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Exmark Lazer ZHP User's Manual

1. LLL 0 A38 D THN 0 ama j ge ono Old 6 08 Bd 1 1 Qxo 34118 SNS m 313 ama 20 ANH n 38 INAI JONO 009 0 MOTA 1111 ds 137014 2220 a AME aL T3 A881311338 014 JAA GLrI DLINS INS tes ANANI 3TTQUH 1735 E L L1 INOW 30010 FODH 1895 ABO 1185 1135 NI MOLVSSdD 095079 ST HOLINS ONG O3N3IA SAOLISNNOI A38 UL 39NVaU XVIBONNId OL IDNYAD NI T8 19915 A X INON 350 1 3AVW 1119819 NOILISOd WNIRSSL X WNIWSL 8 NIHIL N ius NOTLINOI HOLINS Old 313 WNIWQAL A30 1995 X WNIMGHL AY HS 18 15 S WNINSIL HOLINS B3134 I WNIANAL 8 SOLYTNSY 39V 110A Y SNOTLJ3NND2 HJLIMS NDOILINSI 1 ELECTRICAL DIAGRAM KOHLER UNITS NOLITSOd 2001 WALNIN NI SH3A31 TUBING 035010 SSHILINS 703140 NOTLOW 090103 Dia
2. 50 55 ft Ibs 68 75 N m Engine Mounting Bolts 2 222222 2 15 20 ft Ibs 20 27 N m Wheel Motor Mounting 72 77 ft lbs 98 104 N m Wheel Hub Slotted Nut minimum1 25 ft lbs 169 N m WheglEUc NING iet 90 95 ft lbs 122 129 N m Rollover Protection System Roll Bar Mounting Bolts 30 35 ft lbs 41 47 N m Clutch Retaining Bolt secured with threadlocker 55 60 ft lbs 75 81 N m 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE MOWER 3 2 INSTALL ROLLOVER PROTECTION SYSTEM ROLL BAR 3 2 1 Disassemble roll bar from the crate a Remove roll bar tubes from sides of crate and remove screws that attach the wheel hub retaining plate to the bottom of the crate b Remove the two brackets used to mount the bottom of the upper roll bar tube to the crate Remove the 1 2 13 x 3 1 4 capscrews and 1 2 13 hex flange lock nuts from the two brackets at each end of the upper roll bar tube and retain for later use ec 3 2 2 3 2 3 3 2 4 3 2 5 Raise the rear of the unit and support it with jack stands or equivalent support CAUTION POTENTIAL HAZARD Raising the rear of the unit for assembly relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction all
3. and use seat belt C PART NO 107 2112 WARNING 4 and follow rollover protection instructions and warning LOCATION Top Center of Floorpan DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE A CAUTION 103 2644 GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT MUFFLER AND SHIELDS MAY REMOVE GRASS CATCHER UNTIL EXCEED 150 F BLADES HAVE STOPPED 1 513746 1 303508 CR LOCATION Rear of Engine LOCATION Front Right Corner CONTROL Deck Left and Top of Mower Deck CONTROL Right Sides jeld eyes face skin and st connections without proper training In event of an accident flush with water immediately Keep out of reach of children gt CEES 108 5995 LOCATION of Console Under Seat ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm FRONT OF GROUND CLEARANCE 1 413093 44 MOWER 1 413308 48 CUTTING HEIGHT STATIONARY 1 653368 52 mm FOR MAXIMUM FLOTATION ROLLERS MAY BE POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM 1 653477 OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION PART NO 103 0262 PART NO 1 653477 W ROLLERS TO SUPPORT THE MOWER DECK iem LOCATION Below Center of LOCATION Left of Center on Mower PART NO 1 633922 Deck Under Floor Pan LOCATION Front Left Corner Top o
4. 2 3 DO NOT USE WRENCH HERE FOR BLADE INSTALLATION THIS NUT HAS BEEN TORQUED TO 140 145 1 08 190 197 N m AND SECURED WITH THREADLOCKER FRONT OR REAR 5560fdbs 07541840 ll BAFFLES amp BLADE FIGURE 7 BLADE BOLT INSTALLATION IMPORTANT DO NOT use components other than the original blade blade bushing spring disc washer and blade bolt supplied with the unit Failure to use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or weak after striking a foreign object 25 SPLINED BUSHING JH TORQUE TO BLOCK OF WOOD BETWEEN 5 1 6 POTENTIAL HAZARD CAUTION Operating mower deck with loose weakened blade bolts can be dangerous WHAT CAN HAPPEN causing serious injury or property damage A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck HOW TO AVOID THE HAZARD Always re install original Exmark blades blade bushings spring disc washers and blade bolts in the correct positions as shown Check safety interlock system Service Interval Daily 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
5. E y avoid serious ERE PARK AWARNING Do NOT operate unless trained to safely use this machine To avoid serious injury or death Do NOT operate under the influence of alcohol or drugs Pick up objects that could be thrown by the blades p Do NOT operate without shields guards and safely devices lt Do NOT mow when people and pets are in the area La in place and working Do NOT carry passengers Check the function of the operator presence controls OPC Look behind and to the side before changing directions safety system daily Do NOT defeat the OPC system Disengage PTO ENGAGE Move drive levers out to neutral lock position Hearing protection is recommended Engage park brake Stop engine PART NO 103 4891 Read and understand the operator s manual before using machine Q Before leaving operator s position Stop engine and remove key before adjusting servicing or cleaning machine and attachments EN Jim CUTTING HEIGHT 103 4891 LOCATION Center of Console NO STEP COVER IS MISSING DO NOT OPERATE 98 5954 THIS UNIT WHEN COVER IS NOT IN PLACE DO NOT OPERATE WITHOUT GUARD CAUTION PART NO 1 T VARI S ALI 17 LOCATION Under Mower Deck LOCATION On Top of Mower Belt Shield s PART NO 1 513748 Deck Belt Shields Left and Right Sides LOCATIONS Bottom of Floorpan HYDRAULIC OIL U
6. 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 Check 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 stop after approx 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 off of seat but do not get off of machine engine must stop after 1 2 second has elapsed Run engine at one third throttle with brake disengaged move levers in and raise off seat but do not get off of machine engine must stop after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever in engine must stop Repeat again moving the right lever in then moving both levers in engine must stop 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 co
7. 55 ft lbs 68 75 N m 32 60266 o ANTI SCALP ROLLER H 7 MOUNTING BRACKET SPRING DISC WASHER TOWARDS BOLT HEAD FRONT LEFT ANTI SCALP CUTTING HEIGHT BRACKET SHOWN Se INCHES mm a AEN O gt 2 0 51 2 5 64 z O 3 0 76 1 10 3 5 90 TYPE B 3 6 24 x 2 GR8 S TORQUE TO 50 55 fHbs 68 75 N m j FOR CUTTING HEIGHTS ABOVE 3 5 38 mm A 3 8 WHIZLOCK TORQUE 40 45 ft4bs 54 61 N m USE THE BOTTOM HOLE THE ROLLERS WILL B 3 8 NYLOC TORQUE 30 35 ftdbs 41 47 N m STILL BE EFFECTIVE AGAINST SCALPING 5 2 2 a b ANTI SCALP ROLLER INSTALLATION ANTI SCALP ROLLER ADJUSTMENT FIGURE 10 ANTI SCALP ROLLER ADJUSTMENT Deck Leveling Position mower on a flat surface Stop engine wait for all moving parts to stop and remove key Check tire pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Semi Pneumatic caster tires do not need to be inflated Set anti scalp rollers to top holes or remove them completely for this adjustment Raise the deck to the 4 5 11 4 cm height position and take as much force as possible off of the two large deck lift springs by loosening the nuts at the front of each spring See Figure 11 Lower the deck to the 1 1 2 3 8 cm height position Place two 1 5 16 8 3 cm thick blocks under th
8. Parts Plus order he contacts Exmark by 3 00 p m central time with an Exmark Parts Plus order of six 6 line items or less 4 If order is received by 3 00 p m central time Exmark ships part s direct to dealer or customer as requested by distributor same day overnight UPS Exmark bills the distributor for parts and shipping charges where applicable 5 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program 6 Who pays 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 Ifthe part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 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
9. battery Ventilate when charging or using battery an enclosed space Make sure venting path of battery is always open once battery is filled with acid 15 3 3 2 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Percent Maximum Reading Charge Charger Settings Cuarging 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 7596 16 volts 7 amps 1 Hour 12 0 12 2 25 5096 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 096 14 4 volts 2 amps 6 Hours or More CAUTION POTENTIAL HAZARD If the ignition is in the position there is potential for sparks and engagement of components WHAT CAN HAPPEN Sparks could cause an explosion or moving parts could accidentally engage causing personal injury HOW TO AVOID THE HAZARD Besure ignition switch is in the OFF position before charging the
10. battery 3 3 3 Connect the negative battery cables NOTE If the positive cable is also disconnected connect the positive red cable to the positive battery terminal first then the negative black cable and green white wire to the negative battery terminal Slip insulator boot over the positive terminal NOTE If time does not permit charging the battery or if charging equipment is not available connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery EIS M WARNING BATTERY CON NS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN 3 4 INSTALL DRIVE WHEELS 3 4 1 Mount drive wheels with the valve stem to the outside of the unit Secure using four 4 1 2 20 wheel nuts installed on studs in hubs for each wheel Torque to 95 ft lbs 128 N M 3 5 CHECK TIRE PRESSURE 3 5 1 Check tire pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Semi Pneumatic caster tires do not need to be inflated 3 6 INSTALL SEAT 3 6 1 a Remove seat assembly from the crate 16 b Remove the f
11. fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling c Make sure cooling shroud clean out covers or cooling shrouds are reinstalled Operating the engine without cooling shroud clean out covers or cooling shrouds will cause engine damage due to overheating Check spark plugs Service Interval 160 hrs a Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Owners Manual Change fuel filter Service Interval As Required a A fuel filter is installed between the fuel tanks and the engine Replace when necessary For Kohler engines use Kohler P N 2405002 For Kawasaki engines use Kawasaki P N 49019 7001 Change hydraulic system filter Service Interval After First 250 hrs Then yearly thereafter NOTE Use only Exmark Part No 1 513211 for Summer use above 32 F 0 C or Part No 1 523541 for Winter use below 32 F 0 C a Stop engine wait for all moving parts to stop and remove key b Locate filter under right rear corner of engine deck c Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system d Unscrew filter to remove and allow oil to drain from reservoir 30 5 1 24 5 1 25 5 1 26 5 1 27 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 the filter clockwise until rubbe
12. grass or steep slopes can cause sliding and loss of control WHAT CAN HAPPEN Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning HOW TO AVOID THE HAZARD 999 Do not mow slopes when grass is wet Do not mow near drop offs or near water Do not mow slopes greater than 15 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes 1 4 5 See inside the back cover to determine the approximate slope angle of the area to be mowed e Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water This area can be dangerous see Figure 1 Safe Zone G0075 Figure 1 SAFE ZONE FOR MOWING Progressively greater care is needed as the slope increases e Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Avoid sudden starts when mowing uphill Mower tip backwards e aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Remove mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can h
13. operation instructions and warnings 107 2102 M 7 Upper Roll bar PART NO 1 653147 LOCATION Lefthand Side of Cutting Height Adjustment Plate Torque Blade Bolts to 55 60 ft Ibs 75 81 N m 103 7491 4 103 7491 LOCATION On LH Side of Mower Deck LHP4419KA LHP4819KA 4820 4823 LHP5220KC LHP5223KC LHP5223KA 2 2 ENGINE 2 2 1 2 2 2 Engine Specifications See Your Engine Owner s Manual RPM Full Speed 3600 RPM No Load Idle 1500 RPM 10 2 3 FUEL SYSTEM 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 Capacity 11 2 gal 42 L Type of Fuel Regular unleaded gasoline 87 octane or higher Fuel Filter For Kohler Replaceable in line 15 Micron Kohler P N 2405002 For Kawasaki Replaceable in line Kawasaki P N 49019 2075 Fuel Shut Off Valve 1 4 turn increments left tank OFF right tank Fuel gauge in left hand fuel tank 2 4 ELECTRICAL SYSTEM 2 4 1 Charging System Flywheel Alternator 2 4 2 Charging Capacity 15 amps 2 4 3 Battery Type BCI Group U1 2 4 4 X Battery Voltage 12 Volt 2 4 5 Polarity Negative Ground 2 4 6 Fuses Two 20 amp blade type 247 Safety Interlock System PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is 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 co
14. section using the two 1 2 13 x 3 1 4 capscrews from step b and two 1 2 13 hex flange lock nuts Do not over tighten Make sure upper roll bar can pivot freely Notes e sure the capscrew and nuts are installed with the nut to the inside of the roll bar sure the tab on the lanyard washer is installed as shown and points toward the front of the unit d Torque all lower roll bar hardware attached to the machine frame to 30 ft Ibs 41 47 N m e Tighten the front knobs against the upper roll bar ends 2 1243X314 DEM UPPER ROLL CAPSCREW BAR TUBE X LATCH PIN 1 ASSEMBLY Yu APPLY OIL TO INSIDE SURFACE OF EAR SHAPED PLATES 1 2213 HEX FLANGE LOCK NUTS e LATCH PIN ASSEMBLY LAVA 1 243 X3 1 4 D M CAPSCREW 60087 FIGURE 3 UPPER ROLL BAR INSTALLATION 3 3 SERVICE BATTERY WARNING Battery posts terminals and related accessories contain lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling The machine is shipped with a filled lead acid battery 3 3 1 Unhook seat latch and tilt seat up to gain access to the battery DANGER POTENTIAL HAZARD Charging the battery may produce explosive gasses WHAT CAN HAPPEN Battery gasses can explode causing serious injury HOW TO AVOID THE HAZARD Keep sparks flames or cigarettes away from
15. straight line Movement of the lever forward will cause the left drive wheel to rotate in a forward direction Movement of the right lever forward will cause the right drive wheel to rotate in a forward direction To stop forward travel pull the levers back to the neutral position To turn left while moving forward move the left lever back toward neutral to slow the left drive wheel To turn right while moving forward move the right lever back toward neutral to slow the right drive wheel To make a zero turn to the left pull the left lever back beyond neutral while holding the right lever slightly ahead of neutral To make a zero turn to the right pull the right lever back beyond neutral while holding the left lever slightly ahead of neutral 18 Pulling the levers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction spring tension can be felt when moving into reverse from neutral To turn to the left while backing move the left lever forward toward neutral To turn to the right while backing move the right lever forward toward neutral CAUTION POTENTIAL HAZARD Machine can spin very rapidly by positioning one lever too much ahead of the other WHAT CAN HAPPEN Operator may lose control of the machine which may cause damage to the machine or injury HOW TO AVOID THE HAZARD Use caution when making turns Slow the machine down before making sharp turns Trac
16. submitted on this program Monday through Thursday Parts Plus service is available only in the 48 contiguous United States UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exmark by 3 00 p m central time Orders must be six 6 line items orless Exclusions from the Exmark Parts Plus Program are Any wholegood or accessory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions Due to UPS restrictions aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air Exmark Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free op
17. 2 SPECIFICATIONS 2 1 Model 2 e esae FR echa EAR 10 CAE ii MEME 10 Fuel Syste PET 11 24 Electrical 11 25 Operator 11 2 02 M C DR Ea E 11 12 27 Hydrostatic Ground Drive 12 28 Mires 12 29 Cutting boe eee rt bere te riter 12 2 10 DIMENSIONS inquies unte es onm inate neto 13 2 11 Torque Hequirembhlss si ore bae sedes 13 3 ASSEMBLY INSTRUCTIONS 3 1 Uncrate MOWOP eoe E eL B DL LE 13 3 2 Install Rollover Protection System Roll Bar 13 15 3 3 BIVICO Ballet be 15 16 3 4 Install Drive 004224220 16 3 5 Check Tire 2 an en es E 16 3 6 cuem NE 16 17 3 7 Install Motion Control Levers 444 17 3 8 Position Discharge Chute eret 17 3 9 Service Engine x carci ee ee 17 310 Service Olio etit 18 4 OPERATION INSTRUCTIONS 20011852 25 48060 52 44 5253 16 2 ees OR Oen 18 20 2 2 POSSE edi o
18. 455 X um 18415 5 WNIWYAL E E Bo E aR 5 EE 8 HOLIMS Old JILIN WNIWSIL AMALLYE AOLVINIIY 30 171 3 m 00 2 1123 02 Ld Ham HILINS 37100 377003 30010 3100W M JNO 1935 RENTES ATO 1035 ABO 1835 11035 095010 SI HILIMS 9 HYDRAULIC DIAGRAM 71 HIGH PRESSURE P HIGH PRESSURE FORWARD REVERSE BYPASS VALVE FRONT OF UNIT FILTER HYDRAULIC TANK _ HIGH PRESSURE FORWARD HIGH PRESSURE E CHARGE PUMP INLET L _ HIGH PRESSURE CASE DRAIN L PENNE G0052 10 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
19. 9 NOTE When changing cutting height positions always come to a complete stop and disengage the PTO LEVER IN TRANSPORT AND 4 5 11 4 cm CUTTING HEIGHT POSITION FIGURE 9 CUTTING HEIGHT POSITION d Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter See decal on deck lift plate e Move lever out of transport or 4 5 11 4 cm cutting height position and down onto height adjustment pin to mow at selected height f Totransport move lever back up to transport or 4 5 11 4 cm cutting height position 0 Adjust anti scalp rollers for Normal Operating Conditions Place rollers in one of the positions shown in Figure 10 Rollers will maintain 3 4 in 19 mm clearance to the ground to minimize gouging and roller wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts and nuts are installed with the spring disc washer between head of the bolt and mounting bracket Two types of anti scalp roller assemblies are available See Figure 10 to determine which assembly has been installed on the unit Torque hardware as specified or loss of roller may result Type A Torque the 3 8 whizlock nut to 40 45 ft lbs 54 61 N m Type B Torque the 3 8 nyloc nut to 30 35 ft Ibs 41 47 N m Torque the 3 8 24 2 Gr 8 hex capscrew to 50
20. DWA AYER j 09970 p 195 va 1 e NOTION NOLON Und zm 59 SRR BOS 236 E ri ON3 5301 338107 E GE 5 20 8 881107 7 EAAREE a m Bie 22 D pkg 5 A38 DL IONAD HOLINS oy OBANA DL OND NE HOLTS SDN JNIUN3 D 06 541948 13118 JLIHA OR I 9 NIS ng HOLS J33NW LINDAID NOILISOd 200p 32Nfa PNAD 1 OIBNSTDS 34115 ABWYD INA NER a X WNIRGI m PT K ER E ma oo DWAD 5 XN 1 SEL ig i J SN 1 TWNIWSSL WL 000 is wk dj Mum 10 an IDNA i Cn HOLIMS Old 313 TWWNIWAAL AYTHO 1
21. ENT 5 2 7 Brake Adjustment a Check for brake link 2 75 7 0 cm measurement as described in section 5 2 6 b Engage brake lever lever up c Measure the distance between the trunion roller and the rod collar as shown in Figure 9A Measurement should be 3 16 4 8 mm to 1 4 6 4 mm See Figure 12 A 3 16 or 1 4 square key works well as a shim gauge d 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 12 turn nut clockwise to lengthen the gap screws rod into yoke and turn counter clockwise to shorten the gap screws rod out of yoke Tighten nut against yoke and check opposite side of unit repeat if necessary 5 2 8 Adjust Throttle Lever Tension a Stop engine wait for all moving parts to stop and remove key b Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt which is located under the console See Figure 13 LEVER TAB WASHER BELLEVILLE WASHERS FRICTION WASHERS FIGURE 13 THROTTLE TENSION 5 2 9 Electric Clutch Adjustment No adjustment necessary 5 2 10 Reverse Indicator Adjustment a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat forward 35 5 2 11 Oo 2 2 f Begin with either the left or right motion control lever Move lever to the neutral position and pul
22. ENT KNOB 6 DO NOT LOOSEN ANY NUTS ON LH SIDE 90046 FIGURE 15 LH MOTION CONTROL ADJUSTMENT 97 j Shutoff unit Remove jumper wire from wire harness connector and plug connector into seat switch 5 2 12 Caster pivot bearings pre load adjustment a Remove dust cap from caster and tighten 11 nyloc nut until washers are flat and back off 1 4 of a turn to properly set the pre SPRING load on the bearings If disassembled TL WEE make sure the spring washers are reinstalled as shown in Figure 16 60091 FIGURE 16 CASTER ADJUSTMENT 5 2 13 Seat armrest adjustment a Lift armrest on seat Locate square tab marked with the numbers 1 through 4 Rotate square tab 1 4 turn to raise or lower the armrest in approximately 1 4 6 4 mm increments See Figure 17 Armrest Adjustment We Rotate Turn FIGURE 17 2 WASTE Bion ARMREST ADJUSTMENT 6 1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 6 2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and cl
23. For Serial Nos 540 000 amp Higher 1 lt L gt E 22 C MFG CO INC LAZER CONGRATULATIONS on the purchase of your new Exmark mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic Service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the part number description and quantity of the part needed The Serial No plate is located on the right side of the console For ease of ordering and reference we suggest that you record the information requested in the following identification table Place Model No and Serial No Label Here Engine Model No and Spec No Code Included in Literature Pack or Fill in Below Engine Serial No E No Model No Date Purchased Serial No Part No 103 9182 WARNING POTENTIAL HAZARD This product is a piece of power equipment WHAT CAN HAPPEN Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD Keep all shields guards and safety devices especially the grass discharge system in place and in proper working condition Stop engin
24. NT PLATE TO THE REAR amp OUTSIDE OF ARM SHAFT FIGURE 4 FIGURE 5 CONTROL ARM SHAFT LEVER ALIGNMENT b If the ends of the levers hit against each other while in the drive position levers rotated in as far as possible make adjustments by moving the levers outwards to the neutral lock position and carefully bending them outward Move them back to the drive position and check for clearance repeat if necessary 3 8 POSITION DISCHARGE CHUTE 3 8 1 Loosen two 2 5 16 nyloc nuts attaching discharge chute Lower the discharge chute into position Retighten nyloc nuts until chute is snug but can pivot freely 3 9 SERVICE ENGINE Engine is shipped with oil check oil level and if necessary fill to the appropriate level with SAE 10W 30 or 10W 40 AP1 service class SF or SG for operating in temperatures above 0 F 18 C See Engine Operator s Manual 17 3 10 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reservoir Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do not overtighten NOTE The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C Th
25. ON CHART LOCATIONS PUMPS PLACES INTERVAL 2 2 See 5 1 14 Section c for special lubrication instructions on the front caster pivots and Section 5 1 15 for special lubrication instructions on the front caster wheel hubs No 6 Pump Drive Belt Idler Arm ui ba 45 Located Under Engine Frame Grease through hole in top of engine frame between pumps C Lubricate front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thread plug back in Place cap back on 28 5 1 15 Lubricate caster wheel hubs 5 1 16 5 1 17 Service Interval Once Yearly a Stop engine wait for all moving parts to stop and remove key b Remove caster wheel from caster forks C Remove seal guards from the wheel hub Ex 22 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has pem been applied to lock the spacer nuts to 221 the axle Remove the axle with the a other spacer nut still assembled to it from the wheel assembly SPACER NUT WITH WRENCH FLATS e Pry out seals and inspect bearings for wear or damage and replace if FIGURE 8 necessary CASTER WHEEL ASSEMBLY f Pack the bearings with NGLI grade 1 multi purpose grease 0 Insert 1 beari
26. OT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support D Oo 22 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 Temporarily install a jumper wire across the terminals in the connector of the 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 RH pump control linkage See Figure 14 36 f NOTE The nuts to the rear of the unit on each rod have left hand threads REVERSE TURN BOLT INDICATOR qo 7 5 SLOT LOOSEN O O HERE TI 5 O YOKE 6 TURN HERE LOOSEN HERE LOOSEN HERE TO ADJUST RIGHTHAND THREAD LEFTHAND THREAD RH MOTION CONTROL ADJUSTMENT Start engine Brake must be engaged and 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
27. 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 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 124 Avoid mowing while people especially children or pets are nearby Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property 1 3 PREPARATION 1 3 1 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark 1 3 2 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended CAUTION POTENTIAL HAZARD This machine produces s
28. 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 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 Maintenance Section 5 and perform all the necessary inspection and maintenance steps 4 3 MOWING 4 3 1 4 3 2 Operate units with the roll bar in the raised and locked position and use seat belt There is no rollover protection when the roll bar is down If it is necessary to lower roll bar do not wear the seat belt Raise the roll bar as soon as clearance permits Open fuel shut off valve left or right tank 20 4 3 3 4 3 4 4 3 5 4 3 6 Starting Engine Brake must be engaged the PTO switch disengaged and the motion control levers out neutral lock position The operator does not need to be in the seat to start the engine On a cold engine place the throttle midway between the SLOW and FAST positions and push choke lever forward to the ON 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 10 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
29. R TO INSTALLING BUSHING IN SPINDLE 4 b Raise deck to the transport 4 5 11 4cm cutting height position Lift the front of unit and support unit using jack stands or equivalent support CAUTION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Clean out any grass build up from underside of deck and in discharge chute Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 5 1 4 C Inspect blades and sharpen or replace as required d Re install the blades if they were removed in the following order See Figure 7 1 Install bushing through blade with bushing flange on bottom grass side of blade 2 Install bushing blade combo into spindle 3 Install blade bolt and spring disc washer Be sure the spring disc washer cone is installed towards the bolt head Place a block of wood between front or rear baffles and the blade then torque the blade bolts to 55 60 ft Ibs 75 81 N m
30. SE ONLY 4 ROLLER 2 BUSHING m 3 SPRING WASHER J 4 318 16 X4 BOLT 5 MOUNT BRACKET 6 FLAT WASHER MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILLTO TOP OF BAFFLE KEEP HANDS and FEET AWAY 7 WHIZLOCK NUT 37 MUST BE GRADE 8 BOLT AND WASHERS MUST 222222222 SURFACE BE INSTALLED AS SHOWN _ INDIAGRAM TORQUE NUT 1 323540 71 TO 35 45 FT LBS 1 523552 Type Anti Scalp Rollers Only EGG ATI su d PART NO 1 403005 See Figure 10 LOCATION Left and Right Corners PART NO 1 323540 of Mower Deck LOCATION Left Front Corner WARNING Hot exhaust components may A WARNING ignite fuel or debris Fire or explosion may occur Operating on wet grass or steep slopes can cause sliding resulting in property damage and loss of control SS Wheels dropping over edges can cause rollovers which M may result in serious injury death or drowning To avoid loss of control and possibility of rollover Do NOT operate near drop offs or near water tareata personal injury or death Do NOT operate on slopes greater than 15 Do not operate without entire exhaust system in place Reduce speed and use extreme caution on slopes Avoid sudden turns rapid speed changes PART NO 103 2644 and in proper working condition There is no roll over protection when the roll bar is down LOCATION Top of Hydraulic Always keep roll bar in the raised and locked position Reservoir
31. T a Make sure battery is at a full charge b Besure 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 c Make sure there is fuel in the fuel tank and that the fuel valve is open d Be sure the seat switch is properly adjusted See Section 5 2 5 e Make sure the parking brake is set and motion control levers are moved out neutral lock position f Check that the PTO is disengaged h Check that the spark plug wires are properly connected i Check for loose or faulty wiring connections j Check for corrosion at all wiring connections Even minor corrosion may cause a faulty connection Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect NOTE When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors NOTE After carefully checking the above steps attempt to start the engine If it does not start contact your authorized Exmark service dealer IMPORTANT It is essential that all operator safety mechanisms be connected and in proper operating condition 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 item
32. TO AVOID THE HAZARD Allow the engine to cool completely before service or making repairs around the engine area 5 1 PERIODIC MAINTENANCE 5 1 1 Check engine oil level Service Interval Daily a Stop engine wait for all moving parts to stop and make sure unit is on a level surface b Check with engine cold Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick Do not screw into place Remove the dipstick and read the oil level 98 5 1 2 d If the oil level is low add to bring the oil level up to the FULL mark the dipstick Use oil as specified in the 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 Clean engine air cooling system Service Interval Daily or more often in dry conditions CAUTION POTENTIAL HAZARD Excessive debris can cause the engine and hydraulic system to overheat WHAT CAN HAPPEN Excessive debris around the engine cooling air intake and inside of the pump compartment can create a fire hazard HOW TO AVOID THE HAZARD Clean all debris from around the engine and hydraulic pumps daily a Stop engine wait for all moving parts to stop and remove key b Clean all debris from rotating engine air intake screen and from around engine shrouding Check battery charge Service Interval Monthly Allo
33. ally the muffler become extremely hot WHAT CAN HAPPEN Severe burns can occur on contact Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land A WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts 1 4 1 1 4 2 1 4 3 1 4 4 Give complete undivided attention to the job at hand Mow only in daylight or good artificial light Keeping away from holes and hidden hazards NEVER carry passengers DO NOT operate the mower when children or others are in the area When feasible avoid operating the equipment in wet grass Use EXTREME caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes DANGER POTENTIAL HAZARD Mowing on wet
34. any shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we shall have no liability or responsibility for e Expenses related to gasoline oil or lubricants e Travel time overtime after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer e Rental of like or similar replacement equipment during the period of any warranty repair or replacement work e Any telephone or telegram charges or travel charges e Loss or damage to person or property other than that covered by the terms of this warranty e claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment which is the subject of this warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an imp
35. before the following adjustments can be made See Section 5 2 10 NOTE The motion control lever needs to be in neutral while making any necessary adjustments The left rod assembly controls the left wheel and the right rod assembly controls the right wheel Bring the RH motion control lever into the neutral position Adjust RH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse See Figure 14 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 complete tighten lock nuts onto ball joints Bring the LH motion control lever into the neutral position Adjust the LH pump control rod length by rotating the tracking adjustment knob 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 See Figure 15 L LEFT SIDE OF 9 UNIT SHOWN 2 dioe 4 emg 2 f TURN LH TRACKING ID ADJUSTM
36. 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 Series 1 year Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer e 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 e Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance e repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replace
37. can burn out the starter motor After starting a cold engine gradually return choke to the OFF position as the engine warms up On a warm engine place the throttle midway between the SLOW and FAST positions and leave the choke in the OFF position Engaging PTO DANGER POTENTIAL HAZARD The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower deck when the blades are engaged DANGER POTENTIAL HAZARD Anuncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur WHAT CAN HAPPEN Thrown objects or blade contact can cause serious injury or death HOW TO AVOID THE HAZARD 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 clutch push pull switch engages the cutting blades Be sure that all persons are clear of mower deck and discharge area before engaging PTO IMPORTANT Operator must be in seat before the PTO can be engaged Set throttle to midway position Pull outward on the switch to the ROTATE position Accelerate to full throttle to begin mowing Stopping PTO Set the throttle to the midway position Push in on the switch to t
38. dhesive Lubricate seat switch actuator Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up C Lubricate switch actuator rod with spray type lubricant or light oil Lubricate brake handle pivot Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key 29 5 1 18 5 1 19 5 1 20 5 1 21 5 1 22 5 1 23 b Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil Lubricate brake rod bushings Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up C Lubricate bronze bushings on each end of brake rod shafts with a spray type lubricant or a light oil One shaft is located under the console The other is below and behind the seat Lubricate motion control bronze bushings Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up C Lubricate bronze bushings on flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant Remove engine shrouds and clean cooling fins Service Interval 80 hrs a Stop engine wait for all moving parts to stop and remove key b Remove cooling shroud clean out covers Kohler or cooling shrouds Kawasaki Air cooled from engine and clean cooling
39. e 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 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 4 OPERATION INSTRUCTIONS 4 1 CONTROLS 4 1 1 4 1 2 Familiarize yourself with all controls before operating the mower Motion Control Levers Located on each side of the console The left lever controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor The right lever controls the flow of hydraulic oil from the right hydrostatic pump to the right drive wheel motor 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 kill 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 See Figure 6 FRONT OF FORWARD UNIT HANDLES Mu NEUTRAL NEUTRAL LOCK HANDLES OUT REVERSE RIGHT SIDE NEUTRAL LOCK SHOWN G0048 FIGURE 6 MOTION CONTROL POSITIONS By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a
40. e 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 Keep engine engine area and hydraulic pump area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Store fuel in a container specifically designed for this purpose in a cool dry place Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly Check all bolts frequently to maintain proper tightness Keep all guards shields and all safety devices in place and in safe working condition Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as or equivalent to the parts supplied as original equipment WARNING POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrate skin and cause injury WHAT CAN HAPPEN Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor
41. e and wait for all moving parts to stop Remove spark plug wire s or remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 002 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
42. e 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 such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners a Pump drive sheave setscrews b Square head setscrews on Hydro pump control arms Sheave retaining bolt in the end of engine crankshaft d Caster wheel spacer nuts See Section 5 1 16 e Fueltank bulkhead fitting threads f Cutter housing spindle nut Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining or Retaining are used on the following b Fueltank studs where studs are inserted into tank Mobil HTS grease or food grade antisieze is used in the following locations a Between the cutter housing spindle and bearings b Between the cutter housing spindle and sheave c Under top cutter housing bearing guard 31 5 1 28 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 5 2 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine wait for all moving parts to stop and remove key before servicing cleaning or making adjustments to the unit 5 2 1 Cutting Height Adjustment a Stop machine and move drive levers out to neutral lock position b Disengage PTO c Raise the deck lever to the transport position also the 4 5 11 4 cm cutting height position See Figure
43. e operator may be subject to traffic tickets and or fines HOW TO AVOID THE HAZARD Do drive a unit on a public street or roadway A WARNING POTENTIAL HAZARD Loading a unit on a trailer or truck increases the possibility of backward tip over WHAT CAN HAPPEN Backward tip over of the unit could cause serious injury or death HOW TO AVOID THE HAZARD 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 22 4 4 2 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 surface for the frame members to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough indi
44. e rear edge of the cutting deck skirt one on each side of the cutting deck Place a 1 1 8 2 9 cm block under the center front edge but not under the anti scalp roller brackets For units with a socket head adjusting screw and slotted hole in rear deck lift arm Loosen the two 2 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 when pressure is applied to force rear deck support arms down See figure 11 Continue to press down on rear deck support arms and 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 do not move while tightening For units without a socket head adjusting screw and slotted hole in rear deck lift arm Loosen the two 2 bottom chain bolts in slots at the rear of the cutting deck Press down on the rear deck support arm as shown in Figure 11 While holding the rear deck support arm down take the slack out of the rear chains and tighten hardware at the bottom of the rear chains Loosen four 4 nuts which secure front swivels two per side until front chains are loose and front of deck is supported by the 1 1 8 2 9 cm block Do not loosen front chain hardware ug 60095 5 2 3 5 2 4 5 2 5 5 2 6 On left side adjust front swivel using the locking nut behind the swive
45. eration OPERATOR S MANUAL This manual contains assembly operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance TABLE CONTENTS 1 SAFETY PAGE 11 Safety Alert Symbol tee ee eR EE end 1 527 esiste A i ose 1 135 qe eror eio eae ee pofito fatta 1 3 T4 2 4 a 4 7 1 5 Maintenance amp Storage etit ee tee ru aga 7 8 1 5 ION IR 8 10
46. f Mower Deck 9 CHECK SERVICE REFERENCE AID lt GREASE LUBE POINTS AT INTERVALS SHOWN CHECK HYDRAULIC FLUID AT INTERVAL SHOWN USE ONLY MOBIL 1 15W 50 SYNTHETIC MOTOR OIL SEE ENGINE OPERATOR S MANUAL FOR SERVICING ENGINE 3 CHECK TIRE PRESSURE IN PNEUMATIC TIRES 13 PSI AT INTERVAL SHOWN SEE OPERATORS MANUAL FOR ADDITIONAL DETAILS 40 HOURS 40HouRs 3 lt gt 9200 HOURS 2440 HOURS 2 YEARLY 40 HOURS lt 4 YEARLY YEARLY vey 40 HOURS 40 HOURS AUS eae PART NO 103 6340 LOCATION Bottom Side of Floor Pan 111 exmark 103 4892 PART NO 103 4930 LOCATION Right of Choke Control on RH Fuel Tank PART NO 103 4892 LOCATION Right of Throttle Control on RH Fuel Tank 2 SPECIFICATIONS 2 1 MODEL NUMBER Serial Nos 510 000 amp Higher PART NO 107 2102 LOCATION Inside Surface of A WARNING TO AVOID INJURY OR DEATH FROM ROLLOVER Engage and disengage at 1 2 throttle OFF a P an T 0 Keep roll bar in the G N 0 raised and locked N 103 4903 PART NO 103 4903 LOCATION Top Front of RH Fuel Tank PROTECTION WHEN THE ROLL BAR IS DOWN Lower the roll bar 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
47. familiar with this form of injury or gangrene may result HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are 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 system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system 1 6 SAFETY SIGNS 1 6 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels 1 6 2 Safety signs must be replaced if they are missing or illegible 1 6 3 When new components are installed be sure that current safety signs are affixed to the replaced components 1 6 4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc 1 6 5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles 1 6 6 Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower RELEASE 5 DANGER ath n less engine and blades are slopped
48. he STOP position stopping the PTO Stopping Engine Bring unit to a full stop Disengage the PTO move motion control levers out to the neutral lock position and engage parking brake 21 Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engine Rotate ignition switch to DFF position Remove the key to prevent children or other unauthorized persons from starting engine Close fuel shut off valve when machine will not be used for a few days when transporting and when the unit is parked inside a building 4 4 TRANSPORTING 4 4 1 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 CAUTION POTENTIAL HAZARD This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem These items are required to drive on a public street or roadway WHAT CAN HAPPEN 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 th
49. ide obstacles Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control e Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability A Rollover Protection System roll bar is installed on the unit WARNING POTENTIAL HAZARD 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 999 HOW TO AVOID THE HAZARD Keep the roll bar in the raised and locked position and use seat belt 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 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 1 4 15 Becertain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water e Check carefully for overhead clearances i e branches doorways and electrical wires before driving under any objects and do not contact them Use EXTREME caution when backing up LOOK BEHIND YOU Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Never operate the mower with defective gua
50. iner rather than from a gasoline dispenser nozzle lfagasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete A WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks or hot engine exhaust components WHAT CAN HAPPEN Explosion and fire may occur resulting in property damage personal injury and or death HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer to prevent build up of gasoline vapors especially at floor level Refuel only outdoors never inside an enclosed trailer Be sure all fuel tanks and gasoline storage containers have proper caps installed to prevent spillage and minimize vapor escaping into the trailer Do not place any equipment that is leaking gasoline in an enclosed trailer 1 4 OPERATION Although hazard control and accident prevention partially are dependent upon the design and configuration of the equipment these factors are also dependent upon the awareness concern prudence and proper training of the personnel involved in the operation transport maintenance and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing WARNING POTENTIAL HAZARD Operating engine parts especi
51. king Adjustment Knob Located under the seat on the LH pump control link Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position Stop machine and wait for all moving parts to stop Engage park brake Unhook seat latch and tilt seat forward to gain access to the tracking knob Rotate the knob counter clockwise as viewed from the rear of the machine to cause the machine to track more to the right and clockwise to cause the machine to track more to the left Adjust in quarter turn increments until the machine tracks straight Check that the machine does not creep when in neutral with the park brakes disengaged IMPORTANT Do not rotate the knob too far as this may cause the machine to creep in neutral Refer to section 5 2 11 for control linkage adjustment PTO Engagement Switch Located on the 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 Choke Control Located on the right fuel tank Choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the position and moving the choke lever to the rear will put the choke in the OFF position DO NOT run a warm engine with choke in the position Throttle Control Located on the right fuel tank Throttle is used to control engine speed Moving thro
52. l before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Don not operate without entire exhaust system in place and in proper working condition DANGER POTENTIAL HAZARD Incertain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN static charge can ignite gasoline vapors A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD Purchase and store gasoline only an approved container Always place gasoline containers on the ground away from your vehicle before filling Do 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 conta
53. l lever back until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on spring See Figure 14 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 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 Motion control linkage adjustment A WARNING POTENTIAL HAZARD Engine must be running and drive wheels must be turning so motion control adjustment can be performed WHAT CAN HAPPEN Contact with moving parts or hot surfaces may cause personal injury HOW TO AVOID THE HAZARD Keep fingers hands and clothing clear of rotating components and hot surfaces POTENTIAL HAZARD Raising the mower deck for service or maintenance CAUTION relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DON
54. l until the front chain is tight and all slack is removed from linkage Do not lift front of deck off 1 1 8 2 9 cm block Secure front swivel using locking nut in front of swivel Repeat for right side 10 1 2 26 7 cm for 44 deck 10 25 4 cm for 48 deck 9 1 2 24 1 cm for 52 deck Adjust Front Deck Apply Downward Height Here Pressure X gt 2 Swivel EU B Adjust Spring 9 Mec CSS Jam Nut K Tension Here AO NS See Step g Front Socket Head of Adjusting Screw Slotted Hole Unit See Step h See Step g FIGURE 11 SWIVEL ADJUSTMENT m SPRING COMPRESSION ADJUSTMENT Recheck that blocks fit just snugly under the deck skirt and that the tension on all the chains are approximately equal Make sure all chain attachment bolts are tight Raise deck lift lever to the 4 5 11 4 cm cutting height position also transport position See Figure 9 Adjust spring compression until proper distance is obtained between the two washers See Figure 11 by turning the nut at the front of each spring Lock nuts in position with jam nuts Reposition anti scalp rollers and tighten securely NOTE When above adjustments have been made the front of the deck will be slightly lower than the rear of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary Deck Belt Tension Self tensioning No adjustment necessary Adjust Seat Swi
55. 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 27 5 1 12 Check tire pressures Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Check tire pressure in drive tires c Inflate drive tires to 13 psi 90 kPa d 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 5 1 13 Check condition of belts Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Check under engine deck to check pump drive belt c Remove left and right belt shields on deck and lift out floor pan to inspect deck drive belt d See Sections 5 2 3 and 5 2 4 for belt adjustment 5 1 14 Lubricate grease fittings Service Interval Refer to chart a Stop engine wait for all moving parts to stop and remove key b Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule LUBRICATI
56. lied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state SERVICE RECORD Service 45 ALIGN THIS EDGE WITH VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC FOLD ALONG APPROPRIATE LINE LE COMPARE SLOPE WITH FOLDED 46 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 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 Check us out on the Web www exmark com WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1997 2005 CO INC PART 103 9182 INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 ALL RIGHTS RESERVED FAX 402 223 5489 ark MFG CO INC PRINTED IN U S A
57. ment parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or serviceQexmark com 44 Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense As a condition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Comp
58. n 122 4 cm 58 1 in 147 6 cm w 52 Deck 47 9 in 121 7 cm 54 7 in 138 9 cm 63 2 in 160 5 cm 2 10 2 Overall Length w 44 Deck w 48 Deck w 52 Deck Roll Bar Up 74 1 in 188 2 74 1 in 188 2 cm 77 3 in 196 3 cm Roll Bar Down 80 2 in 203 7 80 2 in 203 7 83 4 in 211 8 cm 2 10 3 Overall Height Roll Bar Up Roll Bar Down 69 4 in 176 3 cm 51 3 in 130 3 cm 2 10 4 Tread Width center to center of tires widthwise w 44 Deck w 48 Deck w 52 Deck Drive Wheels 34 4 in 87 4 36 4 in 92 5 cm 38 4 in 97 5 cm Front Casters 32 2in 81 8 cm 322 in 81 8 cm 34 6 in 87 9 cm 2 10 5 Wheel Base center of caster tire to center of drive tire 44 amp 48 Decks w 52 Deck 45 9 in 116 6 cm 47 2 in 119 9 cm 2 10 6 Curb Weight w 44 Deck w 48 Deck w 52 Deck 963 Ibs 437 kg 983 lbs 446 1103 Ibs 500 kg Note Weight will vary slightly depending on engine option 2 11 TORQUE REQUIREMENTS Bolt Location Torque Cutter Housing Spindle Nut secured with threadlocker 140 145 ft Ibs 190 197 N m Blade Mounting Boll ior bitte Prts 55 60 ft Ibs 75 81 N m Engine Deck Front Frame Mount Bolts 30 35 ft lbs 41 47 N m Anti Scalp Roller See Figure 10 Type WhiZlock 40 45 ft lbs 54 61 N m B Nyloc NUL er tree tete ec 30 35 ft Ibs 41 47 N m Type Hex
59. n a Stop engine wait for all moving parts to stop and remove key b Drain oil while engine is warm from operation C Oil drain valve is located on left hand side of Kohler engine and right hand side of Kawasaki engine Place pan under machine to catch oil and open valve with 10 mm wrench Allow oil to drain then close valve d Replace the oil filter every other 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 2 3 to 3 4 turn e 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 f Start the engine and check for leaks Stop engine and recheck oil level Check hydraulic oil level Service Interval 40 hr a Stop engine and wait for all moving parts to stop b 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 HOT and COLD The oil level varies with the temperature of the oil The level shows the level of oil when it is at 225 F 107 C The COLD level shows the
60. ng 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced h Ifthe axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to 1 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 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut i Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing With the open end of the wheel facing up fill the area inside the wheel around the axle full of NGLI grade 1 multi purpose grease k Insert the second bearing and new seal into the wheel l Apply a thread locking adhesive to the 2 spacer nut and thread onto the axle with the wrench flats facing outward m Torque the nut to 75 80 106 8 9 N m loosen then re torque to 20 25 in Ibs 2 3 N m Make sure axle does not extend beyond either nut n Rerinstall the seal guards over the wheel hub and insert wheel into caster fork Re install 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 on spacer nut until there is a slight amount of drag Re apply threadlocking a
61. nnected and in proper operating condition prior to use for mowing Check rollover protections systems roll bar pins Service Interval Daily Make sure latch pin and hair pin are fully installed and lanyard is in good condition 26 5 1 10 5 1 11 Check for loose hardware Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service Interval 50 hrs More often under severe conditions See Engine manual for additional information a Stop engine wait for all moving parts to stop and remove key b Loosen retaining clips and remove air cleaner compartment cover c Remove paper element Check the condition of the paper element Replace if dirty bent or damaged d Allunits except 17HP Kawasaki 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 DO NOT wash or use pressurized air to clean paper element or inner element f Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change engine oil Service Interval 100 hrs NOTE Change oil and filter after first five 5 hrs of operatio
62. ntrol levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged 2 5 OPERATOR CONTROLS 2 5 1 Steering and Motion Control 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 Motion control levers are adjustable to two heights 2 5 2 PTO Switch Engages electric clutch to drive belt which engages mower blades 2 5 3 Parking Brake Lever Engages parking brakes 2 5 4 Deck Height Adjustment Lever Sets cutting height to desired position 255 Deck Lift Assist Lever standard on 48 amp 52 units optional accessory for 44 units Foot pedal that assists in raising the deck 2 6 SEAT 2 6 1 Type Standard seat high back foam padded internal spring suspension with arm rests Optional seat accessories Custom ride suspension system to enhance Standard Seat Deluxe suspension seat with high back low profile foam in place cushion dampened adjustable spring suspension and armrests 2 6 2 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 11 2 6 3 2 6 4 Armrests Standard sea
63. operation Do Not mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Be aware of the mower discharge and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision If jump starting is required connect the positive power cable from the positive post on the booster battery to the positive terminal post on the starter solenoid switch this post has the positive battery cable attached to it b connect the negative or ground cable from the negative post on the booster battery to any engine deck ground preferably the engine block as far away from the battery as possible C disconnect battery cables in the reverse order after starting 1 5 MAINTENANCE AND STORAGE 1 5 1 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 59 1 5 10 1 5 11 1 5 12 For engine maintenance follow the engine manufacturer s recommendations precisely as stated in the engine manual Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use 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 lif
64. othing when handling electrolyte Do not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is 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 238 7 TROUBLE SHOOTING 7 1 MOWER PULLS LEFT OR RIGHT W LEVERS FULLY FORWARD a Refer to Tracking Adjustment Section 4 1 3 b Check air pressure in drive tires 13 psi Semi pneumatic casters do not require inflation C Check reverse indicator and motion control linkage adjustment See Section 5 2 10 and 5 2 11 7 2 MOWER CUTS UNEVENLY a Check air pressure in drive tires 13 psi Semi pneumatic casters do not require inflation A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation b Check deck support chains c Check deck leveling See Adjustments Section 5 2 2 Note The front of the mower deck will be approximately 1 4 6 4 mm lower than the back of the mower deck This is the rake of the deck d Check blades tip to tip for straightness they should be within 3 16 4 8 mm or one blade width from being in line 7 3 ENGINE WILL NOT STAR
65. ound levels in excess of 85 dBA at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine 1 3 3 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals EE 1 3 4 Thoroughly inspect the area where the equipment is to be used and remove all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders A WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide kill you HOW TO AVOID THE HAZARD Do not run engine indoors or in small confined area where dangerous carbon monoxide fumes can collect DANGER POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fue
66. our 5 16 18 whizlock nuts from the seat track studs at the bottom of the seat Retain for use later C Align the seat track studs on the bottom of the seat with the holes in the seat frame Place seat on top of the frame and secure with the four 5 16 18 whizlock nuts remove in step b 3 7 INSTALL MOTION CONTROL LEVERS 3 7 1 Loosen and remove the two 2 3 8 x 1 bolts and spring disc washers which attach the motion control levers to the control arm shafts for shipping and the two 2 3 8 x 1 bolts and spring disc washers which are screwed into the control arm shafts a Install the left motion control lever onto the control arm shaft See Figure 4 on the left side of the console Place the lever with the mounting plate towards the rear on the outside of the control arm shaft and secure with the bolts and washers Position the lever so the bolts are in the center of the slots on the lever mounting plate and tighten until snug Repeat on opposite side of unit NOTE There are two lever height options available Place the levers in the top two holes to increase height of the levers or in the bottom two holes to decrease the height of the levers If the levers do not align with each other when in the neutral position See Figure 5 loosen the hardware and make the appropriate adjustment by sliding tilting the lever s forward or backward until properly aligned and tighten hardware LEVERS IN MOTION CONTROL LEVER iN MOU
67. owing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Remove the wheel nuts from both sides of the unit and retain for later use In a b In al stall the two lower roll bar tubes Locate the left and right lower roll bar tubes Align lower roll bar tubes along wheel motor channels as shown in Figure 2 LOOSELY install lower roll bar hardware four 3 8 16 x 1 capscrews four spring disk washers and four 3 8 16 whizlock nuts from the bolt bag to the tubes on each side as shown in Figure 2 NOTE Be sure the spring disk washer cone is installed towards the head of the capscrew 4 318 16 X1 CAPSCREWS 42132 SPRINGDISK WASHERS 3 8 16 NS WHIZLOCK NC NUTS N FIGURE2 LOWER ROLL BAR INSTALLATION stall the upper u shaped section of the roll bar Reference Figure 3 for ignment and installation instructions below a Locate the latch pin assemblies and hairpin connected with a lanyard b Install a 1 2 13 x 3 1 4 capscrew in the washer on the lanyard of each pin assembly Note Make sure the bent tab in the washer is towards the head of the bolt b Lightly oil the inside surfaces of the ear shaped plates at the upper end of the lower roll bar tubes 14 C Locate the upper u shaped section of the roll bar Install the upper roll bar
68. ptional Mulch or Bag Blade Size 44 deck 48 deck 52 deck 3 ea 15 25 in 38 7 cm 16 25 in 41 3 cm 18 00 in 45 7 cm Blade Spindles solid steel spindles with 1 2 54 1 0 bearings Deck Drive Electric clutch mounted on vertical engine shaft Blades are driven by one B Section belt w self tensioning idler direct from the engine Deck Full floating deck is attached to out front support frame Maximum turf protection is provided by three anti scalp rollers on 44 amp 48 decks and five anti scalp rollers on 52 decks Deck design allows for bagging mulching or side discharge Cutting Height Adjustment an extra long cushioned lever is used to adjust the cutting height from 1 1 2 3 8 cm to 4 5 11 4 cm in 1 4 64 cm increments The cutting height adjustment handle has a transport position and all adjustments can be made while the operator remains seated 48 amp 52 units also have a foot operated deck lift assist lever to aid in raising the deck The deck lift assist lever is an optional accessory for the 44 deck Mulching Kit Optional 12 2 10 DIMENSIONS 2 10 1 Width Without deck Discharge chute up Discharge chute down w 44 Deck 43 9 in 111 5 cm 47 4 in 120 3 cm 54 7 in 138 9 cm w 48 Deck 45 9 in 116 6 cm 50 3 i
69. r seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn e Fill reservoir as stated in Section 5 1 11 f Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 0 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 Do not change hydraulic system oil except for 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 When tightening the slotted nut on the wheel motor tapered shaft a Torque the slotted nut to 125 ft lbs 169 N M b Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 or less should be showing C more than two threads 0 1 are showing remove nut and install washer PN 1 523157 between hub and nut d Torque the slotted nut to 125 ft 105 169 N M e Then tighten the nut until the next set of slots line up with the cross hole in the shaft f Replace cotter pin Note Do not use antiseize on the wheel hub Fuel Tank mounting hardware specification When installing the nuts onto the fuel tank studs fully tighten th
70. rds shields or covers Always have safety shields guards switches and other devices in place and in proper working condition DO NOT change the engine governor settings or overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury Disengage PTO before starting engine Start the engine carefully with feet well away from the blades Keep hands feet and clothing away from rotating parts while the mower is being operated Stop engine wait for all moving parts to stop and remove key e Before checking cleaning or working on the mower e After striking a foreign object inspect the mower for damage and make repairs before restarting and operating the mower e Before clearing blockages e Whenever you leave the mower Stop the engine and wait for all moving parts to stop e Before refueling e Before dumping the grass catcher Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engine The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel e When the machine will not be used for a few days e During transport to and from the job e When parked inside a building NS 1 4 16 1 4 17 1 4 18 1 4 19 1 4 20 1 4 21 This mower was designed for one operator only Keep all others away from mower during
71. s that call for special timing of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer 39 ENGINE TROUBLESHOOTING TABLE C RS PLUG x mem x x X DX x oe ee ee ee Stopssuddeny X X X X X X er Operates Knocks o ings meme por Skip or mists Exe eos ff ft xf x fx x ff tk Overheats High EC consumption 40 8 ELECTRICAL DIAGRAM KAWASAKI UNITS OIONJIDS 7915 TIA NIINI 39055344 110 13705 431415 AVES TID Ur 3LIHM ANH 389 X 980 0 341415 280 xd dag Ad 14115 0 380 xd 341815 341415 IHA NGG NAc swa UU nis ama 1 30yN3 388 035012 08109 H1 La N3389 XI m 940 X HIAS 18 19 ag 1 N3385 X1 n NOLLISUd 2201 WBITEN NI SAAI 035012 INY S3FOLIKS NOTLOW 0 NOTIDA in 1 N39 11 ama 1 ama 1 3dlal s 18 19
72. t foam padded flip up armrests with height adjustment 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 2 7 HYDROSTATIC GROUND DRIVE SYSTEM 2 7 1 2 7 2 2 7 3 2 7 4 2 7 5 2 7 6 eu t Hydrostatic Pumps Two Hydro Gear BDP 10A variable displacement piston pumps Wheel Motors Two Parker Ross with 1 1 4 tapered shafts Hydraulic Oil Use Mobil 1 15W 50 Synthetic Motor Oil Hydraulic Oil Capacity 2 1 qt 2 0 L Hydraulic Filter Replaceable cartridge type P N 1 513211 10 microns 18 psi bypass Summer use above 32 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C Speeds 44 amp 48 units 0 8 1 mph 13 1 km hr forward 0 4 7 mph 7 6 km hr reverse 52 units 0 9 5 mph 15 3 km hr forward 0 5 5 mph 8 9 km hr reverse Drive wheel release valves allow machine to be moved when the engine is not running 2 8 TIRES AND WHEELS 2 8 1 2 9 CUTTING DECK 2 9 1 2 9 2 2 9 3 2 9 4 2 9 5 2 9 6 2 9 7 2 9 8 Tires Size Qty Tread Ply Inflation Drive Tires 23 9 5 12 2 Multi Trac C S 4 13 psi 90 kPa Front Caster Tires Semi Pneumatic 13 5 00 6 2 Smooth Cutting Width 44 deck 48 deck 52 deck 44 in 111 8 cm 47 2 in 120 0 cm 52 in 132 1 cm Discharge Side O
73. tch 0 If necessary adjust the seat actuator rod length to where the machine will shut off when the operator raises off the seat with brake disengaged or 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 5 3 cm with seat up NOTE To prevent rough ground cut outs 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 loosen lock nut on bottom of the actuator rod 5 16 x 7 bolt and adjust the nuts to move the actuator plate up or down on the rod Brake Link Adjustment Check to make sure brake is adjusted properly Disengage brake lever lever down 34 b Measure the length of the spring Measurement should 2 75 7 0 cm between washers see Figure 12 lf adjustment is necessary tighten the lock nut directly below the yoke and loosen the two nuts jammed together below the spring Turn the nut directly below the washer until the correct measurement is obtained Tighten the two jam nuts below the spring together and repeat on opposite side of unit LEVER UP ENGAGED COLLAR LOCK NUT TRUNION ROLLER 4 6 7 DETAIL Poo N ISENCAGED FIGURE 12 BRAKE ADJUSTM
74. te tbe n tpe 20 4 3 MOWING 22 baee dade sed nee teed shee 20 22 4 4 Transporting eet 22 23 5 MAINTENANCE amp ADJUSTMENTS 5 1 Periodic Maintenance oco rU Eos 23 32 5 2 JAdjusim nis eh oe abe 32 38 6 WASTE DISPOSAL 6 1 MOlor Ol DISPOSAL 38 6 2 Battery Disposal tee RR ela pd ea Md etu uas 38 7 TROUBLE SHOOTING 5 erede bx eden npe 39 40 8 ELECTRICAL 6 41 42 9 HYDRAULIC 43 10 22 44 1 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL A is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The safety alert symbol appears above information which alerts you 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
75. 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 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 EXMARK PARTS PLUS PROGRAM EFFECTIVE DATE September 1 1995 Program If your Exmark dealer does not have the Exmark part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed How the Program Works 1 If dealer does not have part in stock for a down unit at the time of request by customer the dealer contacts his distributor by 1 00 p m local time and requests Exmark Parts Plus shipment of six 6 line items or less V Y x A si 2 Distributor ships part s to dealer or customer as E XM ARK P A S P L U ge 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
76. ttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Brake Lever Located on left side 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 the right fuel tank The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert the key into switch and rotate clockwise to the position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position 19 4 1 10 4 1 11 4 1 12 Brake must be engaged motion control levers out neutral lock position and 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 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 Located directly below center of console The fuel shut off valve is
77. 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 has three positions each position made in 1 4 turn increments Valve handle down is the OFF position Rotate valve handle 1 4 turn right from Off position for fuel flow from the right tank Rotate valve handle 1 4 turn left from Off position for fuel flow from the left tank Fuel Gauge Located on the left fuel tank The fuel gauge monitors the amount of fuel in the left tank only Use the fuel from the right fuel tank first When the right fuel tank is empty switch to the left fuel tank Fuel gauge will monitor the remaining fuel Drive Wheel Release Valves Located on the right front corner of the hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Unhook seat latch and tilt seat up to gain access to pumps With a 5 8 wrench turn both valves one turn counter clockwise to release drive system Turn clockwise to reset system DO NOT overtighten DO NOT tow machine 4 2 PRE START 4 2 1 4 2 2 4 2 3 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
78. vidual 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 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 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 5 MAINTENANCE amp ADJUSTMENTS A WARNING POTENTIAL HAZARD While maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the ignition switch and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s A WARNING POTENTIAL HAZARD The engine can become very hot WHAT CAN HAPPEN Touching a hot engine can cause severe burns HOW
79. wing batteries to stand for an extended period 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 a Checkthe voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Percent Maximum Heading Charge Charger Settings Charging Interval 12 6 or greater 10096 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 7596 16 volts 7 amps 1 Hour 12 0 12 2 25 50 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 096 14 4 volts 2 amps 6 Hours or More Clean grass build up under deck Service Interval Daily a Stop engine wait for all moving parts to stop and remove key 24 INSTALL BUSHING IN BLADE PRIO

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