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Exmark Lawn Tractor User's Manual

1. LYS NT HIM 095070 ST 30010 311008 AY B0 1 35 W 8 E 9 real 1 g ope ome eT 8 8 500058 Eee Eae E ERES Lon mn ES d dE Sin 5 s dE Abas ny cud ticus e om s ERAS EE 8 m ae E mom T 54148 13015 HE DL JNO 10121185 DL NVAO NI HOLIMS ANON ze JAYW LINIALD NOILISOd 3dralls o X WNIWASL mL m 1 A WNINWS3L ma 0 s mu 153 Old LES ades VANA 2 Qn cay WNIWASL IWA gl D 9313 S 3m on 8 INYO I WNINII 0 88 INA INA HJLIAS Old 3NI9N3 913 ann WNIKA L WA EU l HILIAS LIIL AVA LVS X WNIRL D 301A Wl n j 100 NOLLINJI 19915 5 MITEA 4 E HOLIMS Old ANIONI SALIW ANO I aunt ASALLY 8 SDIV T3 388170 Y SNOTLISNNOD WNIWASL ROR BS ARR EE HJLIMS 0 42 9 HYDRAULIC DIAGRAM T mm 1 AS MEWED FROM REAR OF UNIT BYPASS VALVE i VAL
2. 11 2 22 11 coca er 11 2 4 Electrical System Lon aee otio 11 2 5 Operator Gonlrols e e c o aH ke 11 2b oA a e D d ate 11 12 2 7 Hydrostatic Ground Drive System ctetu ode but eet doce ut eet one de 12 2 80 c O 12 2 9 CUMING DOCK eco taa 12 2 10 4 118 eS M 13 2 11 Torque Requirements cert pde 13 3 ASSEMBLY INSTRUCTIONS cO MEME 13 e ED ES 13 3 2 Install Rollover Protection System roll 13 15 3 3 Service Balloly scu et tere obest ere E Metus te Lud 15 16 3 4 Install Drive Wheels t orte o sese noe ERG un ERG bone gt 17 2 5 Check Tire PresSUl e 20422 e tpi oet Mp ord cde 17 3 6 ee tav da ea 17 3 7 Install Motion Control Levers 20 17 3 8 Position Discharge Chute Re 18 XP MEI 5 4 5 cc S 18 3 10 Service Hydraulic tra eere ed
3. SE Check tire pressure in Caster tires e Inflate caster tires to 13 psi 90 kPa NOTE Do not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Check condition of belts Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up Lift the rubber flap on front side of the engine to check pump drive belt c Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt d Check under machine to inspect the mule drive belt e See Sections 5 2 3 through 5 2 5 for belt adjustment 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 28 LUBRICATION CHART LOCATIONS PUMPS PLACES INTERVAL 2 Front Caster Pivots 0 2 3 Height Adj Shaft Bearings 1 5 AO hours 4 Deck Drive Belt idlerArm 4 1 Yeay 5 Brake Brackets 1 2 200048 6 Mule Drive Belt ider Arm 1 1 7 Pump Drive Belt Ider Arm 1 1 Yearly 8 Deck Rear Str
4. Stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer 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 Ag
5. 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 the operator may be subject to traffic tickets and or fines HOW TO AVOID THE HAZARD Do not drive a unit on a public street or roadway 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
6. 11 4 cm CUTTING HEIGHT POSITION ones FIGURE 9 CUTTING HEIGHT POSITION 282 T8 G0076 Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter See decal on the side of deck lift plate 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 To transport move lever back up to transport or 4 5 11 4 cm cutting height position 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 minimum clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts and nuts are installed with hte spring disc washer between the head of the bolt and the mounting bracket ANTI SCALP ROLLER FRONT LEFT ROLLER MOUNTING BRACKET MOUNTING BRACKET CUTTING HEIGHT P Ee INCHES mm 20 51 2 5 64 5 3 0 76 C H 3 5 90 CUTTING HEIGHTS ABOVE 3 5 38 mm USE THE BOTTOM HOLE THE ROLLERS WILL STILL BE EFFECTIVE AGAINST SCALPING FIGURE 10 ANTI SCALP ROLLER ADJUSTMENT 5 2 2 Deck Leveling Position mower on a flat surface Stop engine wait fo
7. Mule Drive Belt Tension Adjustment Self tensioning idler adjust as follows a b Stop engine wait for all moving parts to stop and remove key Check to make sure the center of the bolt head in the center of the spring loaded pulley on left side engine deck support is positioned between the centers of the two alignment holes in the left support plate See Figure 12 It is necessary to adjust the belt tension when the center of the bolt head is at or below the center of the bottom alignment hole When adjustment is necessary loosen the idler pulley on the right hand side so it can move up and down in the slot Place a wrench on the 3 8 nut in the center of the spring loaded pulley and apply upward pressure to relieve tension on the spring a 1 2 drive breaker bar and 9 16 socket works best Reposition the adjusting pulley to the bottom of the slot NOTE When installing a new belt it is necessary to reposition the right adjusting pulley upward in the slot in order to position the center of the spring loaded pulley between the alignment holes 34 SPRING IDLER PULLEY RIGHT SIDE IDLER PULLEY ADJUSTABLE FIGURE 12 MULE DRIVE BELT ADJUSTMENT 5 2 5 Deck Belt Tension a The deck belt is tensioned by a self tensioning idler no adjustment is necessary 5 2 6 Adjust Seat Switch a If necessary adjust the seat actuator rod length to where the machine will shut off when the operator raises off the se
8. 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 Tracking Adjustment Knob Located under the seat on the RH 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 clockwise as viewed from the rear of the machine to cause the machine to track more to the right and counterclockwise 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
9. alignment and installation instructions below a Locate the latch pin assemblies pin 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 points toward the head of the capscrew b Lightly oil the inside surfaces of the ear shaped plates at the upper end of the lower roll bar tubes C Locate the upper u shaped section of the roll bar Install the upper roll bar section using one 1 2 13 x 3 1 4 capscrew from step b and one 1 2 13 hex flange lock nut on each side Do not over tighten Make sure upper roll bar can pivot freely Notes Make sure the capscrew and nuts are installed with the nut to the inside of the roll bar e Make sure the tab on the lanyard washer is installed as shown and points toward the front of the unit d Raise the roll bar into the upright position and secure with the latch pin assemblies on each side Install latch pin from outer surface of roll bar assembly and secure with the hairpin to the inside e Torque all lower roll bar hardware attached to the machine frame to 30 35 ft Ibs 41 47 N m f Tighten the front knobs against the upper roll bar ends A a y a 3 UPPER ROLL 1043 314 i CAPSCREW is 5 4 BAR TUBE LATCH PIN Ex N ASSEMBLY NN 2 227 APPLY OIL TO INSIDE SURFACE OF EAR SHAPED PLATES 1 243 HEX FLANGE LOCK NUTS LA
10. Flap behind Seat Torque Blade Bolts to 55 60 ft lbs 75 81 N m 103 7491 Engine RPM 3750 50 no load 103 3270 D PART NO 103 3270 LOCATION On Engine PART NO 103 7491 LOCATION LH Side on Top Front of Mower Deck A WARNING Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning To avoid loss of control and possibility of rollover NOT operate near drop offs or near water NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes There is no roll over protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warning A DANGER COVER IS MISSING DO NOT OPERATE THIS UNIT WHEN COVER IS NOTIN PLACE PART NO 98 5954 LOCATION Under Mower Deck us Belt Shield s PART NO 107 2112 PART NO 103 5368 LOCATION Top Center of Floorpan LOCATION LH Side of Cutting Height Adjustment Plate MOTION MOTION CONTROL CONTROL 103 9256 DRIVE WHEEL RELEASE Battery contains sulfuric acid Avoid contact and always shield eyes face skin and clothing from battery Cigarettes lames or sparks could cause battery to explode fe tum counter Do not ch
11. HOURS 3 40 HOURS 200 HOURS lt 40 HOURS A YEARLY 5 Raise the roll bar as 500 1 513742 as clearance permits 40 HOURS J HOURS Read andfdiowslope PART NO 1 513742 LOCATION of Mower Deck Belt pw Shields Left and Right 40 HOURS 40 88 1072102 Sides PART NO 103 6319 1 fae dt LOCATION Bottom Side of Floor Pan Upper Roll bar 9 ANTESGALP ROLLER 3 BELT ROUTING FOR NORMAL OPERATING CONDITIONS PLACE BLADE BELT eoe ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm 1 643052 72 ES p GROUND CLEARANCE 22 si i CUTTING HEIGHT g SITY INCHES mm LER 288 NE a i 3 0076 m j a 3 5 90 Sa E FOR MAXIMUM FLOTATION ROLLERS MAY BE ull POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM 5 OF 1 4 64 mm GROUND CLEARANCE NEVER POSITION PART NO 103 0262 1 849222 154 55522 5 48555657 4 LOCATION Center Front of PART NO 1 643222 PART NO 1 633922 Console LOCATION Left of Center on Mower LOCATION Front Center on Top of Mower Deck Deo Under Floor Pan PUMP BELT ROUTING ROTATING MECHANICAL DEVICES CAN CAUSE SERIOUS INJURY DO NOT operate without guards in place Stop engine before opening cover 103 5881 V 1 643339 1 643339 LOCATION Top of Right Engine Baffle PART NO 103 0368 LOCATION Rubber Heat Shield
12. 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 md 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 straight line Movement of the left 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 eft lever back toward neutral to slow the left drive wheel 18 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
13. applies only to orders submitted on this program Monday through Thursday Parts Plus service is available only in the 48 contiguous United States UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exmark by 3 00 p m central time Orders must be six 6 line items or less Exclusions from the Exmark Parts Plus Program are Any wholegood or accessory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions Due to UPS restrictions aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air Exmark Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability an
14. cause improper cooling Make sure cooling shrouds are reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating 5 1 22 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 5 1 23 Change fuel filter Service Interval As Required a A fuel filter is installed between the fuel tanks and the engine Replace when necessary with Kohler P N 2405002 5 1 24 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 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 Raise seat 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 IMPORTANT Before reinstalling new filter fill it with Mobil 1 15W 50 and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn e Fill reservoir as stated in Section 5 1 12 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 Sta
15. engine place the throttle midway between the SLOW and FAST positions and pull choke control out into the 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 then 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 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 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 push pull sw
16. 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 safety signs 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 OFF g A WARNING ow avoid serious injury or death Read and understand the operator s manual before using this machine IGNITION Do NOT operate unless trained to safely use this
17. in neutral Refer to section 5 2 13 for control linkage adjustment PTO Engagement Switch Located just left of center on the console left side of ignition switch 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 at lower center on the console right side of ignition switch Choke is used to aid in starting a cold engine The choke control is pulled out to put the choke in the ON position and pushed in to put the choke control in the OFF position DO NOT run a warm engine with choke in the ON position Throttle Control Located on console just right of center Throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Brake Lever Located on left side of unit just to the front of the console The brake lever engages a parking brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake The unit must be tied down and brake engaged when transporting 19 4 1 8 4 1 10 4 1 11 Ignition Switch Located on the lower center of console The ignition switch is used to start and stop the engine The switch has three positions OFF and START Insert key into switch and rotate clockwise to the ON position Ro
18. 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 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 and wait for all moving parts to stop 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 and push it all the way down into the tube Remove the dipstick and read the oil level 23 d If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual DO NOT overfill IMPORTANT DO NOT operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check battery charge Service Interval Monthly Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve opt
19. machine Do NOT operate under the influence of alcohol or drugs Do NOT operate without shields guards and safety devices in place and working Check the function of the operator presence controls OPC safety PTO system daily Do NOT defeat the OPC system Stop the engine and remove key before adjusting servicing Engage and disengage or cleaning machine and attachments at 1 2 throttle Hearing protection is recommended PART NO 103 3996 LOCATION LH Side of Console 2 A WARNING DO NOT OPERATE WITHOUT To avoid serious injury or death Avoid blades unless engine and blades are stopped DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED CUTTING HEIGHT To avoid serious injury or death Pick up objects that could be thrown hy the blades NN Do NOT mow when people and pets are in the area s Do NOT carry passengers bil PART NO 1 303508 Look behind and to the side before changing directions d Before leaving aparator position LOCATION RH Side on Top Rear Disengage PTO Move drive levers out to neutral lock position of Mower Deck Engage park brake Stop engine T H R 0 L E 103 3997 PART NO 103 3997 A WARNING LOCATION RH Side of Console DISENGAGE BLADE CLUTCH SHUT OFF ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR C
20. 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 are partially dependent upon the design and configuration of the equipment these factors are also dependent upon the awareness concern prudence and proper training of the personnel involved in the operation 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 POTENTIAL HAZARD Operating engine parts especially the muffler beco
21. 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 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 OPERATING INSTRUCTIONS 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 200 4 3 3 4 3 4 4 3 5 Starting Engine Brake must be engaged motion control levers out neutral lock position PTO switch OFF to start engine It is not necessary for the operator to be in the seat to start the engine On a cold
22. 085 Ibs 492 kg w 60 Deck 1126 Ibs 511 kg 2 11 TORQUE REQUIREMENTS Bolt Location Torque Cutter Housing Spindle Nut secured with threadlocker 140 145 ft lbs 190 197 N m Blade Mounting Boll ott treten 55 60 ft Ibs 75 81 N m Engine Deck Front Frame Mount Bolts 30 35 ft Ibs 41 47 N m Anti Scalp Roller Nuts ert e 40 45 ft Ibs 54 61 N m Engine Mounting Bolts 30 35 ft Ibs 41 47 N m Wheel Lug IUIS ERG Fe rte ont 90 95 ft Ibs 122 129 N m Wheel Motor Mounting 72 77 ft lbs 98 104 N m Wheel Hub Slotted minimum 125 ft lbs 169 N m Rollover Protection System Roll Bar Mounting Bolts 30 35 ft Ibs 41 47 N m Deck Drive Jackshaft 75 80 ft Ibs 102 108 N m Clutch Retaining Bolt secured with threadlocker 55 60 ft Ibs 75 81 N m 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE MOWER 3 2 INSTALL ROLLOVER PROTECTION SYSTEM ROLL BAR 3 2 1 3 2 2 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
23. 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 Raise the rear of the unit and support it with jack stands or equivalent support 13 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 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 3 2 3 Remove the wheel nuts from both sides of the unit and retain for later use 3 2 4 Install the two lower roll bar tubes a Locate the left and right lower roll bar tubes b Align lower roll bar tubes along the rear engine frame as shown in Figure 2 c LOOSELY install the 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 223846 WHIZLOCK NUTS SPRING DISK WASHERS 3846 X1 N CAPSCREWS EN A C m 90273 FIGURE 2 LOWER ROLL INSTALLATION 14 3 2 5 Install the upper u shaped section of the roll bar Reference Figure 3 for
24. ATIC GROUND DRIVE SYSTEM 2 7 1 Hydrostatic Pumps Two Hydro Gear PJ variable displacement piston pumps 2 7 2 Wheel Motors Two Hydro Gear Danfoss with 1 1 4 tapered shafts 2 7 3 Hydraulic Oil Type Synthetic Mobil 1 15W 50 2 7 4 Hydraulic Oil Capacity 2 1 qt 2 0 L 2 7 5 Hydraulic Filter Replaceable cartridge type P N 1 513211 10 microns 18 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C 2 7 6 Speeds 0 9 0 mph 14 5 km hr forward 0 5 8 mph 9 3 km hr reverse 2 7 1 Drive wheel release valves allow machine to be moved when engine is not running 2 8 TIRES Drive Front Caster Pneumatic Air Filled Pneumatic Air Filled Quantity 2 2 Tread Turf Mate Smooth Size 23 x 10 50 12 13 x 5 00 6 Ply Rating 4 4 Pressure 13 psi 90 kPa 13 psi 90 kPa 2 9 CUTTING DECK 2 9 1 Cutting Width 52 in 132 1 cm 60 in 152 4 cm 2 9 2 Discharge Side 2 9 3 Blade Size 3 ea w 52 Deck 18 0 in 45 7 cm w 60 Deck 20 5 in 52 1 cm 2 9 4 Blade Spindles Solid steel spindles with1 I D bearings 2 9 5 Deck Drive Electric clutch mounted on horizontal engine shaft B Section belt with self tensioning idler from electric clutch to transfer shaft mounted on deck Blades are driven by one B Section belt w self tensioning idler from transfer shaft on deck to blade spindles 2 9 6 Deck Full floating deck is attached to ou
25. 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 16 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 Check tire pressure in Caster tires Proper inflation pressure for tires is 13 psi 90 kPa 3 6 INSTALL SEAT a Remove seat assembly from the crate b Remove the four 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
26. For Serial Nos 540 000 amp Higher L gt as Lr c AK MFG CO INC ADVANTAGE SERIES MODELS 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 9170 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
27. ING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 24 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
28. LEANING DECK 1 633313 PART NO 1 633313 LOCATION RH Side on Top CAUTION Front of Mower Deck DO NOT OPERATE WITHOUT GUARD IN PLACE _ 1 513748 HYDRAULIC OIL USE ONLY MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILL TO TOP OF BAFFLE KEEP HANDS and FEET AWAY N PART NO 1 513748 LOCATION Bottom Side A CAUTION of Floorpan HOT 2222222 1 523552 AWARNING PART NO 1 523552 LOCATION Top of Hydraulic Reservoir Under PART NO 1 403005 LOCATION Left and Right Corners of Mower Deck the Seat TO AVOID INJURY OR DEATH FROM ROLLOVER CHECK SERVICE REFERENCE AID Keep roll bar in the lt 1 GREASE LUBE POINTS AT INTERVALS SHOWN raed and locked IMPORTANT CHECK HYDRAULIC FLUID AT INTERVAL SHOWN USE ONLY MOBIL 1 15W 50 SYNTHETIC MOTOR OIL BEFORE STARTING ENGINE 2 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 CLEAN GRASS FROM PUMP DRIVE BELT COMPARTMENT CHECK MORE OFTEN IN DRY CONDITIONS YEARLY gt UNDER ENGINE DECK THERE IS NO ROLL OVER PROTECTION WHEN PART NO 1 633462 THE ROLL BAR IS LOCATION Rubber Heat Shield DOWN Lower the roll bar Flap behind Seat only when absolutely necessar Do not wear seat belt when the roll bar is down Drive slowly and N O STEP carefully 40
29. ND THREAD TURN HERE Q TO ADJUST A 4 9 5 TURN RH TRACKING ADJUSTMENT KNOB LEFT HAND SIDE OF UNIT RIGHT HAND SIDE OF UNIT DO NOT LOOSEN ANY NUTS ON RH SIDE NOTE The nut to the front of the unit on the LH rod has left hand tnreads FIGURE 17 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 before the following adjustments can be made See Section 5 2 12 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 LH motion control lever into the neutral position Adjust LH 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 17 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 RH motion control lever into the neutral positi
30. S 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 2004 EXMARK MFG CO INC PART NO 103 9170 INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 ALL RIGHTS RESERVED FAX 402 223 5489 ank MFG CO INC PRINTED IN U S A
31. TANT 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 items that call for special timing of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer 40 ENGINE TROUBLESHOOTING TABLE No improper pirtin FAULTY gencine BLOCKED INCORRECT DIRTY INSUFFICIENT PROBLEM FUEL FUEL FUELLINE FILTER SPARK FUEL AIR BATTERY PLUG FILTER LEVEL SCREEN CHARGE Hard starting e e Lacks power 25 Operateserraticaly X X x x X x xX __ eese X x Spem X x x x X 1 High fuel consumption 41 8 ELECTRICAL DIAGRAM ADLIJNNDIJ ANIONS IONS 05 431815 dAV 02 OZ HLIM 90 095070 10302 Ha NILLISUd 211 NI 583 81 SSHILINS JAIM SSELJ3NNUJ
32. TCH PIN ASSEMBLY 1 243 1 4 CAPSCREW 0087 FIGURE3 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 15 3 3 2 3 3 3 DANGER POTENTIAL HAZARD Charging the battery may produce explosive gasses WHAT CAN HAPPEN Battery gasses can explode causing serious injury HOW TO AVOID THE HAZARD Keep sparks flames or cigarettes away from battery Ventilate when charging or using battery enclosed space Make sure venting path of battery is always open once battery is filled with acid 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 the following chart for recommended charger settings Voltage Percent Maximum intent Reading Charge Charger Settings ging 12 6 or gre
33. 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 lbs 75 81 N m OB 1 2 3 DO NOT USE WRENCH HERE FOR BLADE INSTALLATION THIS NUT HAS BEEN TORQUED TO 140 145 ft lbs 190 197 N m AND SECURED WITH THREADLOCKER SPLINED BUSHING uem N TOWARDS BOLT HEAD N op Y Y dil 4 INSTALL BUSHING IN BLADE PRIOR TO INSTALLING BUSHING IN SPINDLE Ner BLOCK OF WOOD BETWEEN TORQUE TO FRONT OR REAR 55 60 ftHbs BAFFLES 8 BLADE 75 81N m ag G0259 FIGURE 7 BLADE BOLT INSTALLATION IMPORTANT DO NOT use components o
34. VE 50 RO HIGH PRESSURE HIGH PRESSURE HIGH PRESSURE FORWARD FORWARD REVERSE 4 1 z 2 eL m 1 1 d j HIGH PRESSURE Y L REVERSE HIGH PRESSURE CHARGE PUMP INLET CASE DRAIN 43 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 by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Products Warranty Period e All Products except as noted below 2 years e All Attachments and Accessories 1 year Metro 21 Series 1 year e 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 handl
35. arge or use booster cables or adjust post connections without proper training In event of an accident flush with water immediately Keep out of reach of children PART NO 103 9256 LOCATION Top of console 10 2 SPECIFICATIONS 2 1 MODEL NUMBER LZ23KC524AS LZ25KC604AS 2 2 ENGINE 2 2 1 Engine Specifications See your Engine Owner s Manual 2 2 2 RPM Full Speed 3750 RPM No Load Idle 1500 RPM 2 3 FUEL SYSTEM 2 3 1 Capacity 11 gal 42 L 2 3 2 Type of Fuel Regular unleaded gasoline 87 octane or higher 2 3 3 Fuel Filter In line 15 Micron Kohler P N 2405002 2 3 4 Fuel Shut Off Valve 1 4 turn increments left tank OFF right 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 Battery Voltage 12 Volt 2 4 5 Polarity Negative Ground 2 4 6 Fuses Two 20 amp blade type 2 4 7 Safety Interlock System PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine lt 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 control 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 co
36. ass 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 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 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 1 4 16 e 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 damaged guards shields or covers Always have safety sh
37. at 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 the engine from cutting out when operating over rough ground the unit is equipped with a time delayed seat switch When the operator raises off the seat with either the brake disengaged or the PTO engaged the engine should stop after 1 2 second has elapsed b To adjust seat switch actuator rod length loosen lock nut on bottom of the actuator rod 5 16 x 7 bolt and adjust the nuts to move the actuator plate washer up or down on the rod then retighten 5 2 7 Belt Guide Adjustment a Stop engine wait for all moving parts to stop and remove key b Remove the belt shield on the right side of mower deck C Note belt guide bolted to deck near the shield support stud and right hand pulley Guide should be 1 8 3 2 mm away from the belt with bolt end of guide near end of slot See Figure 13 d If adjustment is necessary loosen the bolt securing the belt guide and make proper adjustment Tighten hardware 0090 FIGURE 13 BELT GUIDE POSITIONING 5 2 8 Brake Link Adjustment Check to make sure brake is adjusted properly a Disengage brake lever lever down 35 b Measure the length of the spring Measurement should be 2 75 7 0 cm between washers see Figure 14 c If adjust
38. ater 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 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 ON 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 battery Connect the negative battery cables NOTE If the positive cable is also disconnected connect the positive red cable and the red wire to the positive terminal on the battery first then connect the negative black cable and white white wire to the negative terminal on the battery red wire and white white wire are only on some units 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 A WARNING BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND
39. ck leveling See Adjustments Section 5 2 2 Note The front of the mower deck will be approximately 1 4 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 or one blade width from being in line 7 3 ENGINE WILL NOT START a Make sure the battery has a full charge See section 5 1 3 for charging instructions b Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the 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 Besure the seat switch is properly adjusted See Section 5 2 6 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 g Check that the spark plug wires are properly connected h Check for loose or faulty wiring connections i 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 IMPOR
40. contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn 27 5 1 12 5 1 13 5 1 14 5 1 15 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 Check hydraulic oil level Service Interval 40 hr a Stop engine and wait for all moving parts to stop b Unhook seat latch and tilt seat up Clean area around hydraulic reservoir 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 level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level Check tire pressures Service 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
41. d hydraulic system to overheat WHAT CAN HAPPEN Excessive debris around the engine cooling air intake and inside of the pump drive belt compartment can create a fire hazard HOW TO AVOID THE HAZARD Clean all debris from inside of pump drive belt compartment daily IMPORTANT Information located BEFORE STARTING ENGINE e On console decal 103 3996 below ignition switch CLEAN GRASS FROM PUMP decal 1 633462 behind seat on rubber heat DRIVE BELT COMPARTMENT shield fla CHECK MORE OFTEN IN DRY P CONDITIONS E633462 24 5 1 4 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 Clean all debris from inside of pump drive belt compartment d Inspect rubber engine baffles for proper fit Replace if necessary Clean grass build up under deck Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Raise deck to the transport 5 12 7 cm 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
42. d years of trouble free operation OPERATOR S MANUAL This manual contains assembly operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance TABLE OF CONTENTS 1 SAFETY PAGE 1 Salely Ar Symbols su uio pb or ERR ages tie PR aet pon bad dee 1 T2 mta RR alain ahead etiem atte e 1 1 3 1 3 ODBBISUOIT 4 7 1 5 Maintenance 7 8 8 10 2 SPECIFICATIONS 2 1
43. e 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 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 replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Depar
44. earing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced 29 5 1 17 5 1 18 5 1 19 5 1 20 5 1 21 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 j 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 Apply a thread locking adhesive to the 274 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
45. eerta ed eve de 18 4 OPERATION INSTRUCTIONS d d eue tea sed eder diei 18 20 42 al ain aden olen cts ons 20 4 3 Operating ER RE EU 20 22 BA Transporting 22 23 5 MAINTENANCE amp ADJUSTMENTS 5 1 Periodic Maintenance nier teer ecol FERRE 23 32 525 AO UISIMEING RESQUE unes Quae dut 32 39 6 WASTE DISPOSAL 6 1 Motor Qil Disposal ste 2 cR e t 39 6 27 Battery ee pp oe ed P teme 39 7 TROUBLE SHOOTING aora ceca coca pd ef GA eG a RA ira 39 41 8 ELECTRICAL DIAGRAMS e ele ree ada ads 42 9 HYDRAULIC DIAGRAM 1 eere 43 10 WARRANTY rebate adt tpa as dutem tdt 44 1 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents 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 WARN
46. ency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously or its distributors and dealers accept no 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 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 s
47. ery electrolyte contains sulfuric acid which is poisonous and can cause severe burns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do 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 7 TROUBLE SHOOTING 7 1 MOWER PULLS LEFT OR RIGHT W LEVERS FULLY FORWARD a Referto Tracking Adjustment Section 4 1 3 b Check air pressure in tires 13 psi drive 13 psi pneumatic casters 39 Check reverse indicator and motion control linkage adjustment See section 5 2 12 and 5 2 13 7 2 MOWER CUTS UNEVENLY a Check air pressure in tires 13 psi drive 13 psi pneumatic casters A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation Higher pressures in front casters may cause them to shimmy on hard surfaces b Check deck support chains Check de
48. hich is located under the console See Figure 15 LEVER TAB WASHER BELLEVILLE WASHERS FIGURE 15 THROTTLE TENSION 5 2 11 Electric Clutch Adjustment No adjustment necessary 5 2 12 Reverse Indicator Adjustment a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat forward Begin with either the left or right motion control lever Move lever to the neutral position and pull lever back until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on spring See Figure 16 FRICTION WASHERS 36 d Check where lever is relative to notch in console should be centered allowing lever to pivot outward to the neutral lock position e 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 f Repeat on opposite side of unit REVERSE INDICATOR ak TURN BOLT HERE LOOSEN HERE 90050 FIGURE 16 REVERSE INDICATOR ADJUSTMENT 5 2 13 Motion control linkage adjustment WARNING POTENTIAL HAZARD Engine must be running and drive wheels must be turning s
49. ields 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 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 This mower was designed for one operator only Keep all others away from mower during operation Be 1 4 17 1 4 18 1 4 19 1 4 20 1 4 21 Do Not mow with the discharge deflector raised removed or altered unless there is a gras
50. imum 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 Yoltags Maximum Charging Interval Reading Charge Charger Settings gng 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 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 IMPORTANT For Kohler EFI units Unplug the harness from the ECU before performing any welding on the equipment 5 1 3 Clean engine cooling system Service Interval Daily or more often in dry conditions CAUTION POTENTIAL HAZARD Excessive debris and damaged or missing rubber baffles can cause the engine an
51. ing fasteners a Pump drive sheave set screws b Square head setscrews on Hydro pump control arms Sheave retaining bolt in the end of engine crankshaft d Caster wheel spacer nuts e Fuel tank bulkhead fitting nuts f Cutter housing spindle nut Adhesives such as Loctite RC 609 or 680 or Fel Pro Pro Lock Retaining or Retaining are used on the following a Fueltank studs where studs are inserted into tank 5 1 28 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 d Between jackshaft and bearings and jackshaft and sheaves 5 1 29 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 any 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 9 The deck can be raised by pulling the deck lever up NOTE When changing cutting height positions always come to a complete stop and disengage the PTO KNS LEVER IN TRANSPORT LO AND 4 5
52. 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 individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible 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
53. itch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging PTO IMPORTANT Operator must be in seat before the PTO can be engaged Set throttle to midway position Pull outward on the switch to the ROTATE position Accelerate to full throttle to begin mowing Stopping PTO Set throttle to the midway position Push in on the switch to the STOP position stopping the PTO EE 4 3 6 Stopping Engine Bring unit to a full stop Disengage the PTO move motion control levers out to the neutral lock position and set parking brake 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
54. ke 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 implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state SERVICE RECORD Date Description of Work Done Service Done By 45 ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC FOLD ALONG APPROPRIATE LINE EXAMPLE COMPARE SLOPE WITH FOLDED 46 SEE EXMARK S COMPLETE LINE OF ACCESSORIE
55. 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 ALIGNMENT MOTION MOUNT 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 bend them outward Move them back to the drive position and check for clearance repeat if necessary Ern 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
56. ly charged before putting away for winter storage Keep engine engine area and pump drive belt compartment free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire 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 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
57. machine produces sound levels in excess of 85 at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 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 2 1 34 Thoroughly inspect the area where the equipment is to be used and remove all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders A WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide can kill you HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN Afire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD 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 childre
58. me extremely hot WHAT CAN HAPPEN Severe burns can occur on contact Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working Keep hands feet hair jewelry or clothing away from rotating parts 1 4 1 1 4 2 1 4 3 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 POTENTIAL HAZARD Mowing wet grass or steep slopes can cause sliding and loss
59. ment is necessary tighten the nut directly below the yoke and loosen the bottom nut bottom one of the two tightened together below the spring Turn the nut directly below the washer top nut of the two tightened together until the correct measurement is obtained Tighten the two nuts together and repeat on opposite side of unit Turn clockwise to shorten spring length and turn counter clockwise to lengthen the spring DETAIL A LEVER UP ENGAGED COLLAR 3 16 4 8 mm to 1 4 6 4 mm TRUNION ROLLER LEVER DOWN DISENGAGED ADJUSTMENT FIGURE 14 BRAKE ADJUSTMENT 5 2 9 Brake Adjustment a Check for brake link 2 75 7 0 cm measurement as described in section 5 2 8 b Engage brake lever lever up c Measure the distance between the trunion roller and the rod collar Measurement should be 3 16 4 8 mm to 1 4 6 4 mm See Figure 14 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 14 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 10 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 w
60. n Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do not operate without entire exhaust system in place and in proper working condition POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN A static charge can ignite gasoline vapors A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container
61. n is tight and all slack is removed from linkage Do not lift front of deck off 3 4 19 mm block Secure front swivel using locking nut in front of swivel Repeat for right side Recheck that the 3 4 19 mm blocks fit just snugly under the brackets and that the tension on all the chains are approximately equal Make sure all chain attachment bolts are tight Reposition anti scalp rollers and tighten securely 11 1 8 28 3 cm For 52 Deck C 101 2 26 7 cm For 60 Deck Remove force on _7 deck springs by X loosening nuts here 9 Jam nut lt Socket head __ adjusting screw 5 2 3 5 2 4 5 2 0 a 8 ai GR UN NA 0 60105 Front of Unit FIGURE 11 SWIVEL ADJUSTMENT SPRING COMPRESSION ADJUSTMENT Raise deck lift lever to the 4 5 11 4 cm cutting height position See Figure 9 Adjust spring compression until proper distance is obtained between the two large washers See Figure 11 Adjustment is made by turning the nut at the front of each spring clockwise will shorten the spring counter clockwise will lengthen the spring Lock in position with jam nuts NOTE When above adjustments have been made the front of the deck will be slightly lower than the rear of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary
62. n with the right lever in then with both levers in starter must not crank b Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must stop after approx 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain 26 5 1 7 5 1 10 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 connected and in proper operating condition prior to use for mowing Check rollover protections systems roll bar pins Service Interval Daily a Make sure latch pin and hair pin are fully installed and lanyard is in good condition Check for loose hardware Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Vi
63. nsole 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 NOTE Motion control levers are adjustable to two heights 2 5 2 PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades 2 5 3 Parking Brake Lever Engages parking brake 2 5 4 Deck Height Adjustment Lever Sets cutting height to desired position NOTE The Deck Lift Assist Lever is an optional accessory This lever is a foot pedal that assists in raising the deck 2 6 SEAT 2 6 1 Type Standard seat with high back foam padded internal suspension and armrests NOTE The following are optional seat accessories 11 2 6 2 2 6 3 2 6 4 e 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 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 Armrests Standard seat 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 HYDROST
64. o 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 Ay 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 DONOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 37 LOOSEN HERE LEFTHAND THREAD G0049 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 LH pump control linkage See Figure 17 LOOSEN HERE RIGHTHA
65. 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 Do 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 Seeinside the back cover to determine the approximate slope angle of the area to be mowed e Usea walk behind mower and or a hand trimmer near drop offs ditches steep banks or water This area can be dangerous see Figure 1 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 may tip backwards Be 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 or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Use extreme care with gr
66. on Adjust the RH 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 17 Shut off unit Remove jumper wire from wire harness connector and plug connector into seat switch 38 5 2 14 Caster pivot bearings pre load adjustment a Remove dust cap from caster and tighten nyloc nut until washers are flat and back 11 off 1 4 of a turn to properly set the pre load on the bearings If disassembled make EN 5 2 15 Seat armrest adjustment a sure the spring washers are reinstalled as shown in Figure 18 G0091 FIGURE 18 CASTER ADJUSTMENT 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 19 l Armrest Adjustment Me Tab Rotate 1 4 Turn FIGURE 19 6 WASTE DISPOSAL 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 Batt
67. r 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 Check tire pressure in Caster tires Proper inflation pressure for tires is 13 psi 90 kPa Set anti scalp rollers to top holes or remove them completely for this adjustment Raise the deck to the 4 5 11 4 height position also transport position and take all force off of the two large deck lift springs by loosening the nuts at the front of each spring See Figure 11 Lower the deck to the 1 1 2 3 81 cm height position Place a 3 4 19 mm thick block of wood under each of the two 2 rear anti scalp roller brackets and place one under one of the front center anti scalp roller brackets 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 Turn the socket head adjusting screws in until slack is taken out of each chain Tighten the jam nuts Tighten the chain bolts in the deck lift arms making sure they don t move while tightening Loosen the four 4 nuts which secure the front swivels two per side until the front chains are loose and front of deck is supported by the 3 4 19 mm block Do not loosen the front chain hardware 283 On left side adjust front swivel using the locking nut behind the swivel until the front chai
68. rt 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 5 1 25 Wheel hub slotted nut torque specification Service Interval 500 hrs 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 If more than two threads 0 1 are showing remove nut and install washer 1 523157 between hub and nut 31 d Torque the slotted nut to 125 ft lbs 169 N M e Then tighten nut until the next set of slots line up with the cross hole in shaft f Replace cotter pin NOTE Do not use antisieze on wheel hub 5 1 26 Fuel Tank mounting hardware specification When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels 5 1 27 Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the follow
69. s 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 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 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 5 9 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 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 ful
70. sually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service air cleaner 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 wing nut and remove air cleaner compartment cover c Remove foam pre cleaner element and wash in warm water with detergent Rinse until all traces of detergent are eliminated and squeeze out excess water DO NOT wring Air dry Saturate with engine oil and squeeze out excess oil d Check paper element DO NOT wash or use pressurized air to clean paper element Replace if dirty bent or damaged e Reinstall foam pre cleaner to paper element then reinstall paper element and cover Change engine oil Service Interval 100 hrs NOTE Change oil and filter after first five 5 hrs of operation a Stop engine wait for all moving parts to stop and remove key b Drain oil while engine is warm from operation The oil drain is located on right hand side of engine Place pan under machine to catch oil and remove drain plug Allow oil to drain then replace plug 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
71. t front support frame Six anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge Deck Depth 5 5 14 0 cm 2 9 7 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 2 9 8 Mulching Kit Optional 12 2 10 DIMENSIONS 2 10 1 2 10 2 2 10 3 2 10 4 2 10 5 2 10 6 Curb Weight Overall Width without deck deflector up deflector down w 52 Deck 49 8 in 126 5 cm 53 4 in 135 6 cm 64 2 in 163 1 cm w 60 Deck 53 8 in 136 7 cm 61 4 in 156 0 cm 72 2 in 183 4 cm Overall Length w 52 Deck w 60 Deck Roll Bar Up 78 2 in 198 7 cm 78 2 in 198 7 cm Roll Bar Down 88 9 in 225 8 cm 88 9 in 225 8 cm Overall Height Roll Bar Up Roll Bar Down 71 4 in 181 4 cm 53 3 in 135 4 cm Tread Width center to center of tires widthwise w 52 Deck w 60 Deck Drive wheels 39 7 in 100 1 43 7 in 111 0 cm Caster wheels 37 0 in 93 9 39 0 in 99 1 cm Wheel Base center of caster tire to center of drive tire w 52 amp 60 Decks 50 3 in 127 8 cm w 52 Deck 1
72. tate clockwise to the next position to engage the starter key must be held against spring pressure in this position 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 just left of center on console The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If the ignition switch is left on without engine running hour meter will not run NOTE This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve Located directly below center of console The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the job site and when parked inside a building The valve has three positions each position made in 1 4 turn increments FUEL FLOW VALVE HANDLE POSITION OFF DOWN RIGHT TANK RIGHT LEFT TANK LEFT Drive Wheel Release Valves Located on the top left front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine 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
73. ther 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 CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN Aloose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck causing serious injury or property damage 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 5 1 6 Check safety interlock system Service Interval Daily a Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat agai
74. tment 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 Company shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we shall have no liability or responsibility for e Expenses related to gasoline oil or lubricants e Travel time overtime after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer e Rental of li
75. tock to satisfy Exmark Parts Plus order he contacts Exmark by 3 00 p m central time with an Exmark Parts Plus order of six 6 line items or less 4 If order is received by 3 00 p m central time Exmark ships part s direct to dealer or customer as requested by distributor same day overnight UPS Exmark bills the distributor for parts and shipping charges where applicable 5 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program 6 Who pays for the part and freight if it fails to arrive overnight in accordance to the program A Under any circumstance the customer does not pay B If the part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following restrictions apply The Exmark Parts Plus Program is available only through participating Exmark Dealers and
76. until there is a slight amount of drag Re apply threadlocking adhesive 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 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 seat latch and tilt seat up C Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings Lubricate motion control bronze bushings Service Interval 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 30 b Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can
77. uts 1 2 4hours See Section 5 1 15 c for special lubrication instructions on the front caster pivots and Section 5 1 16 for special lubrication instructions on the front casters wheel hubs No 6 Mule Drive Idler Arm us E WI Located Under Engine Frame 41 P No 7 Pump Drive Belt ldler 3 i JU cap Located Under Engine Frame EE l A H 1 A La d 1111 5 83 4312 A 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 5 1 16 Lubricate caster wheel hubs 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 d Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the PACER NUT WITH axle Remove the axle with the other 23 spacer nut still assembled to it from the wheel assembly FIGURE 8 Pry out seals and inspect bearings for CASTER WHEEL ASSEMBLY wear or damage and replace if necessary f Pack the bearings with NGLI grade 1 multi purpose grease 0 Insert 1 b
78. with oil check oil level and if necessary and fill to the appropriate level with oil as specified in Engine Owner s Manual 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 The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C Fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 4 OPERATION INSTRUCTIONS 4 1 CONTROLS 4 1 1 Familiarize yourself with all controls before operating the mower 4 1 2 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

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