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Exmark Mower Pioneer E-Series 4500-996 Rev A User's Manual

1. WHEN THE ROLL 116 1119 BAR IS DOWN Lower the roll bar 116 1119 only when absolutely necessary Do not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Read and follow slope operation instructions and warnings 15 fo Pop 20 57 25 foot 10 116 1496 116 1496 107 2102 107 2102 Lubricate Blade threads with copper based WARNING antiseize r 9 rease Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers Going up or backing down steep slopes or ramps can result in backward rollovers To avoid loss of control and possibility of rollover resulting in serious injury or death Do not operate near drop offs or water Do not operate on slopes or ramps greater than 15 Do not use split ramps use full width ramps to load a unit for transport Reduce speed and use extreme caution on slopes or ramps Avoid sudden turns and rapid speed changes and torque to 55 60 ft lbs 75 81 109 3148 There is no rollover protection when the is down 1 09 31 48 Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warnings GREATER THAN 15 116 3303 12 Safety DRIVE WHEEL RELEASE Knob loca
2. WARNING Incorrect installation of the blade or components used to retain the blade can be dangerous Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death Always install the original Exmark blades blade bushings and blade bolts as shown Note To prevent engine cut outs on rough terrain the seat kill switch has a 1 2 second delay 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must Figure 20 not crank 1 Spindle Try to start with operator in seat parking brake 2 Blade engaged PTO engaged and motion control 3 Blade drive washer levers in the neutral lock position starter must 4 Blade bolt washer assembly Torque to 50 60 ft lb not crank 68 81 N m Apply lubricant to threads as needed to prevent seizing Copper based anti seize preferable Try to start with operator in seat parking Grease acceptable substitute brake engaged PTO disengaged and the left motion control lever in starter must not crank B Apply lubricant to the threads of the blade 1 bolt as nee
3. td 8 MOTISA A M AD 3140 5399 LATOIA 4 HOLIMS 40 NVL 1 1083 Y 9 5188 1491 T a 9 2 30 5 g 53002 40109 HOLIMS 5 9 NOILOSNNOD HOLIMS AFA LMS 6015188 45 Pioneer E Series Turf Equipment 1 Year Limited Commercial Warranty 4Year or 500 Hours Limited Consumer Warranty General Warranty 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 on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship 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 Commercial Warranty Conditions This warranty applies to Exmark Pioneer E Series turf equipment sold in the U S or Canada for a period of one year for commercial usage This warranty includes the cost of parts and labor for a period of one year This warranty does not cover pickup and de
4. 6016635 Figure 22 1 Engine 2 Expansion tank Check Tire Pressures Service Interval Every 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tite pressure in drive tires Inflate drive tires to 13 psi 90 kPa Check tire pressure in caster tires Ur Inflate caster tires to 13 psi 90 kPa Check Condition Of Belts Service Interval Every 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove left and right belt shields on deck and lower the deck to inspect deck drive belt 3 Check under machine to inspect the pump drive belt Note No adjustments are required for belt tension Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval 1 Deck and 1 2 50 hours Pump Idler Pivot 25 hours 2 Front 1 Caster Axles 0014848 Check Spark Plugs Service Interval Every 200 hours Remove spark plugs check condition and reset gaps replace with new plugs See Engine Owner s M
5. Armrests Molded flip up armrests Seat Safety Switch Integrated seat switch Time delay seat switch eliminates rough ground cut outs Hydrostatic Ground Drive System Two unitized hydrostatic transmissions Hydro Gear Z T2800 Hydraulic Oil Type Exmark Premium Hydro Oil Hydraulic Oil Capacity 77 oz 2 3 L per side Hydraulic Filter P N 109 3321 Speeds 0 7 mph 11 3 km hr forward 0 4 mph 6 4 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running 16 Tires amp Wheels Pneumatic Air filled Pneumatic Air filled Cutting Deck Cutting Width 48 inch Deck 121 9 cm 52 inch Deck 132 1 cm Discharge Side Blade Size 3 ea 48 inch Deck 16 25 inches 41 3 cm 52 inch Deck 18 00 inches 45 7 cm Blade Spindles Solid steel spindles with 67 inch 17 mm I D bearings Deck Drive B Section belt with self tensioning idler Electric clutch 125 ft lb Mag Stop Deck Full floating deck is attached to out front support frame Anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge 48 inch Deck 3 anti scalp rollers 52 inch Deck 3 anti scalp rollers Deck Depth 48 inch Deck 4 0 inches 10 cm 52 inch Deck 4 0 inches 10 cm Cutting Height Adjustment Foot activated lever is used to adjust the cutting height from 1 1 2 inch 3 8 cm
6. lever 37 Maintenance Full Forward Tracking 1 Prior to starting the engine push the deck lift pedal and remove the height of cut pin Lower Adj ustment deck to the ground If the machine travels or pulls to one side when the 2 Raise the rear of machine up and support with motion control levers are in the full forward position jack stands or equivalent support just high adjust the cover plates enough to allow drive wheels to turn freely 1 Loosen the screws a cover plate see Figure 29 3 Remove the electrical connection from the seat 2 Slide the cover plate backward or forward to safety switch located under the bottom cushion adjust the travel of the lever and tighten the of the seat The switch is a part of the seat Screws assembly 3 Drive the machine and check the full forward 4 Temporarily install a jumper wire across the tracking terminals in the connector of the main wiring harness 4 Repeat steps 1 through 3 until desired tracking is obtained 5 Start engine Brake must be engaged and motion control levers out to start engine Operator does not have to be in the seat Run engine at full throttle and release brake G016717 6 Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature Note The motion control lever needs to be in neutral while making any necessary adjustments 7 Bring the motion control levers into t
7. oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and Do Not store neat flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s ot wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools 4 DANGER Charging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery e Ventilate when charging or using battery in an encl
8. 3 Wipe up any excessive grease or oil around the engine and exhaust system area Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 100 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause inadequate cooling 3 Make sure cooling shrouds are reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating Clean Hydro Fan Cooling Fins Service Interval Before each use or daily Removing debris from the hydro fan cooling fins will allow the hydro system to run cooler and improve the life of the hydro system Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Unlatch and flip the seat up Remove accumulated debris from the hydro fan cooling fins and upper surfaces Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Clean off any oil debris or grass build up on the machine and cutting deck especially under deck belt shields around the fuel tank around engine and exhaust area Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Park the machine on a level surface and disengage the bla
9. After the first 5 hours Every 100 hours Yearly whichever comes first May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Drain oil while engine is warm from operation 3 The oil drain hose is located on right hand side of engine at the rear Place pan under machine to catch oil Remove plug from end of drain hose Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft lb 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 Exmark 4 Premium Engine oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in the Check Engine Oil Level section Do Not overfill Start the engine and check for leaks Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Before each use or daily 31 Maintenance 1 Stop engine and wait for all moving parts to stop Engage parking brake Wait until the unit cools before checking the hydraulic oil Check expansion tank and if necessary add Exmark Premium Hydro Oil to the FULL COLD line see Figure 22
10. but not limited to tires belts blades and fuel system components with original Exmark parts Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system 10 Safety Safety and Instructional Decals e Keep all safety signs legible Remove all grease e New safety signs may be obtained from dirt and debris from safety signs and instructional your authorized Exmark equipment dealer or labels distributor or from Exmark Mfg Co Inc Replace all worn damaged or missing safety Safety signs may be affixed by peeling off the signs backing to expose the adhesive surface Apply When replacement components are installed be only to a clean dry surface Smooth to remove sure that current safety signs
11. to 5 inches 12 7 cm in 1 4 inch 6 4 mm increments Mulching Kit Optional Specifications Dimensions Torque Requirements Blade Drive Sheave 75 85 ft lb 102 115 N m Mounting Nut Blade Mounting Bolt 50 60 ft lb 68 81 N m lubricate with anti seize Overall Width 48 inch Deck 52 inch Deck Without Deck 44 1 inches 112 0 44 1 inches 112 0 cm cm Anti Scalp Roller Nyloc 27 33 ft lb 37 45 N m Nut See Figure 18 Anti Scalp Roller Whizlock 27 33 ft lb 37 45 N m Nut See Figure 18 Engine Mounting Bolts Kawasaki 27 33 ft lb 37 45 N m Deflector Up 48 0 inches 121 9 52 8 inches 134 1 cm cm Deflector Down 59 2 inches 150 4 64 0 inches 162 6 cm cm Overall Length 8 Deck 52 inch Deck Wheel Lug Nuts 70 90 ft lb 95 122 N m Roll Bar Up 77 8 inches 197 6 77 8 inches 197 6 Rollover Protection 77 95 ft lb 104 129 N m cm cm System Roll Bar 1 2 Roll Bar Down 78 6 inches 199 6 78 6 inches 199 6 Mounting Bolts cm cm Clutch Retaining Bolt 49 61 ft lb 66 83 N m secured with threadlocker Overall Height Roll Bar Up Roll Bar Down 70 0 inches 177 8 cm 46 8 inches 118 9 cm Tread Width Center to Center of Tires Widthwise 48inchDeck 52 inch Deck Drive Wheels 35 8 inches 35 8 inches 90 9 cm 90 9 cm Caster Wheels 33 5 inches 33 5 inches 85 1 cm 85 1 cm Wheel Base Center of Caster Tire t
12. 27 3 Clevis 4 nut Adjusting the Brake to Engage Shorten the linkage by turning the yoke clockwise e Adjusting the Brake to Disengage Lengthen the linkage by turning the yoke counterclockwise Reinstall the clevis pin and hair pin and tighten down the jam nut Repeat step 6 and readjust if necessaty 9 When adjustment is complete remove the jack stands or equivalent support and lower the machine 10 Place the machine into the operating position Refer to the Drive Wheel Release Valves section in Operation Motion Control Handle Adjustment Adjusting the height The motion control levers can be adjusted higher or lower for maximum operator comfort 1 Remove the hardware holding the control lever to the control arm shaft Figure 28 6016716 Figure 28 1 Bolts 4 Control arm shaft 2 Washer 5 Slotted hole 3 Control lever 2 Move the control lever to the next set of holes Secure the lever with the hardware 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort 1 Loosen the upper bolt holding the control lever to the control arm shaft 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 28 Tighten both bolts to secure the control in the new position 3 Repeat the adjustment for the opposite control
13. Operating INStrUCHONS 21 aN 25 Coca AL Recommended Maintenance Schedule s 21 Periodic Maintenance 28 Check Engine 28 Cheek Battery wading 28 Check Mower Blades 29 Check Safety Interlock System 30 Check Rollover Protections Systems Roll in abbey tens 31 Check Seat Beltine 31 Check for Loose Hardware 31 Service 31 Chance Enotne 31 Check Hydraulic Oil Level 31 Check Tire Pressures 32 Check Condition 32 Lubricate Grease 32 Check Spark 32 Replace Emissions Air Intake 33 Change Hydraulic System Filter and 33 Check Spark Arrester if 34 Thread Locking 2121 111 34 Copper Based Anti seize 34 Dielectric 34 aE 35 Deck evel nor srs 35 Adjusting the Blade 35 Pump Drive Belt Tension 36 Deck Belt 36 Adjusting the Parking eee eee 36 Motion Control Handle Adjustment 37 Pull F
14. Steering and Motion Control Note Motion control levers are adjustable to three heights Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the position of the levers relative to each other Specifications Moving motion control levers outward in slots locks the drive system in neutral PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades Parking Brake Lever Engages parking brake Deck Height Adjustment Lever Sets cutting height to desired position Deck Lift Pedal Foot pedal that lifts deck Transport Lock Latching position Automatically latches at the transport position Seat Type Standard seat with foam padded seat cushion with armrests and integral safety switch Optional seat Seat with high back extra wide foam padded seat cushion with internal suspension thick bolstering two tone cover armrests integral safety switch and seat vibration isolation system Optional seat accessories for units with standard seats Custom ride suspension system to enhance Standard Seat Adds approximately 3 inches 7 6 cm to seat height Deluxe suspension seat with high back dampened adjustable spring suspension armrests and integral safety switch Adds approximately 1 2 inch 1 3 cm to seat height Mounting Adjustable fore and aft on seat tracks
15. Tension Self tensioning No adjustment necessary Deck Belt Tension Self tensioning No adjustment necessary Adjusting the Parking Brake Service Interval Every 500 hours Check to make sure brake is adjusted properly This procedure must be followed after the first 100 hours when a brake component has been removed or replaced 1 Drive the machine onto a level surface 2 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine wait for all moving parts to stop and remove the key 4 Setup the machine to be pushed by hand see Drive Wheel Release Valves in the Operation section 5 Raise the back of the machine up and support the machine with jack stands Maintenance CAUTION Raising the mower deck for service or maintenance relying solely on mechanical ot hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support ot may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Engage disengage the brake and check each drive tire to make sure each brake engages disengages If adjustment is necessary loosen the jam nut from the yoke on the side that needs adjustment Remove the hairpin and clevis pin see Figure 27 6017127 Figure
16. approximately one blade thickness 1 Cutting blade s is are bent or unbalanced 2 Blade mounting bolt is loose 3 Engine mounting bolts are loose 4 Loose engine pulley idler pulley or blade pulley 5 Engine pulley is damaged 6 Blade spindle is bent 1 Drive belt is worn loose or broken 2 Deck belt is worn loose or broken 3 Deck belt is off pulley 4 Broken or missing idler spring 5 Drive belt not routed correctly 43 1 Position handle in operating position see Drive Wheel Release Valves section in Operation 2 Change the belt 3 Change the belt 4 Replace the spring 5 Add hydraulic fluid to reservoir or let it cool down 1 Sharpen the blade s 2 Install new cutting blade s 3 Level mower deck from side to side and front to tear 4 Clean the underside of the mower 5 Adjust tire pressure in the drive tires 6 Contact an Authorized Service Dealer 7 Replace blades spindles and or check for damage to mower deck 1 Install new cutting blade s 2 Tighten the blade mounting bolt 3 Tighten the engine mounting bolts 4 Tighten the appropriate pulley 5 Contact an Authorized Service Dealer 6 Contact an Authorized Service Dealer 1 Check the belt tension 2 Install new deck belt 3 Install belt on clutch and deck pulleys idlers and tensioning idler per routing decal on deck 4 Replace the spring 5 Refer to belt routing decal on
17. deck Schematics Schematics Electrical Diagram AYTAY 18915 HOLIMS 2 HOLIMS WHLNAN HT 2 5 i HOLNTS Old 1 YNOH SAL a 1818109 zt 1 1 SAL Old lavis 2 bt LU L 60 9 8 av av zL t S SHOLIINNOI k Ly 11 WOVTE 4 wove 2 4 9 s p C Cmos mvs 1083105 7303 z mon O BEO DVN E E onos uvis 8 z z EAEL INE 086322 a Lo lt BE BREEE z wae peose cet 26196 2 49 1 ze 21 WSL vol Soc 3904 3904 3904 oS 938 20097 MIFE z Dom ar 6 8 HOLIMS NOILIN I HOLIMS 135 HOLIMS Old 1 22018 3514 stitute uvas 5 31 Y TVN
18. in serious personal injury Do Not jump start a weak battery if these conditions exist Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries Note The following instructions are adapted from the SAE J1494 Rev Dec 2001 Battery Booster Cables Surface Vehicle Recommended Practice SAE Society of Automotive Engineers A WARNING Batteries contain acid and produce explosive gases Shield the eyes and face from the batteries at all times Do Not lean over the batteries Note Be sure the vent caps tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 19 0012785 Figure 19 Positive cable on dischar
19. previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2011 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT FREF 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 Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN 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 gt If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor Exmark parts manuals are available online at http www exmark com All Exmark equipment
20. voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Voltage Reading Maximum Charging Charger Settings 16 volts 7 amps 12 4 12 6 75 100 16 volts 7 30 Minutes amps 12 6 greater 100 12 2 12 4 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 50 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours or amps Mote Recommended Jump Starting Procedure Service Interval As required 1 Check the weak battery for terminal corrosion white green or blue snow it must be cleaned off prior to jump starting Clean and tighten connections as necessaty CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur 28 Maintenance DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting
21. water can cause rollovers which may result in serious injury death or drowning Do Not mow slopes when grass is wet Do Not mow near drop offs near water Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution slopes Avoid sudden turns or rapid speed changes Keep the roll bar in the raised and locked position and use seat belt See inside the back cover to determine the approximate slope angle of the area to be mowed e Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figure 3 G000963 Figure 3 1 Safe Zone Use the mower here on slopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water e Remove mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwards e Be aware that operating on wet grass across steep slopes or downhill may cause the mower to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage th
22. After the first 5 hours After the first 100 hours Change the hydraulic filter and fluid neck t heck the seat belt Before each use or daily he engine oil level heck the mower blades heck the safety interlock system heck the rollover protections systems roll bar knobs heck for loose hardware heck the hydraulic oil level in the expansion tank ean the engine and exhaust system area ean the hydro fan cooling guards ean the grass and debris build up from the machine and cutting deck ean the grass build up from under the cutting deck Every 25 hours Grease the front caster axles Check the tire pressures Check the condition of the belts Every 50 hours the deck and pump idler pivot Check spark arrester if equipped Check the air cleaner replace if dirty or damaged May need more often under severe Every 100 hours conditions See the Engine Owner s Manual for additional information Change the engine oil May need more often under severe conditions Remove the engine shrouds and clean the cooling fins Every 200 hours Check the spark plugs Every 500 hours Replace the emissions air intake filter Change the hydraulic filter and fluid Every 250 hours if using Mobil 1 15W50 Check the park brake adjustment 27 Maintenance Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 St
23. Brake must be engaged motion control levers out neutral lock position and PTO switch disengaged to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located on the control panel see Figure 6 and Figure 8 The hour meter records the number of hours that the engine has run G012334 Figure 8 1 LCD indicators 2 Low voltage indicator light 3 Hour Voltage display Fuel Shut Off Valve Located by the lower LH ROPS tube mounting Operation The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Align valve handle with the fuel line to open Rotate 90 to close Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck which could result in serious injury or death Stop engine remove key allow all the moving parts to stop before accessing the drive wheel release valves WARNING The engine and hydraulic drive units can become hot Touching a hot engine or hydraulic drive units can cause severe burns Allow the engine and hydraulic drive units to cool completely before accessing the drive wheel release valves Located on the left and right sides underneath the engine deck During normal operating conditions th
24. IDnUDW 5 100 1 312 000 000 amp Higher Part No 4500 996 Rev A For Serial Nos WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Important The engine in this product is not equipped with a spark arrester muffler It is a violation of California Public Resource Code CPRC Section 4442 to use or operate this engine on any forest covered brush covered or grass covered land as defined in CPRC 4126 Other states or federal areas may have similar laws To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with the Canadian standard ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured
25. ION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training e Read the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them e Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users e Never let children or untrained people operate 1 the equipment Local regulations may restrict the age of the operator e Only adults and mature teenagers should operate a mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Manual and recognizes the risks involved 2 is sufficiently
26. IWYSL 1 18915 1 431511934 TWNIWYAL NOILINS 1 TWNIWYAL Adawa 8 1 055322 1 SNOLLOANNOD HOLIMS 44 Schematics Electrical Logic Schematic 3NIONA ya ya H 1 4 5 5 8 5 HOLNTO 5 Old CaaS SSS SSS Sa 8 SAL 999989 8 2 4415 aOINTOS gt a 808 p gt 3 9 7 OF 5 5 6 1 9 3NIONA vol vse 10 4 ed S g 19715 a 1915 NAN Ni ov b OIA YMS 4 S 8 OV oe 430 8 MS Old lt 1 36 NI 1901 Sor NI 1 MS 1 36 MS Divya HOLIMS b OMS EMS ININ HY Waves SMS 4 id 3NIONA
27. acts the filter adapter then tighten the filter an additional 3 4 to 1 full turn Remove the vent plug on each transmission and fill through expansion reservoir when oil comes out of vent reinstall plug Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours Torque plugs to 180 in lb 244 N m Continue to add oil until it reaches the FULL COLD line on the expansion reservoit 2 2 2 6014851 3 Figure 23 1 Oil filter 3 Left rear tire 2 Vent plug 6 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely CAUTION Raising the mower deck for service or maintenance relying solely on mechanical hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 7 Start engine and move throttle control ahead to 1 2 throttle position Disengage parking brake WARNING Engine must be running and drive wheels must be turning so adjustments can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating c
28. and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty 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 All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are l
29. anual Change Fuel Filter Service Interval As required A fuel filter is installed between the fuel tank and the engine Replace when necessary Replacement Filters Kawasaki Kawasaki P N 49019 7005 Note It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were 32 Maintenance originally installed at the factory to keep the fuel line away from components that could cause fuel line damage Replace Emissions Air Intake Filter Service Interval Every 500 hours 1 Stop engine wait for all moving parts to stop and remove key or spark plug wire s Engage parking brake Remove the filter from the vent hose Insert a new filter into the end of the vent hose Change Hydraulic System Filter and Fluid Service Interval After the first 100 hours Every 500 hours thereafter Every 250 hours if using Mobil 1 15W50 Stop engine wait for all moving parts to stop and allow engine to cool Remove key and engage parking brake Locate the two filters under the transmissions Remove filter guards Carefully clean area around filters It is important that no dirt or contamination enter hydraulic system Unscrew filters to remove and allow oil to drain from drive system Important Before reinstalling new filters apply a thin coat of Exmark Premium Hydro Oil on the surface of the filters rubber seal Turn the filters clockwise until rubber seal cont
30. are affixed to the any ait bubbles replaced components e Familiarize yourself with the following safety signs If an attachment or accessory has been installed and instruction labels They are critical to the safe make sure current safety signs are visible operation of your Exmark commercial mower ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm GROUND CLEARANCE WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 CUTTING HEIGHT 5 1 FOR MAXIMUM FLOTATION ROLLERS MAY POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS TO SUPPORT THE MOWER DECK 1 533922 KEEP HANDS and FEET AWAY 1 633922 1 403005 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 CAUTION 24 103 2076 103 2076 11 Safety AWARNING cig TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked 109 6014 position and use seat belt 109 6014 AWARNING ROTATING MECHANICAL DEVICES Can cause serious injury Stop engine remove key and wait until all moving parts have stopped before reaching into area under seat THERE IS NO
31. cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Deck Leveling 1 Position the mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check the tire pressure in the drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Position the transport lock in the latching position Carefully rotate the blades from side to side 6 Measure between the outside cutting edges and the flat surface Figure 24 If both measurements ate not within 3 16 inch 5 mm an adjustment is required continue with this procedure Deck Front Block Size Height A 48 amp 2 54 inches 2 58 inches 1 16 5 16 inch 52 6 5 cm 6 6 cm 1 6 7 9 mm 9 10 Set the height of cut lever to the 3 inch 76 mm position Place two B thick blocks see Block Height and Rake Table under the rear edge of the cutting deck skirt one on each side of the cutting deck Place two thick blocks under each side of the front edge of the deck but not under the anti scalp roller brackets Block Height and Rake Table Rear Block Height B Carefully rotate the blades side to side Figure 24 Loosen the leveling adjust locking nuts item 1 Figure 25 on all four corners so that the deck is sitting securely on all four blocks Make sure that the slack is r
32. ccidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service 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 or Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service
33. connect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Replace module Troubleshooting Engine loses power Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate 1 Engine load is excessive 2 cleaner is dirty 3 Oil level in the crankcase is low 4 Cooling fins and air passages for the engine are plugged Dirt in fuel filter 5 6 Dirt water or stale fuel is in the fuel system 1 Reduce the ground speed 2 Clean or replace the air cleaner element 3 Add oil to the crankcase 4 Remove the obstructions from the cooling fins and air passages 5 Replace the fuel filter 6 Contact an Authorized Service Dealer 1 Tire pressure in drive tires not correct 1 Adjust tire pressure in the drive tires 1 Drive release handle not in operating position 2 Drive or pump belt is worn loose or broken 3 Drive or pump belt is off a pulley 4 Broken or missing idler spring 5 Hydraulic fluid level is low or too hot 1 Blade s not sharp 2 Cutting blade s is are bent 3 Mower deck is not level 4 Underside of mower is dirty 5 Tire pressure in drive tires not correct 6 Blade spindle bent 7 Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is
34. d Do Not adjust the rollers to support the deck sure the whizlock nuts are installed with the spring disc washer between the head of the nut and the mounting bracket Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure that PTO is disengaged 8 Torque the 3 8 16 whizlock nut to 27 33 ft lb 37 45 N m Figure 18 9 Torque the 3 8 nyloc nut to 27 33 ft lb 37 45 N m 6017198 Figure 18 1 Spring disc washer 3 3 8 nyloc torque to 27 33 cone towards nut ft lb 37 45 N m 2 Front right anti scalp 4 3 8 16 whizlock nut bracket shown torque to 27 33 ft lb 37 45 N m Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain A CAUTION This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not drive a unit on a public street or roa
35. d grass covered or brush covered unimproved land A WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect e Operate only in daylight or good artificial light keeping away from holes and hidden hazards e Be sure all drives are in neutral and parking brake is engaged before starting engine Use seat belts with the roll bar in the raised and locked position Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition e Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting overspeed the engine e Park machine level ground Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mowet After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping t
36. d inside a building Driving the Machine A CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop When the motion control levers are positioned fully outward apart in the T slot the drive system is in the neutral lock position Figure 13 When the motion control levers are moved directly inward together the drive system is in the neutral operate position 1 2 Figure 13 1 Neutral lock position 4 Forward handles out 2 Neutral operate position 5 handles in 3 Front of Unit Neutral operate 6 Reverse Driving Forward 1 Release the parking brake 2 Move the motion control levers inward to the center to the neutral position 3 To move forward in a straight line move both levers forward with equal pressure Operation 6016947 Figure 14 To turn left or right pull the motion control lever back toward neutral in the desired turn direction The machine will move faster the farther the motion control levers are moved from the neutral posit
37. d slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness e Avoid prolonged breathing of vapors e Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Safety Operation WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching e Remove accumulated debris from muffler and engine area Install and maintain in working order spark arrester before using equipment on forest covere
38. de control switch Stop engine wait for all moving parts to stop and remove key Engage parking brake Raise deck to the transport 5 inch 12 7 cm cutting height position Lift the front of unit and support unit using jack stands or equivalent support A CAUTION Raising the mower deck for service or maintenance relying solely on mechanical hydraulic jacks could be dangerous mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical hydraulic jacks for support Use adequate jack stands equivalent support Clean out any grass build up from underside of deck and in discharge deflector Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified 40 Maintenance recycling center or according to your state and local regulations Battery Disposal DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be p
39. dealers and distributors are kept informed of the latest methods of servicing and ate equipped to provide prompt and efficient service the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmatrk Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 9014545 Figure 1 Model and serial number location Model No Serial No Contents ule ala hr 3 SALET 5 Safety 5 Safe Operating 5 Safety and Instructional Decals 11 Specifica 15 15 15 17 Torque Requirements 17 Product Overview ar aa 18 Operat EE 18 18 21
40. ded to prevent seizing Copper CER EVER based anti seize is preferable Grease is an 2 Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown after one second has elapsed if the handles are in The delay will be 1 2 second if the handles are out 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 initiate shutdown after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever engine must initiate shutdown after 1 2 second has elapsed Repeat again moving the right lever in then moving both levers in engine must initiate shutdown after 1 2 second has elapsed whether operator is on seat or not Check Safety Interlock System Service Interval Before each use or daily Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER 30 Maintenance Important It is essential that operator safety mechanisms be connected and in proper operating condition p
41. device Keep the roll bar in the raised and locked position when operating the mower Lower the roll bar temporarily only when absolutely necessary 1 The knob must be completely latched with the tabs interlocking as shown in Figure 11 to lock the roll bar in the raised operate position 2 Apply forward pressure to the upper hoop of the roll bar 3 Pull the knob and rotate 90 to hold in the unlatched position to lower the roll bar 4 To return to the operate position raise the roll bar and then rotate knobs 90 so that the tabs interlock partially Apply forward pressure to the roll bar upper hoop and observe that the knobs return to the completely latched position Operation 5 Figure 11 6008592 Roll bar upper hoop Knob in latched position Pull knob to unlatch Rotate 90 to hold unlatched Knob unlatched position akWN gt 5 Make sure the knobs are fully engaged with the roll bar in the raised position The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged see Figure 12 9008619 Figure 12 1 Engaged 2 Partially engaged Do Not operate with ROPS in this condition Important Always use the seat belt with the roll bar in the operate raised position Ensure that the rear part of the seat is secured with the seat latch Op
42. dway 25 Operation WARNING Loading a unit on a trailer or truck increases the possibility of backward tip over Backward tip over could cause serious injury or death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit Ifindividual 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 e Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward Having a full width ramp provides a sutface for the frame 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 caus
43. e blades and proceed slowly off the slope Follow the manufacturet s recommendations for wheel weights or counter weights to improve stability Use extreme care with grass catchers attachments These can change the stability of the machine and cause loss of control Using the Rollover Protection System ROPS A Rollover Protection System roll bar is installed on the unit WARNING There is no rollover protection when the roll bar is down Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Keep the roll bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely necessary Do Not wear seat belt when the roll bar is down e Drive slowly and carefully e Raise the roll bar as soon as clearance permits e Check carefully for overhead clearances i e branches doorways and electrical wires before driving under any objects and Do Not contact them In the event of a rollover take the unit to an Authorized Service Dealer to have the ROPS inspected Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Safety Keep engine and engine area free from accumulation of grass leaves excessive grease
44. e could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly 22 Operation The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle midway between the SLOW and FAST positions 2 Pull the PTO switch outward to engage the blades 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle midway between the SLOW and FAST positions 2 Push the PTO switch in to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Move the motion control levers out to the neutral lock position 3 Engage the parking brake 4 Place the throttle midway between the SLOW and FAST positions 5 Disengage the PTO 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parke
45. e drive wheel release valves are positioned in front of the slots If the machine has to be pushed by hand the valves must be in the released position see Figure 9 2 3 1 4 a 5 6016690 Figure 9 Front of the machine Rotate bypass release knob counterclockwise to loosen Lever position for operating the machine Pull lever in this direction to push the machine Lever position for pushing the machine Rotate bypass release knob clockwise to tighten NOOR Release lever To release the drive system see item 1 in Figure 9 loosen the knob by turning counterclockwise Then pull the release lever on the underside of machine towards the back of the machine and retighten the knob to hold the release lever back in the released state Repeat this on each side of the machine Release the parking brake The machine is now able to be pushed by hand To reset the drive system see item 2 in Figure 9 loosen the knob by turning counterclockwise Then push the release lever on the underside of machine towards the front of the machine and retighten the knob to hold the release lever in the operating state Repeat this on each side of the machine Do Not tow machine PTO Engagement Switch Located on right console see Figure 6 20 Operation Switch must be pulled out up to engage the blades Switch is pushed in to disengage the blades Deck Lift Pedal Located at the right fron
46. e jack stands 11 Raise the deck and re install the height of cut pin 12 Check that the machine does not creep in neutral with the park brake disengaged Adjusting the Seat Ride Suspension The number of seat springs can be changed to maximize rider comfort More springs should be used with heavier operators and on rough terrain Fewer springs should be used with lighter operators and when mowing smooth well established lawns Always keep the number of springs on the left and right side the same when adding and removing springs 39 G016719 4 Figure 31 1 Bolt 3 Nut 2 Spring 4 Additional mounting holes Up to five springs can be secured to the seat box with a nut and bolt see Figure 31 Refer to the Parts Manual for spring and hardware part numbers Electric Clutch Adjustment No adjustment necessary Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions A CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen around engine shrouding and exhaust system area
47. e 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 Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A WARNING While maintenance or adjustments are being made someone could start the engine Accidental starting of the engine could seriously injure you or other bystanders Remove the key from the ignition switch engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s WARNING The engine can become very hot Touching a hot engine can cause severe burns Allow the engine to cool completely before service or making repairs around the engine area Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval Change the engine oil
48. een or welds are observed replace arrester If plugging of the screen is observed remove arrester and shake loose particles out of the arrester and clean screen with a wire brush soak in solvent if necessary Reinstall arrester on exhaust outlet Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners ROPS spring pin housing Sheave and clutch retaining bolt in the end of engine crankshaft e Hydro cross member mounting bolts Thread locking adhesives are required for some hardware on engines see the Engine manual Copper Based Anti seize Copper based anti seize is used in the following location On threads of Blade Bolts See Check Mower Blades section Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Dielectric grease should not be applied to sealed connectors 34 Maintenance Adjustments 5 Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit A CAUTION Raising the mower deck for service or maintenance relying solely on mechanical hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support may malfunction allowing the unit to fall which could
49. emoved from the deck hangers and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts 6016715 Figure 25 Leveling adjust locking 3 Deck hanger nuts Deck lift arm 4 Chain 2 11 6010313 12 25 12 Figure 24 1 Blades side to side 2 Measure here 7 Set anti scalp rollers to top holes or remove 15 completely for this adjustment 35 Recheck that blocks fit just snugly under the deck skirt Make sure all attachment bolts are tight Continue leveling the deck by checking the front to rear blade slope refer to Adjusting the Blade Slope Recheck blades for levelness and repeat deck leveling procedure if necessary Adjusting the Blade Slope Check the front to rear blade level any time you install the mower If the front blade tip is not Maintenance R see Block Height and Rake Table in Deck Leveling lower than the rear blade tip adjust the blade level using the following instructions Park the machine on a level surface and disengage the blade control switch Move the motion control levers outward to the neutral position engage the parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Check the air pressure of all four tires If needed adjust to the recommended inflation refer to Checking the Tire Pressure in D
50. en the Fuel Shut Off Valve Rotate the valve and align with the fuel line to open Starting the Engine 1 Move the motion control levers out to the neutral lock position Pull up and back on the parking brake lever to engage the parking brake Push down on the PTO switch to the disengage position Note It is not necessary for the operator to be in the seat to start the engine Place the throttle midway between the SLOW and FAST positions On a cold engine push the choke lever forward into the position a warm engine leave the choke in the OFF position Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the position gradually return choke to the OFF position as the engine warms up Engaging the PTO DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged DANGER An uncovered discharge opening will allow objects to be thrown in an operators or bystander s direction Also contact with the blad
51. ged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block NOaR WN SD 4 Connect the other end of the positive cable to the positive terminal of the booster battery 5 Connect the black negative cable to the other terminal negative of the booster battery 6 MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK 7 Start the vehicle and remove the cables in the reverse order of connection the engine block black connection is the first to disconnect Check Mower Blades Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck section 3 Inspect blades and sharpen or replace as required 4 Reinstall the blades if they were removed in the following order A Install the blade onto the spindle shaft 29 Maintenance acceptable substitute C Install the washer and blade bolt washer assembly onto the spindle Make sure the hex in the washer is engaged on the spindle before tightening the bolt Install blade bolt finger tight D Place wrench on the top spindle nut then torque the blade bolts to 50 60 ft lb 68 81 N m
52. he grass catcher WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry clothing away from rotating parts NEVER carry passengers DO NOT operate the mower when people especially children or pets are in the area Be alert slow down and use caution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed e Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Slope Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes Safety DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or
53. he neutral position The control plate tabs should touch the Figure 29 return to neutral plates on the hydros Adjust 1 Control arm shaft 3 Tracking plate pump control rod lengths by loosening the nuts 2 Tracking plate screw and rotating the turnbuckle in the appropriate direction until the wheels slightly creep in reverse Figure 30 Move the motion control levers to the s reverse position and while applying slight pressure Motion Control Li nkage to the lever allow the reverse indicator springs to Adj ustment bring the levers back to neutral The wheels must stop turning or slightly creep in reverse Located on either side of the unit below the seat the pump control linkages Rotating the turnbuckle with a 1 2 inch wrench allows fine tuning adjustments so that the machine does not move in neutral Any adjustments should be made for neutral positioning only WARNING Engine must be running and drive wheels must be turning so adjustments can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces 38 Maintenance G016718 Figure 30 1 Nut 4 Control plate 2 Turnbuckle 5 Return to neutral plate 3 Stationary plate 6 Tabs touching return to neutral plate 8 Tighten nuts 9 Shut off unit Remove jumper wire from wire harness and plug connector into seat switch 10 Remove th
54. ill put the choke in the OFF position Do Not run a warm engine with choke in the position 6014235 Figure 6 4 Blade control switch power take off Ignition switch 1 Throttle lever 2 Choke lever 5 3 Hour meter Throttle Control Located on right console red lever see Figure 6 The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle Brake Lever Located on left side of unit just to the front of the LH motion control lever The brake lever engages a parking brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake The unit must be tied down and brake engaged when transporting Ignition Switch Located on right console see Figure 6 The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Allow the key to return to the on position immediately after the engine starts 1 a aX i G008610 2 Figure 7 1 Off 2 On 3 Start Note
55. imited to the duration of the express 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 G4500 749_A 46 Notes 47 Notes 48 Service Record Date Description of Work Done Service Done By 49 MAXIMIZE THE PERFORMANCE OF YOUR EXMARK 4 CYCLE PREMIUM ENGINE OIL PREMIUM HYDRO OIL Part No 116 3373 Part No 109 9828 Both SAE 30 and SAE 10W 30 in one Commercial quality for tough high bottle heat conditions Contains increased levels of zinc and Designed specifically for zero turn phosphorus for better lubricity mower hydraulic systems No Viscosity Index Improvers that tend Superior shear resistance under to shear down in high heat heavy loads Synthetic formulation Gas amp Diesel compatible Anti corrosion additives SL and JASO rated with wet clutch compatibility for other machines EXMARK MAINTENANCE Gari Available from your local Exmark dealer Find your closest dealer at exmark com 50 6011841 Figure 32 This page be copied for personal use The maximum slope you can safely operate the machine on is 15 degrees Use the slope indicator to determine the degree of slope of hills before o
56. in the crankcase is low The throttle and choke ate not in the correct position Dirt in fuel filter Dirt water or stale fuel is in the fuel system Air cleaner is dirty Seat switch is not functioning properly Electrical connections corroded loose faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Faulty module 42 Disengage the PTO Set the parking brake Ensure the drive levers are in the neutral lock position Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Replace module Fill the fuel tank Open the fuel shutoff valve Add oil to the crankcase Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the seat switch indicator Replace seat if needed Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and re
57. ion To stop position both motion control levers in the neutral operate position Driving in Reverse 1 Move the motion control levers inward to the neutral operate position 2 To move rearward in a straight line move both levers rearward with equal pressure 0 5 ves tell Figure 15 6016948 To turn right release pressure on RH motion control lever and the rear of the machine will move towards the rear and to the right To turn left release pressure on the LH motion control lever and the rear of the machine will move towards the rear and to the left To stop position both motion control levers in the neutral operate position Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 1 2 to 5 inches 3 8 cm to 12 7 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position 2 Disengage the PTO Raise and lock the deck to the 5 inch 12 7 cm transport position Figure 16 The deck is raised by pushing the foot operated deck lift pedal forward The pedal is located at the front right corner of the floor pan Note When changing the cutting height positions always come to a complete stop and disengage the PTO 6016479 Figure 16 Transport lock handle 3 Height of cut decal Height adjustment pin 4 Deck foot pedal Insert the height ad
58. justment pin into the hole corresponding to the desired cutting height See the decal on the side of the deck lift plate for cut heights Push the foot lever forward pull the transport lock handle rearward and let the deck lower down to the predetermined cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward 24 Operation Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed 1 Stop the machine and move the motion control levers outward to the neutral locked position Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 After adjusting the height of cut adjust the anti scalp rollers by removing the nyloc nut bushing spring disc washer and whizlock nut 6 Place the rollers in one of the positions shown Figure 17 Rollers will maintain 3 4 inch 19 mm clearance to the ground to minimize gouging and roller wear or damage 1 2 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm OOOO Figure 17 For cutting heights above 3 5 inches 90 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller mounting bracket 2 Cutting height For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 4 mm clearance to the groun
59. laced 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 41 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running PTO is engaged Parking brake is not engaged Drive levers are not in neutral lock position Battery does not have a full charge Electrical connections corroded loose faulty Fuse is blown Relay or switch is defective Faulty module Fuel tank is empty Fuel shutoff valve is closed Oil level
60. lends of gasoline such as 15 E85 with more than 10 ethanol by volume Performance problems and or engine damage may result which may not be covered under warranty Do Not use gasoline containing methanol Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used Do Not add oil to gasoline Fuel Filter Kawasaki Kawasaki P N 49019 7005 e Fuel Shut Off Valve All Units 1 4 turn increments Electrical System e Charging System Flywheel Alternator e Charging Capacity 15 amps 15 Battery Type BCI Group U1 Recommended Minimum Battery CCA 260 CCA Battery Voltage 12 Volt Polarity Negative Ground Fuses All units 25 amp main fuse 20 amp charging system fuse 10 amp PTO fuse 15 amp accessory fuse Safety Interlock System LCD indicators appear for the PTO park brake drive levers and operator presence in the message display on the RH control panel PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers ate moved from neutral lock position while brake is engaged Operator Controls
61. livery charges to and from any authorized Exmark Service Dealer Consumer Warranty Conditions This warranty applies to Exmark Pioneer E Series turf equipment sold in the U S or Canada for a period of four years or 500 hours whichever occurs first for residential usage Residential usage means use of the product on the same lot as your home Use at more than one location is considered commercial use and the commercial use warranty detailed above would apply This warranty only includes the cost of parts and labor For the first warrantable service repair Exmark will cover up to 45 for associated pick up and delivery charges to and from any authorized Exmark Service Dealer Additional transportation charges may apply contact your Dealer for details Warranty Exceptions Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet Items and Conditions Not Covered This warranty does not cover the following Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear a
62. mature to use caution and 3 is of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks The owner user can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation e Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark e Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Safety Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders 4 DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire or explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors on level ground in an open area when the engine is cold Wipe up any gas
63. o Center of Drive Tire 48 inch Deck 52 inch Deck 48 7 inches 123 7 cm 48 7 inches 123 7 cm Curb Weight 48 inch Deck 52 inch Deck Kawasaki Units 799 lb 805 362 365 17 Operation Product Overview Figure 4 1 Rollover Protection 5 Motion control levers System ROPS 2 Engine Controls right 6 Parking brake console 3 Seat belt 7 Height of cut adjustment 4 Fuel cap Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of the machine Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position into the T slot locks them in the neutral position Figure 5 1 2 9016706 Figure 5 1 Neutral lock position 4 Forward handles out 2 Neutral operate position 5 handles in Neutral operate 3 Front of unit 6 Reverse Choke Control Located on right console black lever see Figure 6 The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the position and moving the choke lever to the 18 Operation rear to the detent w
64. oline that spills Never refill the fuel tank or drain the machine indoors inside an enclosed trailer Do Not fill the fuel tank completely full Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system e Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot 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 DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container an
65. omponents and hot surfaces 33 Maintenance A With the bypass valve open and the engine running slowly move the directional control in both forward and reverse 5 or 6 times With the bypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping the engine It may be necessary to repeat steps A and until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged Note Do Not change the 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 contaminants into the system Check Spark Arrester if equipped Service Interval Every 50 hours WARNING Hot exhaust system components may ignite gasoline vapors even after the engine is stopped Hot particles exhausted during engine operation may ignite flammable materials Fire may result in personal injury or property damage Do Not refuel or run engine unless spark arrester is installed 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Wait for muffler to cool 3 If any breaks in the scr
66. op engine and wait for all moving parts to stop Make sure unit is on a level surface Check with engine cold Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick according to the engine manufacturer s recommendations Remove the dipstick and read the oil level 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 Exmark 4 Cycle Premium Engine Oil is recommended refer to the Engine Owner s manual for an acceptable alternative 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 A WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter Locate the
67. orward Tracking 38 Motion Control Linkage Adjustment 38 Adjusting the Seat Ride Suspension 39 Electric Clutch 39 CICAD D eoori 40 Clean Engine and Exhaust System 521422 Rg 40 Remove Engine Shrouds and Clean Cooling 40 Clean Hydro Fan Cooling 105 40 Clean Debris From 40 Clean Grass Build Up Under Deck 40 Waste Disposal 40 42 DEHEIMA TICS 44 Safety Safety Safety Alert Symbol This lawn mower meets or exceeds the B71 4 specifications of the American National Standards Institute in effect at the time of production Exmark designed and tested this lawn mower to offer reasonably safe service however failure to comply with the following instructions may result in personal injury This Safety Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 Safety Alert Symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUT
68. osed space Make sure venting path of battery is always open once battery is filled with acid Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately CAUTION If the ignition is in the ON position there is potential for sparks and engagement of components Sparks could cause an explosion moving parts could accidentally engage causing personal injury Be sure ignition switch is in the OFF position before charging the battery Keep all guards shields and all safety devices place and in safe working condition e Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard WARNING Removing standard original equipment parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Making unauthorized changes to the engine fuel or venting system may violate EPA and CARB regulations Replace all parts including
69. perating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope Align this edge with a vertical surface a tree building fence pole etc Example of how to compare slope with folded edge 51 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM 12V POWER PORT MICRO MULCH SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB WALK BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO MULCH SYSTEM TURF STRIPER STANDON Place Model No and Serial No Date Purchased Label Here Included in the Literature Pack or Fill in Below Engine Model No and Spec No Model No Engine Serial No E No Serial No 2011 Exmark Mfg Co Inc Part No 4500 996 Rev A Industrial Park Box 808 402 223 6300 Beatrice 68310 402 223 5489 8 Righ
70. rior to use for mowing Check Rollover Protections Systems Roll Bar Knobs Service Interval Before each use or daily Check that both the mounting hardware and the knobs are in good working condition Make sure the knobs are fully engaged with the ROPS in the raised position The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged 1 6008619 Figure 21 1 Engaged 2 Partially engaged Do Not operate with ROPS in this condition Check Seat Belt Service Interval Before each use or daily Visually inspect seat belt for wear cuts and proper operation of retractor and buckle Replace before operating if damaged Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Visually inspect machine for any loose hardware ot any other possible problem Tighten hardware ot correct the problem before operating Service Air Cleaner Service Interval Every 100 hours Check the air cleaner replace if dirty or damaged May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake See the Engine Owner s Manual for maintenance instructions Change Engine Oil Service Interval
71. rive System Maintenance section Check and adjust the side to side blade level if you have not checked the setting refer to Deck Leveling Set the height of cut lever to the 3 inch 76 mm position Place two B thick blocks see Block Height and Rake Table in Deck Leveling under the rear edge of the cutting deck skirt one on each side of the cutting deck Place two thick blocks see Block Height and Rake Table in Deck Leveling under each side of the front edge of the deck but not under the anti scalp roller brackets Loosen the leveling adjust locking nuts item 1 Figure 25 on all four corners so that the deck is sitting securely on all four blocks Make sure that the slack is removed from the deck hangers and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts Carefully rotate the blades so they are facing front to rear Figure 26 Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface Figure 26 If the front blade tip is not R see Block Height and Rake Table in Deck Leveling lower than the rear blade tip adjust the front deck hanger 36 J2 2p Figure 26 2 010291 1 Blades front to rear 2 Measure here 10 When the front to rear blade slope is correct check the side to side level of the mower again refer to Deck Leveling Pump Drive Belt
72. t corner of the floor pan Push the pedal forward with your foot to raise the cutting deck Allow the pedal to move rearward to lower the cutting deck to the cut height that has been set 6016479 Figure 10 1 Transport lock handle 3 Height of cut decal 2 Height adjustment pin 4 Deck foot pedal Transport Lock Located on the height of cut adjustment plate see Figure 10 The transport latching mechanism will automatically engage when the deck is raised to the transport position To release the deck from the transport position push the foot pedal to remove the load from the transport latching mechanism pull the transport lock handle rearward and let the pedal come back to lower the deck down to the desired cut height Pre Start Fill fuel tanks See Fuel Recommendations in the Specifications section for additional gasoline information Do Not add oil to gasoline Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Raise the Rollover Protection System ROPS Important The roll bar is an integral and effective safety
73. ted directly below E ITRANSPORT LOCK 5 0 2 116 6363 1 Rotate the drive release 2 Push the machine knob to loosen slide the knob and tighten 116 4308 1 Latch 2 Unlatch PTO Switch Symbols 1 PTO disengage 2 PTO engage 116 4465 1 Fast 3 Choke on 2 Slow 4 Choke off 13 Safety oH 2 0 5 109 6016 109 6016 1 Read the instructions before servicing or performing 4 Refer to the Operator s manual for grease instructions maintenance 2 Time interval 5 Check hydraulic oil level and refer to the Operator s manual or further instructions 3 Check oil level 6 Check tire pressure WARNING 116 4430 1 Park brake engage 4 Neutral 2 Fast 5 Reverse 14 Specifications Specifications Model Numbers Serial Nos 312 000 000 and Higher PNE651K A482 PNE691K A522 Systems Engine Engine Specifications See your Engine Owner s Manual Engine Oil Type Exmark 4 Premium Engine Oil RPM Full Speed 3600 50 RPM PTO not engaged Idle 1500 100 RPM Fuel System e Capacity 7 0 gal 26 5 Fuel Recommendations For best results use only clean fresh unleaded gasoline with an octane rating of 87 or higher R M 2 rating method Oxygenated fuel with up to 10 ethanol or 15 MTBE by volume is acceptable Do Not use ethanol b
74. ts Reserved Printed in the USA www exmark com

Exmark Mower Pioneer E-Series 4500-996 Rev A User's Manual

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