi
20. the end of engine crankshaft Maintenance Caster wheel spacer nuts Fuel tank bulkhead fitting nuts Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining are used on the following Fuel tank studs where studs are inserted into tank Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations Between the cutter housing spindle and bearings Between the jackshaft and bearings and the jackshaft and sheaves Copper Based Anti seize Copper based anti seize is used in the following location On threads of Blade Bolts See Check Mower Blades section Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 33 Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit Deck Leveling 1 Position mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check tire pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Set anti scalp rollers to top holes or remove them completely for this adjustment 5 Raise the de
21. 4 7 cm Wheel Base Center of Caster Tire to Center of Drive Tire 53 7 inches 136 4 cm Curb Weight 1290 Ib 585 kg Torque Requirements Figure 4 1 Motion Control Lever 5 Controls 2 parking Blake Lever 16 558 Belt Cutter Housing Spindle 140 145 ft lb 190 197 3 Height of Cut Lever 7 Roll Bar Nut N m 4 Fuel Cap Both Sides Blade Mounting Bolt 55 60 ft lb 75 81 N m lubricate with anti seize Engine Deck Front Frame 30 35 ft lb 41 47 N m Mount Bolts Anti Scalp Roller Nyloc 30 35 ft lb 41 47 N m Nut See Figure 10 Anti Scalp Roller Whizlock 30 35 ft lb 41 47 N m Nut See Figure 10 E m Engine Mounting Bolts 30 35 ft lb 41 47 N Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Motor Mounting 72 77 ft lb 98 104 N m Bolts Wheel Hub Slotted Nut minimum 125 ft lb 169 N m Rollover Protection System 30 35 ft lb 41 47 N m Roll Bar Mounting Bolts Deck Drive Jackshaft Nut 75 80 ft lb 102 108 N m Clutch Retaining Bolt 55 60 ft lb 75 81 N m secured with threadlocker 17 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of the machine The levers control the flow of hydraulic oil from the hydrostatic pump to the drive wheel motor for each side Moving the levers
22. For Serial Nos 720 000 amp Higher OPERATORS MANUAL LAZER Z LZ27KC604 MODEL ONLY Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Engine Model No and Spec No Date Purchased Model 1 Engine Serial E No Serial No Part No 4500 246 Rev A AWARNING 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 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 This spark ignition system complies with Canadian ICES 002 Ce syst me 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 Exmark reserves the right to make changes or
23. Locking Adhesives Mobil HTS Grease Or Food Grade AMI SEIZE ibo Hebdos Copper Based Anti seize snnm Dielectric AA c Deck oie eter d apenas 33 Pump Drive Belt Tension eee p tps 34 Mule Drive Belt Tension Adjustment 34 D ck 35 Belt Giudedj stmett su ettet ts 35 Brake Link Adjustments o none 35 Brake Adjustment us erue duet 35 Electric Clutch Adpistrmient uite 36 Reverse Indicator Adjustment 36 Motion Control Linkage Adjustment 36 Motion Control Damper Adjustment 37 Adjust Seat over teens 38 Caster Pivot Bearings Pre Load Adjustment carus ares e eu ene Ou ets 38 ea ue ose icut pe DR AERA TR ER T VM due E 39 Clean Engine Cooling System 39 Remove Engine Shrouds and Clean Cooling iji R P A A EA 39 Clean Grass Build Up Under Deck 39 Waste Disposal oss e e patuit dett 39 Txonbles OG fe 41 SCHeMAHES cheat in Saat aunt aria 43 Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 Safe
24. OP OF BAFFLE HOT SURFACE 1 523552 IMPORTANT BEFORE STARTING ENGINE CLEAN GRASS FROM PUMP DRIVE BELT COMPARTMENT CHECK MORE OFTEN IN DRY CONDITIONS 1 633462 1 633462 1 633706 11 Safety ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm GROUND CLEARANCE i CUTTING HEIGHT r INCHES mm FOR MAXIMUM FLOTATION ROLLERS MAY POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS TO SUPPORT THE MOWER DECK 1 633922 1 633922 BELT ROUTING BLADE BELT 1 643052 72 1 633127 60 1 633366 52 1 643222 1 643222 PUMP BELT ROUTING 1 643339 1 643339 A DANGER COVER IS MISSING DO NOT OPERATE 98 5954 THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 T H R T T L f 103 1798 103 1798 Engine RPM 3750 50 no load 103 3270 103 3270 zo 4 zo Engage and disengage at 1 2 throttle IMPORTANT Before starting engine clean grass from pump drive belt compartment Check more often in dry conditions 103 4474 103 4474 Safety 103 4930 103 4930 ROTATING MECHANICAL DEVICES CAN CAUSE SERIOUS INJURY DO NOT operate without guards in place Stop engine before opening cover 103 5881
25. S 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 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 Whenever you need service genuine Exmark parts or additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 Figure 1 Model and serial number location G006108 Model No Serial No Introduction Safety Safety Alert Symbol ou osito geteilt tisse Safe Operating Practices Contents Safety and Instructional Decals Specifi cati
26. al Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tire pressure in drive tires Inflate drive tires to 13 psi 90 kPa Semi pneumatic caster tires do not need to be inflated Note Do Not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up Lift the rubber flap on front side of the engine to check pump drive belt Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt Check under machine to inspect the mule drive belt See Mule Drive Belt Tension Adjustment section Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 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 Maintenance Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval 0 2 1 Front Yearly Caster Wheel Hubs Caster
27. arily install a jumper wire across the terminals in the connector of the main wiring harness Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature Unhook seat latch and tilt seat forward Loosen lock nuts from the ball joints at each end of the pump control linkage Figure 20 G006128 Figure 20 Left Hand Side of Unit Turn here to adjust 3 Loosen here right hand thread Loosen here left hand thread 7 Start engine Brake must be engaged and 8 motion control levers out to start engine Operator does not have to be in the seat because of the jumper wire being used Run engine at full throttle and release brake The reverse indicator spring must be correct before the following adjustments can be made See the Reverse Indicator Adjustment section Note The motion control lever needs to be in neutral while making any necessary adjustments Bring the motion control lever into the neutral position Adjust pump control rod length by rotating the double nuts on the rod in the 10 1 appropriate direction until the wheels slightly creep in reverse Figure 20 Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral The wheel must stop turning or slightly creep in reverse When adjustment is c
28. ase the deck drive belt idler arm Grease the mule drive belt idler arm Grease the pump drive belt idler arm Lubricate the caster wheel hubs Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery 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 for recommended charger settings 26 Maintenance Maximum Charging Charger Interval Settings 12 6 or 16 volts 7 No greater amps Charging Required 12 4 12 6 75 100 16 volts 7 30 Minutes amps 122 124 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 509 o 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps G006781 Figure 12 11 7 or less 0 14 4 volts 2 6 Hours or 1 Use wrench here for 2 Torque to 55 60 ft Ib a
29. away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use Do Not operate without entire exhaust caution may cause serious injury or illness system in place and in proper working a Avoid prolonged breathing of vapors condition Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Safety Operation A WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire 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 A WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect Operate only in daylight or good artificial li
30. bers to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible 23 Operation Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 24 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A WARNING A WARNING While maintenance or adjustments are being The engine can become very hot Touching made someone could start the engine a hot engine can cause severe burns Accidental starting of the engine could seriously injure you or other bystanders Allow the engine to cool completely before service or making repairs around t
31. bility or responsibility for Expenses related to gasoline oil or lubricants 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 Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty 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 Some states do not allow exclusions of incidental or consequential damages 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 G006117 Service Record Date Description of Work Done Service Done By 46 Fold along appropriate line SD pH MI CIE THIS IS A 5 SLOPE nn HUE PORE 47 Industrial Park Box 808 See Exmark s Complete Line of Accessories Riding Accessories Custom Ride Seat Suspension System Deck Lift Assist Kit Hitch Kit Light Kit Micro mulch System
32. cause drive wheels to slip and cause loss of Do Not mow neat drop offs or neat watet braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution e 1 on slopes Follow the manufacturer s recommendations for wheel weights or counter weights to improve Avoid sudden turns or rapid speed stability changes Use extreme care with grass catchers or attachments These can change the stability of the See inside the back cover to determine the machine and cause loss of control approximate slope angle of the area to be mowed Usea walk behind mower and or a hand trimmer Using the Rollover Protection System neat drop offs ditches steep banks or water ROPS Figure 3 A Rollover Protection System roll bar is installed on the unit A WARNING There is no rollover protection when the roll bar is down Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Keep the roll bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely G000963 Figure 3 necessary 1 Safe Zone Use the 3 Water Do Not wear seat belt when the roll bar mower here on slopes is dowh less than 15 degrees 2 Danger Zone Use a
33. ccurring to himself or herself other people or property Preparation Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark e Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety A DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire or explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or
34. ck to the 5 inch 12 7 cm height position also transport position and take all force off of the two large deck lift springs by loosening the nuts at the front of each spring Figure 14 6 Lower the deck to the 1 1 2 inch 3 81 cm height position 7 Place a 3 4 inch 19 mm thick block of wood under each of the two rear anti scalp roller brackets and place one under one of the front center anti scalp roller brackets 8 Loosen the two top chain bolts in slots in the rear deck lift arms Loosen jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose Turn the socket head adjusting screws in until slack is taken out of each chain Tighten the jam nuts Tighten the chain bolts in the deck lift arms making sure they don t move while tightening 9 Loosen the four nuts which secure the front swivels two per side until the front chains are loose and front of deck is supported by the 3 4 inch 19 mm block Do Not loosen the front chain hardware 10 On left side adjust front swivel using the locking nut behind the swivel until the front chain is tight and all slack is removed from linkage Do Not lift front of deck off 3 4 inch 19 mm block Secure front swivel using locking nut in front of swivel Repeat for right side Recheck that the 3 4 inch 19 mm blocks fit just snugly under the brackets and that the tension on 11 Maintenance N all the chains i
35. d above exists Maintenance between the spring retainer bracket and the adjacent nyloc nut Tighten the jam nut above the trunnion roller If adjustment is necessary loosen the nut directly below the yoke Turn the bottom nut below washer until the correct measurement is obtained see Figure 18 turn nut clockwise to lengthen the gap screws rod into yoke and turn counterclockwise to shorten the gap screws rod out of yoke Tighten nut against yoke and check opposite side of unit repeat if necessary Lengthen or shorten the brake rod until the correct gap can be achieved by following steps 2 and 3 Electric Clutch Adjustment No adjustment necessary Reverse Indicator Adjustment 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat forward 3 Begin with either the left or right motion control lever Move lever to the neutral position and pull lever back until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on spring Figure 19 Check where lever is relative to notch in console should be centered allowing lever to pivot outward to the neutral lock position If adjustment is needed loosen the nut against the yoke and while applying slight rearward pressure on the motion control lever turn the head of the adjustment bolt in the appropriate direction until lever is centered keeping
36. e the mower when people especially children or pets are in the area Be alert slow down and use caution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Slope Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes Safety A DAN GER e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could Operating on wet grass or steep slopes can overturn the machine cause sliding and loss of control Wheels Avoid sudden starts when mowing uphill because dropping over edges ditches steep banks or the mower may tip backwards water can cause rollovers which may result m 1 1 in serious injury death or drowning Be aware that loss of traction may occur going downhill Weight transfer to the front wheels Do Not mow slopes when grass is wet may
37. e to the next position to engage the starter key must be held against spring pressure in this position Note Brake must be engaged motion control levers out neutral lock position PTO switch OFF to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right fuel tank The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If the ignition switch is left on without engine running hour meter will not run Note This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building The valve is located in the fuel line behind and to the right of the seat Rotate the valve 1 4 turn clockwise to shut off fuel Rotate the valve 1 4 turn counterclockwise to turn on fuel Fuel Gauge Located on the left fuel tank The fuel gauge monitors the amount of fuel in both tanks Fuel is used evenly from both tanks 18 Operation Drive Wheel Release Valves Located on the top right front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine
38. eluxe suspension seat with high back low profile foam in place cushion dampened adjustable spring suspension and armrests Mounting Hinged to tilt up for access to hydraulic pumps battery and other components Held in tilted position with prop rod Adjustable fore and aft seat track e Armrests Standard seat foam padded flip up armrests 15 Specifications Optional suspension seat molded adjustable flip up armrests Seat Safety Switch Incorporated into the Safety Interlock System Time delay seat switch eliminates rough ground cut outs Hydrostatic Ground Drive System Hydrostatic Pumps Two Hydro Gear variable displacement piston pumps Wheel Motors Two Parker with 1 1 4 inch tapered shafts Hydraulic Oil Type Use Mobil 1 15W 50 Synthetic motor oil Hydraulic Oil Capacity 2 1 qt 2 0 L Hydraulic Filter Replaceable cartridge type Summer use above 32 F 0 C P N 109 4180 25 microns 10 psi bypass Winter use below 32 F 0 C P N 1 523541 40 microns 18 psi bypass Speeds 0 9 8 mph 15 8 km hr forward 0 6 3 mph 10 1 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running Tires amp Wheels pe Rescue Pneumatic Air Filled Smooth Semi Pneumatic Multi Trac C S Cutting Deck Cutting Width 60 inch 152 4 cm Discharge S
39. ght keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Use seat belts Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mowet After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage patking brake Before refueling Before dumping the grass catcher A WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts NEVER carry passengers DO NOT operat
40. he engine Remove the key from the ignition switch area engage parking brake 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 Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil After the first 100 hours Ch he wheel hub slotted nut torque specifications Ch he wheel lug nuts h eck t eck t After the first 250 hours ange the hydraulic filter eck t he engine oil level heck the mower blades heck the safety interlock system heck the rollover protections systems roll bar pins heck the seat belt heck for loose hardware ean the engine cooling system ean the grass build up from under the deck Check the hydraulic oil level Check the tire pressures Every 40 hours Check the condition of the belts Grease the height adjustment shaft bearings Grease the rear deck struts Service the air cleaner May need more often under severe conditions See the Engine Every 50 hours MR Owner s Manual for additional information Every 80 hours Remove the engine shrouds and clean the cooling fins Every 100 hours Change the engine oil May need more often under severe conditions Lubricate the brake handle pivot Lubricate the brake rod bushings Every 160 hours Lubricate the motion cont
41. hen the center of the bolt head is at or below the center of the bottom alignment hole When adjustment is necessary loosen the idler pulley on the right hand side so it can move up and down in the slot Place a wrench on the 3 8 inch nut in the center of the spring loaded pulley and apply upward pressure to relieve tension on the spring a 1 2 inch drive breaker bar and 9 16 inch socket works best Reposition the adjusting pulley to the bottom of the slot Note When installing a new belt it is necessary to reposition the right adjusting pulley upward in the slot in order to position the center of the spring loaded pulley between the alignment holes 1 1 G006782 Figure 15 Front of unit 2 Alignment holes 34 Maintenance 1 N G06783 Figure 16 3 Right side idler pulley adjustable Spring idler pulley 2 Front of unit Deck Belt Tension Self tensioning No adjustment necessary Belt Guide Adjustment 1 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove the belt shield on the right side of mower deck Note belt guide bolted to deck near the shield support stud and right hand pulley Guide should be 1 8 inch 3 2 mm away from the belt with bolt end of guide near end of slot Figure 17 If adjustment is necessary loosen the bolt
42. ics Hydraulic Diagram AS VIEWED FROM REAR OF UNIT e e e HIGH PRESSURE HIGH PRESSURE HIGH PRESSURE FORWARD Ow FORWARD REVERSE Ac 6 9 HIGH PRESSURE 9 REVERSE HIGH PRESSURE CHARGE PUMP INLET CASE DRAIN 0006791 44 2 Year Limited Warranty Exmark Turf Equipment For units purchased on or after October 1 2004 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 for a period of two years This warranty applies to Exmark turf equipment purchased on or after October 1 2004 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 All Products except as noted below 2 years All Attachments and Accessories 1 year Metro 21 and Metro 26 Series 1 year
43. ide Blade Size 3 ea 20 50 inches 52 1 cm Blade Spindles Solid steel spindles with 1 inch 25 4 mm bearings Deck Drive Electric clutch mounted on horizontal engine shaft Section belt with self tensioning idler from electric clutch to transfer shaft mounted on deck Blades are driven by one B Section belt w self tensioning idler from transfer shaft on deck to blade spindles Deck Full floating deck is attached to out front support frame Six anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge Deck Depth 5 5 inches 14 0 cm Cutting Height Adjustment An extra long cushioned lever is used to adjust the cutting height from 1 1 2 inch 3 8 cm to 5 inches 12 7 cm in 1 4 inch 6 4 mm increments The cutting height adjustment handle has a transport position and all adjustments can be made while the operator remains seated Units also have a foot operated deck lift assist lever to aid in raising the deck Mulching Kit Optional Dimensions Overall Width Without Deck 53 5 inches 135 9 cm Deflector Up 61 4 inches 156 0 cm Overall Length Roll Bar Up 81 9 inches 208 0 cm Roll Bar Down 92 6 inches 235 2 cm Product Overview IU Product Overview Tread Width Center to Center of Tires Widthwise Drive Wheels 41 9 inches 106 4 cm Caster Wheels 37 3 inches 9
44. ire pressure in the drive tires Adjust the reverse indicator and the motion control linkage Tighten the bypass valve Change the belt Change the belt Replace the spring Add hydraulic fluid to reservoir or let it cool down Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to rear Clean the underside of the mower Adjust tire pressure in the drive tires Contact an Authorized Service Dealer Replace blades spindles and or check for damage to mower deck Install new cutting blade s Tighten the blade mounting bolt Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Contact an Authorized Service Dealer Check the belt tension Install drive belt and check adjusting shafts and belt guides for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Replace the spring Schematics Schematics Electrical Diagram NOILISOd 3907 TV HLNIN NI
45. mps More blade installation This 75 81 N m Apply nut has been torqued to lubricant to threads 140 145 ft lb 190 197 as needed to prevent N m seizing Copper based Check Mower Blades anti seize preferable Grease acceptable substitute Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake C Apply lubricant to threads of blade bolt as d e needed to prevent seizing Copper based 2 Lift deck and secure in raised position as stated in anti seize preferable Grease acceptable the Clean Grass Build Up Under Deck section substitute Install blade bolt finger tight Place wrench on the top spindle nut then torque the Inspect blades and sharpen or replace as required blade bolts to 55 60 ft lb 75 81 N m 4 Reinstall the blades if they were removed in the following order A WARNING A Install bushing through blade with bushing flange on bottom grass side of blade Incorrect installation of the blade or components used to retain the blade can be dangerous Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death Always install the original Exmark blades blade bushings and blade bolts as shown G006780 1 Figure 11 1 Install bushing in blade prior to installing bushing in Check Safety Interl
46. n choke to the OFF position as the engine warms up Engaging the PTO A DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged A DANGER An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle to the MIDWAY position 2 Pull the PTO switch outward to the ROTATE position 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle to the MIDWAY position 2 Push the PTO switch in to the STOP position to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Disengage the PTO 3 Move the motion control levers out to the neutral lock position 4 Engage the parking brake 5 Place the throttle midway between the
47. nd local Clean Cooling Fins regulations Service Interval Every 80 hours Battery Disposal 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake A DANGER 2 Remove cooling shroud clean out covers from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns 3 Make sure cooling shroud clean out covers are reinstalled Operating the engine without cooling shroud clean out covers will cause engine damage due to overheating e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte Maintenance 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 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 40 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition
48. ner s Manual Maintenance Change Fuel Filter Service Interval As required A fuel filter is installed between the fuel tanks and the engine Replace when necessary Replacement Filters Kohler Kohler P N 2405010 Change Hydraulic System Filter Service Interval After the first 250 hours Yearly thereafter Note Use only Exmark Part No 109 4180 for summer use above 32 F 0 C or Part No 1 523541 for winter use below 32 F 0 C 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise seat Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system 4 Unscrew filter to remove and allow oil to drain from reservoir Important Before reinstalling new filter fill it 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 then tighten the filter an additional 2 3 to 3 4 turn 5 Fill reservoir as stated in Check Hydraulic Oil Level section 6 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 7 Start engine and move throttle control ahead to full throttle position Move the speed control levers to the full speed and run for several minutes Shut down machine and recheck oil level Note Do Not change hydraulic system oil except fo
49. ns MT ET Model Numbers did e ER eM RP tns Bini Torque Requirements Product Overview seed yah E A mede d a as i PEGS SEAEE Operating Instructions onere Trans POR g onie aa Meo MNA Maintenance nonora Recommended Maintenance Schedule s Periodic Maintenance dee Check Engine Oil Check Battery Check Mower Blades Check Safety Interlock System Check Rollover Protections Systems Roll Bar Pin S ces cade etae dv anda ts Check Seat Belti Check for Loose Hardware Service Air Cleaner pes Change Engine Check Hydraulic Check Tire Pressures vedo bn Check Condition Of Lubricate Grease FittifigS Labricate Caster Wheel Lubricate Brake Handle Pivot Lubricate Brake Rod Bushings Lubricate Motion Control Bronze Busines oe cedo cede i qui Lubricate Seat Switch Actuator Check Spark pt hd Change Hydraulic System Filter Wheel Hub Slotted Nut Torque Sp cif cati n piod cau Duae ai Thread
50. ns and secure them with the hairpin cotter pins Figure 5 Important Always use the seat belt with the roll bar in the raised position Ensure that the rear part of the seat is secured with the seat latch G006159 Figure 5 3 Pin 4 Hairpin cotter pin 1 Roll bar 2 Raised position Open the Fuel Shut Off Valve The fuel shut off valve is located in the fuel line behind and to the right or left of the seat Rotate the valve 1 4 turn counterclockwise to turn on fuel Starting the Engine 1 Move the motion control levers out to the neutral lock position 2 Pull up and back on the parking brake lever to engage the parking brake 3 Push in on the PTO switch to the STOP position Note It is not necessary for the operator to be in the seat to start the engine 19 Operation Place the throttle midway between the SLOW and FAST positions On a cold engine push the choke lever forward into the ON position On warm engine leave the choke in the OFF position Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the ON position gradually retur
51. ns or rapid speed changes There is no rollover protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warning 107 2112 WARNING To avoid serious injury or death Read and understand the operator s manual before using this machine Do NOT operate unless trained to safely use this machine Do NOT operate under the influence of alcohol or drugs Do NOT operate without shields guards and safety devices in place and working Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system Stop engine and remove key before adjusting servicing or cleaning machine and attachments Hearing protection is recommended ENGAGE 109 1214 109 1214 Lubricate Blade Bolt threads with copper based antiseize or grease and torque to 55 60 ft lbs 75 81 N m 109 3148 109 3148 Ya DANGER To avoid serious injury or death Avoid blades unless engine and blade are stopped WARNING To avoid serious injury or death Pick up objects that could be thrown by the blades Do NOT mow when people and pets are in the area Do NOT carry passengers Look behind and to the side before changing directions CUTTING HEIGHT Mil 109 1215 Before leaving the operator s position Disengage PTO Move drive levers o
52. ock spindle System B Install bushing blade assembly into spindle Service Interval Before each use or daily Note To prevent engine cut outs on rough terrain the seat kill switch has a 1 2 second delay 27 Maintenance 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank 2 Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise offof seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Run engine
53. oil change 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 1 2 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks Check Hydraulic Oil Level Service Interval Every 40 hours 1 Stop engine and wait for all moving parts to stop Engage parking brake Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use only Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Note The baffle is labeled and COLD The oil level varies with the temperature of the oil The HOT level shows 29 the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level Check Tire Pressures Service Interv
54. omplete tighten lock nuts onto ball joints Adjustment for the RH motion control lever Bring the RH motion control lever into the neutral position Adjust the RH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral The wheel must stop turning or slightly creep in reverse Figure 21 Figure 21 Right Hand Side of Unit Loosen here right hand 3 Loosen here left hand thread thread 2 Turn here to adjust 11 Shut off unit Remove jumper wire from wire harness connector and plug connector into seat switch Motion Control Damper Adjustment The top damper mounting bolt can be adjusted to obtain a more desired motion control levet resistance See Figure 22 for mounting options 37 Maintenance Caster Pivot Bearings Pre Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1 4 of a turn to properly set the pre load on the bearings If disassembled make sure the spring disc washers are reinstalled as shown in Figure 23 Figure 22 Motion control bracket Least resistance softest feel Medium resistance medium feel Most resistance fi
55. on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil Lubricate Brake Rod Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up Lar a Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings Lubricate Motion Control Bronze Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up 3 Lubricate bronze bushings on flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant Lubricate Seat Switch Actuator Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up Lubricate switch actuator rod with spray type lubricant or light oil Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Ow
56. ore often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Unhook seat latch and tilt seat up to gain access to the air cleaner 3 Loosen retaining clips and remove air cleaner compartment cover B Remove paper element Check the condition of the paper element Replace if dirty bent or damaged 5 Check the condition of the inner element Replace whenever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine Maintenance 6 Do Not wash or use pressurized air to clean paper element or inner element Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change Engine Oil Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first May need more often under severe conditions Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Drain oil while engine is warm from operation The oil drain hose is located on right hand side of engine Place pan under machine to catch oil Remove plug from end of drain hose Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft lb 27 33 N m Replace the oil filter every other
57. orward in a straight line apply equal forward pressure to both levers To turn left or right pull the motion control lever back toward neutral in the direction desired The machine will move faster the farther the motion control levers are moved away from neutral To stop pull the motion control levers back to the neutral position d 2 5 4 a Figure 7 1 Handles Out Neutral 4 Forward Lock 2 Handles In Neutral 5 Reverse 3 Front of Unit Driving in Reverse 1 Move the motion control levers inward to the center to the neutral unlocked position 2 move rearward in a straight line applying equal pressure pull both motion control levers rearward To turn left or right release pressure on the motion control lever toward the direction desired 3 stop push the motion control levers to the neutral position Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 1 2 to 5 inches 3 8 cm to 12 7 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position Disengage the PTO Raise the deck height lever to the transport position also the 5 inch 12 7 cm cutting height position Figure 8 The deck can be raised by pulling the deck lever up and or by pushing down on the foot operated 21 Operation deck lift assist lever located at the front right corner of the floor pan
58. pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate Engine load is excessive Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Tracking needs adjustment Tire pressure in drive tires not correct Reverse indicator and motion control linkage need adjustment Bypass valve is not closed tight Drive or pump belt is worn loose or broken Drive or pump belt is off a pulley Broken or missing idler spring Hydraulic fluid level is low or too hot Blade s not sharp Cutting blade s is are bent Mower deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Cutting blade s is are bent or unbalanced Blade mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Drive belt is worn loose or broken Drive belt is off pulley Deck belt is worn loose or broken Deck belt is off pulley Broken or missing idler spring 42 Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust the tracking Adjust t
59. r what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Wheel Hub Slotted Nut Torque Specification Service Interval After the first 100 hours Every 500 hours thereafter When tightening the slotted nut on the wheel motor tapered shaft 1 Torque the slotted nut to 125 ft lb 169 N m 2 Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 inch or less should be showing 3 If more than two threads 0 1 inch are showing remove nut and install washer P N 1 523157 between hub and nut 4 Torque the slotted nut to 125 ft lb 169 N m 5 Then tighten nut until the next set of slots line up with the cross hole in shaft 6 Replace cotter pin Note Do Not use anti seize on wheel hub Fuel Tank Mounting Hardware Specifications Service Interval As required When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners Pump drive sheave set screws Square head setscrews on Hydro pump control arms Sheave retaining bolt in
60. rmest feel Torque nyloc nut to 200 in Ib 16 7 ft lb Bolt must 1 protrude past end of nyloc nut after torque Damper Damper must move freely on bolt Adjust Seat Switch EI 1 G006131 I If necessary adjust the seat actuator rod length Figure 23 to where the machine will shut off when the 1 Spring disc washers operator raises off the seat with brake disengaged ot PTO engaged but will continue to run with operator in seat a slight shift in weight should not shut machine off Normal adjustment is when length of spring is 2 09 inches 5 3 cm with seat up Note To prevent the engine from cutting out when operating over rough ground the unit is equipped with a time delayed seat switch When the operator raises off the seat with either the brake disengaged or the PTO engaged the engine should stop after 1 2 second has elapsed To adjust seat switch actuator rod length loosen lock nut on bottom of the actuator rod 5 16 x 7 inch bolt and adjust the nuts to move the actuator plate washer up or down on the rod then retighten 38 Maintenance Cleaning E Grass Build Up Under ec Clean Engine Cooling Service Interval Before each use or daily System 1 Stop engine wait for all moving parts to stop and key E king brake Service Interval Before each use or daily MER EC d Sumas qure May be required more 2 Raise deck to the transport 5 inch 12 7 cm
61. rol bronze bushings e Lubricate the seat switch actuator Check the spark plugs n Before each use or daily 25 Maintenance Maintenance Service Maintenance Procedure Interval Every 200 hours Grease the brake brackets Check the wheel hub slotted nut torque specifications bey oho Check the wheel lug nuts Grease front caster pivots Yearly Periodic Maintenance Change the hydraulic filter Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving parts to stop Make sure unit is on a level surface Check with engine cold 3 Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level 4 Ifthe oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval Monthly AWARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Gre
62. 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 for the part and freight if it fails to arrive overnight in accordance to the program A Under any circumstance the customer does not pay B If the part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 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 continen
63. s approximately equal Make sure all chain attachment bolts are tight Reposition anti scalp rollers and tighten securely NOUV 1 2 4 3 o o IN 8 6 G006122 5 7 maa Figure 14 Apply downward pressure here Place locking pliers here to hold spring 10 1 2 inches 26 7 cm Remove force on deck springs by loosening nuts here Swivel Front of unit Socket head adjusting screw Jam nut Raise deck lift lever to the 5 inch 12 7 cm cutting height position Figure 8 Adjust spring compression until proper distance is obtained between the two large washers Figure 14 Adjustment is made by turning the nut at the front of each spring clockwise will shorten the spring counterclockwise will lengthen the spring Lock in position with jam nuts Note When above adjustments have been made the front of the deck will be slightly lower than the reat of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary Mule Drive Belt Tension Adjustment Self tensioning idler adjust as follows 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Check to make sure the center of the bolt head in the center of the spring loaded pulley on left side engine deck support is positioned between the centers of the two alignment holes in the left support plate Figure 15 and Figure 16 It is necessary to adjust the belt tension w
64. securing the belt guide and make proper adjustment Tighten hardware 1 8 inch G006125 Figure 17 End of slot 2 Belt guide 35 Brake Link Adjustment Check to make sure brake is adjusted propetly 1 2 Disengage brake lever lever down Measure the length of the spring Measurement should be 2 3 4 inches 7 0 cm between washers Figure 18 If adjustment is necessary tighten the nut directly below the yoke and loosen the bottom nut bottom one of the two tightened together below the spring Turn the nut directly below the washer top nut of the two tightened together until the correct measurement is obtained Tighten the two nuts together and repeat on opposite side of unit Turn clockwise to shorten spring length and turn counterclockwise to lengthen the spring Figure 18 Lever down 6 Yoke disengaged Lever up engaged 7 Lock nut 1 4 to 5 16 inch 6 4 to 8 Spring adjustment 7 9 mm Collar 9 23 4 inches 7 0 cm Trunnion roller Brake Adjustment 1 Check for brake link 2 3 4 inches 7 0 cm measurement as described in the Brake Link Adjustment section Engage the brake lever lever up The space between the trunnion roller and the rod collar should measure 1 4 inch to 5 16 inch 6 4 7 9 mm If adjustment is necessary loosen nut above the trunnion roller Adjust the nyloc nut under the trunnion roller until distance liste
65. t and negative last Use care when checking blades Wrap the blade s ot wear gloves and use caution when servicing them Only replace blades Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as ot equivalent to the parts supplied as original equipment 10 A WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury 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 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 not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic sys
66. tal United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by 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 Introduction 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 This manual contains operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN IT
67. tem by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible 4 WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 KEEP HANDS and FEET AWAY 1 403005 ES NO STEP 1 513742 1 513742 A CAUTION DO NOT OPERATE WITHOUT GUARD IN PLACE 1 513748 1 513748 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 ait bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower HYDRAULIC OIL USE ONLY MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILL TO T
68. th a NGLI grade 1 multi purpose grease 7 Insert one bearing one new seal into the wheel Note Seals Exmark P N 103 0063 must be replaced 8 If the axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do Not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 With the open end of the wheel facing up fill the atea inside the wheel around the axle full of NGLI grade 1 multi purpose grease 11 Insert the second bearing and new seal into the wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward 13 Torque the nut to 75 80 in Ib 8 9 N m loosen then re torque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut 14 Reinstall the seal guards over the wheel hub and insert wheel into caster fork Reinstall caster bolt and tighten nut fully Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque
69. the fuel cap is plugged Dirt in fuel filter Dirt water or stale fuel is in the fuel system 41 Disengage the PTO Set the parking brake Ensure the drive levers are in the neutral lock position Charge the battery Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Fill the fuel tank Open the fuel shutoff valve Add oil to the crankcase Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Adjust the seat switch Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mower
70. ty alert symbol 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 White lettering Red background Indicates an imminently hazardous situation which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator e The owner usert can prevent and is responsible for accidents or injuries o
71. ut to neutral lock position Engage park brake Stop engine 109 1215 MOTION CONTROL 4 WARNING Led Torque Wheel Lug Nuts to 90 95 ft Ibs 122 129 N m Check after first Torque Wheel Hub Slotted Nut to 125 ft Ibs 169 N m min 100 hrs then every See Operator s Manual for more details 500 hrs thereafter 109 7949 109 7949 MOTION CONTROL 103 9255 lt DRIVE WHEEL RELEASE Battery contains sulfuric acid Avoid contact and always shield eyes face skin and clothing from battery Cigarettes flames or sparks could 103 9255 cause battery to explode Do not charge or use booster cables or adjust post connections without proper training In event of an accident flush with water immediately Keep out of reach of children One turn counterclockwise to release Do not over tighten 14 Specifications Specifications Model Numbers Serial Nos 720 000 and Higher LZ27KC604 Systems Engine Engine Specifications See your Engine Owners Manual RPM Full Speed 3750 50 RPM No Load Idle 1500 RPM Fuel System e Capacity 13 5 gal 51 0 L Type of Fuel Regular unleaded gasoline 87 octane or higher Fuel Filter In line 15 Micron Kohler P N 2405010 Fuel Shut Off Valve 1 4 turn increments Fuel gauge left hand fuel tank Electrical System Charging System Flywheel Alternator Charging Capacity 15 amps Battery
72. walk Drive slowly and carefully behind mower and or 7 hand trimmer near Raise the roll bar as soon as clearance drop offs and water permits Remove or mark obstacles such as rocks tree Check carefully for overhead clearances i e limbs etc from the mowing area Tall grass can branches doorways and electrical wires before hide obstacles driving under any objects and do not contact them Safety Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine engine area and pump drive belt compartment free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and do not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive firs

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