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IRiver iFP-500 Series MP3 Player User Manual

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1. G007006 Number 4 Idler Pivot Pump Drive Located under engine deck Number 5 Clutch Arm Pivot Located under engine deck 3 Lubricate pivot points with a spray penetrating lubricant as shown in the Spray Lubricant Chart Spray Lubricant Chart Spray Lubricant Chart cont d Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary Change Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 Note Use only Exmark Part No 109 4180 for Summer use above 32 F 0 C or P N 1 523541 for Winter use below 32 F 0 C Refer to Transmission section in Specifications for filter specifications 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system 3 Unscrew filter to remove and allow oil to drain from reservoir Important Before reinstalling new filter fill it with Exmark Premium Hydro Oil and apply a thin coat of oil on the surface of the rubber seal Turn fi
2. Transporting Transporting a Unit WARNING Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous The ramps could collapse causing the unit to fall which could cause injury Use proper ramps that are secured to the truck or trailer Keep feet and legs out from under the unit when loading and unloading Ifnecessary use assistance when loading Be sute the fuel shut off valve is closed Use a heavy duty trailer to transport the machine Engage neutral lock latches and patk brake then block wheels Securely fasten the machine to the trailer with straps chains cables or ropes Do Not rely solely on the parking brake to hold the machine on the trailer Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain 23 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position 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 caus
3. gt Ld e 1 1 e 1 1 1 1 1 1 1 1 BYPASS BYPAS VALVE VALVE Farron a a Na A eue A su HIGH PRESSURE CHARGE PUMP INLET FRONT OF UNIT G006197 o e e e CASE DRAIN 43 Exmark Commercial Turf Equipment 2 Year Limited 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 for a period of two years This warranty applies to Exmark commercial turf equipment sold in the U S or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 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 This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following Pickup and delivery charge
4. squeeze the drive levers past the neutral position See Figure 5 position 4 Operation 1 3 Figure 5 1 Drive Lever in neutral 3 Drive Lever in forward position position 2 Drive Lever locked in 4 Drive Lever in reverse neutral position position Driving Forward 1 Release the parking brake 2 With drive levers locked in neutral shift speed control lever to desired forward speed Slowly squeeze and hold both drive levers in the neutral position and rotate both neutral lock latches from the neutral lock position to the forward position Note Do Not squeeze both drive levers all the way back This will cause the drive wheels to engage in the reverse direction To move forwatd in a straight line smoothly release both drive levers to engage drive wheels To turn left or right squeeze the right hand drive lever to turn right and the left hand drive lever to turn left To make a zero turn squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forwatd position at an equal but opposite speed Note For smooth operation of this machine avoid quick jerky movements of the drive levers Move the drive levers smoothly and deliberately To stop squeeze drive levers back to the neutral position Move the neutral lock latches into the neutral lock position and release drive levers Move the speed co
5. Maintenance Procedure Interval Change the hydraulic filter Every 250 hours yearly if using Mobil 1 15W50 Every 500 hours Replace the emissions air intake filter Check wheel hub slotted torque specification Monthly Check the battery charge Grease the PTO engagement bellcrank Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving patts 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 and push it all the way down into the tube Do Not screw into place 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 Electric Start Units Only Service Interval Monthly 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 ba
6. TERMINAL X TERMINAL B TERMINAL A TERMINAL Y POSITION CIRCUIT MAKE 1 0FF NONE 2 RUN B l A X Y 3 START B l S NOTE CONNECTORS VIEWED FROM MATING COMPONENT IGNITION SWITCH FUSE FUSE 1 Electrical Diagram 20 HP KAWASAKI ELECTRIC START GROUND KILL RELAY ENGINE 5 321 BRAKE OPERATOR renes Ou SWITCH PRESENCE SWITCH J E 2 4 5 6 GHE B 2 1 12543 523461 12 111 S 5 g 2 m eo 5 9 ae uo E 8 HKE 8s WHITE Ei ORANGE z A ORANGE 5 S BLUE 4 B RED 4 LX VioLET 2 Y RED PINK 1 2 RED 1 2 1 VIOLET E S 41 1 4188 NEUTRAL PTO SWITCH 6014389 42 Schematics Hydraulic Diagram HIGH PRESSURE a FORWARD E ca 4 HIGH PRESSURE REVERSE B HYDRAULIC TANK HIGH PRESSURE HIGH PRESSURE idi pecu L FORWARD 1 FILTER 12 gt Ld d e
7. unit using jack stands or equivalent support 3 Clean out any grass build up from underside of deck and in discharge chute Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 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 placed in the gatbage Management and disposal practices must be within relevant federal state ot local laws 38 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 adjustments procedures such as valves governor etc Have t
8. 3 16 inch 4 8 mm to 1 4 inch 6 4 mm clearance between the park brake tire bars and the tires with the park brake disengaged Re install the hairpin Hydro Drive Linkage Adjustment Adjust Speed Control Linkage and Neutral Safety Switch 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key ot spark plug wire s 2 Move the speed control lever located on the console to the full forward position and check the orientation of the tabs on the ends of the speed control crank see Figure 18 These tabs should be pointing straight down at the 6 o clock position or slightly forward Adjust the threaded yoke at the bottom of the speed control linkage see Figure 18 until the tabs are positioned correctly G006961 Figure 18 Viewed from Left Side of Unit 1 Neutral Safety Switch 2 Actuating Tab in neutral position 3 5 16 inch 7 9 mm 3 Pull the speed control lever back to neutral Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is about 5 16 inch 7 9 mm between the tab and the switch see Figure 18 If necessary move the switch fore and aft Adjust Neutral Control Linkages 1 Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground 2 Statt the engine and move the throttle ahead to the full throttle position Place the neutral lock latches in the forwar
9. USE EXMARK HYDRO OIL FILL TO TOP OF BAFFLE 4 CAUTION OT 116 0404 116 0404 CALIFORNIA SPARK ARRESTER WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrester may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements 417 2718 117 2718 13 Specifications Specifications Model Numbers Serial Nos 920 000 and Higher Manual Start Models T TS16K A363 TTS16K A363CA TTS16K A483 TTS16KA483CA TTS18K A523 Electric Start Models TTS20KAE483 TTS20KAE483CA TTS20K AE523 Systems Engine Engine Specifications See your Engine Owner s Manual Engine Oil Type Exmark 4 Cycle Premium Engine Oil RPM Full Speed 3600 No Load Idle 1550 RPM Fuel System e Capacity 5 0 gal 18 9 L Type of Fuel Regular unleaded gasoline 87 octane or higher containing no more than 10 methanol or ethanol Fuel Filter Replaceable In line Fuel Shut Off Valve 1 4 turn increments Electrical System Electric Start Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type BCI Group U1 Battery Voltage 12 Volt e Polarity Negative Ground e Fuses Two 20 amp blade type Safety Interlock System Operator must have OPC Operator Presence Control levers held in contact with handle gtips speed control lever in neutral
10. WARNING OPEN BELT DRIVE STOP ENGINE BEFORE REACHING UNDERNEATH 1 303517 J 1 303517 KEEP HANDS and FEET AWAY 1 403005 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any ait bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower Use Only Exmark Riding Attachments Use of Other Riding Attachments May Create a Hazardous Condition Resulting in Injury 493143 1 403143 STATIONARY FRONT OF MOWER 1 413094 1 413206 1 413206 36 inch Decks Only TRACKING L US R gt 1 413214 10 Safety FRONT OF MOWER 413093 48 413308 52 STATIONARY IDLERS 1 413327 48 inch and 52 inch Decks Only TENSION INDICATOR CHECK HOURLY FOR THE FIRST 4 HRS CHECK DAILY THEREAFTER ALIGN BOLT WITH TENSION INDICATOR 1 16 1 413421 1413421 SC o Y A WARNING cT e FOR NORMAL OPERATING CONDITIONS PLACE DISENGAGE BLADE CLUTCH SHUT OFF Pepe SHOWN FOR 24 19 mm ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR CLEANING DECK CUTTING HEIGHT INCHES mm CUTTING HEIGHT AD
11. and refuel the equipment with its wheels on the ground e 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 Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Safety Operation A WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING Engine exhaust contains carbon monoxide which is an odorl
12. and PTO disengaged to start engine Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged e Park brake must be disengaged to move speed control out of neutral or engine will kill Operator Controls Steering Control Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning Transmission Twin Hydrostatic Drive Two Hydro Gear variable displacement high efficiency pumps independently coupled to two high efficiency Parker Ross wheel drive motors Hydraulic Oil Use Exmark Premium Hydro Oil Hydraulic Oil Capacity 2 4 qt 2 2 L Hydraulic Filter is replaceable cartridge type P N 109 4180 25 microns 10 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C e Speeds 0 6 2 mph 10 0 km hr forward 0 22 mph 3 5 km hr reverse Drive wheels release valves allow machine to be moved when engine is not running Wheel Drive System Drive wheels are direct coupled to Parker wheel drive motors with 1 inch 25 4 mm tapered shaft 14 Specifications Tires amp Wheels Dimensions Overall Width 36 inch 48 inch 52 inch Deck Deck Deck Pneumatic Semi Air Filled Pneumatic Deflector 36 1 inches 48 1 inches 53 0 inches Up 91 7 cm 122 2 cm 134 6 cm Deflec
13. area 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 improper cooling 3 Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating 37 Maintenance Clean Debris From Machine If a battery is being replaced or if the unit containing the battery is no longer operating and is being Service Interval Before each use or daily scrapped take the battery to a local certified recycling 1 Stop engine wait for all moving parts to stop and center If no local recycling is available return the remove key Engage parking brake battery to any certified battery reseller 2 Clean off any oil debris ot 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 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise deck to the transport maximum cutting height position Lift the front of unit and support
14. charge pump cap with your hand to check the pump temperature If the cap is too hot to touch turn off engine The pumps may be damaged if the pump becomes too hot If either drive wheel still does not rotate continue with step 4 Maintenance 4 Thoroughly clean the area around each of the charge pump housings 5 prime charge pump loosen two hex socket head capscrews shown in Figure 14 1 1 2 turns only Make sure engine is not running Lift the charge pump housing upward and wait for a steady flow of oil to flow out from under the housing Retighten the capscrews Do this for both pumps Note Hydraulic reservoir can be pressutized up to 5 psi to speed this process 6 If either drive wheel still does not rotate stop and repeat steps 4 and 5 above for the respective pump If wheels rotate slowly the system may prime after additional running Check oil level as stated in Check the Hydraulic Oil Level section 7 Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position Check oil level as stated in Check the Hydraulic Oil Level section 8 Check hydro drive linkage adjustment as stated in Hydro Drive Linkage Adjustment section in Adjustments Replace Emissions Air Intake Filter Service Interval Every 500 hours 1 Stop engine wait for all moving parts to stop and remove key ot spatk plug wire s Engage parking brake 2 Remove the fil
15. 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 10 2 3 5 G012785 Figure 10 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block zi 26 Connect the other end of the positive cable to the positive terminal of the booster battery Connect the black negative cable to the other terminal negative of the booster battery MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK Start the vehicle and remove the cables in the reverse order of connection the engine block black connection is the first to disconnect Maintenance 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 requir
16. control lever in neutral and the PTO disengaged to start engine Ignition Switch Electric Start Only Located on the control console The ignition switch 1s used to start and stop the engine The ignition switch has three positions Off On and Start Insert key into switch and rotate clockwise to the position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Operator must have speed control lever in neutral OPC levers depressed and PTO disengaged to start engine When engine starts release key Fuel Shut Off Valve Located in the fuel line midway between the tank and engine The fuel shut off valve is used to shut off the flow of fuel when parking inside a building during transportation to and from the job sites and when the machine will not be used for a few days Rotate valve 1 4 tutn clockwise to shut fuel off Rotate valve 1 4 turn counterclockwise to turn fuel on Drive Wheel Release Valves Located on the left rear corner of the hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be moved by hand without the engine running With a 5 8 wrench turn both valves one turn counterclockwise to release the drive system Turn clockwise to reset the drive system Do Not overtighten Tracking Adjustment Knob Located on the right hand side of the rear
17. prevent children or other unauthorized persons from starting engine 9 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine Drive Lever Neutral Lock Latch Operation To lock the drive levers in neutral lock squeeze the drive levers to the neutral position Do Not squeeze the drive levers all the way back as this will cause the drive wheels to go into full reverse direction See Figure 5 position 1 Place thumbs on the inner lobe of the neutral lock latches and rotate them under the drive levers into the neutral lock position See Figure 5 position 2 Release the drive levers CAUTION If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage Be sure the drive levers are past the roller and securely seated at the bottom of the neutral lock latches To place the drive levers in the forward position slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches or the index finger on the front lobe and rotate them from under the drive levers Slowly and carefully release the drive levers See Figure 5 position 3 To place the drive levers in the reverse position
18. procedure Make this adjustment on both sides After adjustments are made and the wheels stop when the drive levers are in the neutral position tighten the nuts against the yokes Adjust Hydro Control Linkages 1 Place the speed control lever in the neutral position This adjustment is again made with reat of machine on jack stands and engine running at full throttle OPC levers will have to be held down and the park brake must be 35 Left Hydro Control Link 4 left side shown disengaged whenever speed control levers are moved out of the neutral position Note The neutral lock latches should be unlocked and in the forward position Loosen the front nut on left hydro control linkage as shown in Figure 19 Turn the rear control linkage adjusting nut counterclockwise until wheel rotates forward Turn the rear nut of left control linkage clockwise 1 4 of a turn at a time stopping to move the speed control forwatd and back to neutral until left wheel stops rotating forward Turn the rear nut an additional 1 2 tutn and tighten the front nut making sure not to put a bind on the linkage Make sure flat part of linkage is perpendicular to pin part of swivel see Figure 20 G006195 Figure 20 Linkage is perpendicular to pin correct position Front nut 5 Linkage in incorrect position Rear nut 6 End view of swivel After adjusting the left hydro control linkage move the speed control l
19. result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower 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 limited 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 589 C Service Record Date Description of Work Done Service Done By 45 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 API SL and JASO rated with wet clutch compatibility for other machines EXMARK MAINTENANCE A
20. throttle control midway between the Slow and Fast positions 3 Turn the key switch to the Run position 4 Pull recoil rope to start engine 5 After engine warms up gradually push in the choke control Do Not run warm engine with the choke in the ON position Note Kawasaki engines generally need to be choked even when warm Starting the Engine Electric Start Note Operator must have PTO disengaged speed control lever in neutral position and OPC levers depressed when starting the engine 1 Lock drive levers in neutral and engage park brake Pull out the choke control Place the throttle control midway between the Slow and Fast positions Turn the 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 starter cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor After engine warms up gradually push in the choke control Do Not run warm engine with the choke in the ON position Note Kawasaki engines generally need to be choked even when warm 19 Operation PTO Engagement A DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet u
21. will need to be adjusted G006953 Figure 21 2 Adjust the linkage length by loosening the jam nuts at both ends of the linkage and rotating the linkage in the ball joints Lengthen the linkage if the tire is turning in reverse and shorten the linkage if the tire is creeping forward Tighten the jam nuts at both ends Release and re engage the neutral lock latch checking that the tire stops Continue this process until the tire is at a dead stop 3 Make this adjustment for both sides Stop engine and wait for all moving parts to stop Raise rear of machine remove jack stands and carefully lower machine to the ground Tracking Adjustment 2 Stop engine and wait for all moving parts to stop Check the drive tire pressures and tire circumferences as stated in Check the Tire Pressures section in Maintenance Run the unit and observe the tracking on a level smooth hard surface such as concrete or asphalt If the unit tracks to one side or the other turn the quick track knob Turn the knob right to steer right turn the knob left to steer left Hydro Pump Spring Tension Setting 1 For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling For a heavier drive setting relocate the spring anchor link as shown in Figure 13 The spring anchor links a
22. 7 19 Operating Instr retloris eter 19 MAUS POPU 62255525 auta tab ud 23 MM 24 Recommended Maintenance Schedule s 24 Periodic Maintenance iuo de de eSATA 25 Check Engine Oil Level 25 Check Battery Charge Electric Start Units ET 25 Check Mower Blades 27 Check Safety Interlock System 28 Check for Loose Hard wares 28 Service eC leather S afe is 28 Change tap eati eis 29 Check Hydraulic Oil Level aie sio vete e 29 Check Tite Pressures 29 Check Condition Of nan aste sete ts 29 Lubricate Grease Fittings nibo 29 Check Spar P ugs eater enti ted m DARK 30 Change Hydraulic System Filtet 30 Replace Emissions Air Intake Filter 32 Wheel Hub Slotted Nut Torque SDECHICObOR ER Mis OUS 32 Inspect PTO Clutching Belt Tension 33 Thread Locking Adhesives 33 Mobil HTS Grease Or Food Grade nieht eH 33 Copper Based Anti seize ee nete 33 Dielectric Geass wo comte Wa teque 33 Eas 34 Deck evel 34 Pump Drive Belt uie eic 34 PTO Clatching Belt Iension tees 34 Deck osea rati metas 34 Park Brake Auljusttdeht oret m tete 34 Hydro Dr
23. EDITO qu e ew m For Serial Nos 920 000 amp Higher Part No 4500 696 Rev B 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 spatk 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 t
24. JUSTMENT 1 5 38 CUTTING 2 0 61 HEIGHT S1 3006 INCHES mm FOR MAXIMUM FLOTATION ROLLERS MAY BE DECK 1 3 POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM SUPPORT PIN Pepper OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION sma THE ROLLERS TO SUPPORT MOWER DECK 1 553049 1 553049 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 11 T H R T T L E f 103 1798 103 1798 Read operator s manual before operating Do NOT operate unless trained to safely Do NOT carry passengers Clear area of debris before mowing Before leaving operator s position Shut off engine and remove key before Use extreme caution when operating on slopes WARNING operate this machine Do NOT operate without shields guards and safely devices in place and working DANGER Thrown objects or blade contact can cause serious injury or death Keep all people and pets out of m area when mowing Avoid blades unless blades and E NES engine are stopped CAUTION Lock drive levers in neutral lock position Disengage PTO Shift speed control lever to neutral Engage park brake adjusting servicing or cleaning Do NOT operate on slopes greater than 20 Mow across slope NOT up and down Do NOT mow wet slopes 103 1976 20 HP Kawasaki Electric Start WARNING Read operator s manual b
25. Product Overview Torque Requirements Product Overview Bolt Location Cutter Housing Spindle 140 145 ft Ib Nut 190 197 N m Blade Mounting Bolt 55 60 ft lb 75 81 N m lubricate with anti seize Engine Deck Mower 30 35 ft lb 41 47 N m Deck Support Mount Bolts Anti Scalp Roller Nyloc 30 35 ft lb 41 47 N m Nut See Figure 9 Anti Scalp Roller Whizlock 30 35 ft lb 41 47 N m Nut See Figure 9 Engine Mounting Bolts 17 23 ft lb 23 31 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Hub Slotted Nut 140 155 ft lb Style A 190 210 N m Wheel Hub Slotted Nut minimum 100 ft lb Style B 136 N m 1 Park Brake Lever 3 Fuel Cap 2 Control 4 Height of Cut Pi Wheel Motor Mounting 30 35 ft lb 41 47 N m ORTOS eight of Cut Pins Bolts 16 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Operator Presence Control OPC Levers Located on the upper handle assembly directly above the handle grips When these levers are depressed the OPC system senses that the operator is in the normal operatot s position When the levers are released the OPC system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the PTO is engaged see Figure 4 Figure 4 1 Lever 3 Neutral Lock Latch Rotate neutral lo
26. ait for all moving parts to stop 5 Install hairpin clips in the holes for the desired cutting height See Figure 6 Important To maintain correct cutting height and rake check the following for proper adjustment A The front and rear hairpins are in the same holes with the proper spacers under the hair pins See Figure 6 21 Operation 2 2 1 5 inch 38mm 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm 4 0 inch 102mm 4 5 inch 114mm G006182 D OvOrO Figure 6 Deck support pin 2 Cutting Height B The tire pressures are set as directed in Check Tire Pressures in the Maintenance section C The length of the rear deck support link assemblies average 6 89 inches approximately 6 7 8 inches 175 01 mm from the center of the balljoint to the center of the farthest hole See Figure 7 Note All four pins must equally support the weight of the deck Adjustment in the length of the rear deck support assemblies may be necessary If one side is longer than 6 89 inches approximately 6 7 8 inches 175 01 mm than the opposite side must be shorter by the same amount 1 4 inch 6 7 8 inches 175 01 mm Figure 7 Left Hand Side Shown 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 drive levers to the neutral lock position 2 Disengag
27. and down Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 20 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes See inside the back cover to determine the approximate slope angle of the area to be mowed Remove ot mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles 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 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 the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counter weights to improve stability Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from ac
28. atrice 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 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
29. bly 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 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 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 e Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire or explosion from gasoline can burn you others and cause property damage the fuel tank outdoors on level ground in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or drain the machine indoors or inside an en
30. charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid Always shield eyes and face from battery Safety 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 e 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 ot 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 in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard WARNING Removing standard original equipment parts or using non Exmark replacement parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Replace all parts including but not limited to tires bel
31. ck latch 4 Drive Lever in neutral downward for neutral position lock position Drive Levers Located on each side of the upper handle assembly ahead of and below the handle grips These levers individually control the speed and direction of each drive wheel When the speed control lever is moved out of the neutral position and the neutral lock latches are moved into the drive position as shown in Figure 4 and the drive levers are released the drive wheels are engaged in the forward direction Squeezing the left hand and or right hand lever causes the left hand and or right hand drive wheel respectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the position of the neutral lock latches and the speed control lever Neutral Lock Latches Located on the upper handle assembly on the ends of the handle grips These latches allow the operator to lock the drive levers in a neutral position where the drive wheels are not engaged in either a forward or reverse direction Choke Control Located on the front left corner of the fuel tank suppott Choke is used to aid in starting a cold engine The choke control is pulled out to be in the ON position and pushed in to be in the OFF position Do Not run a watm engine with choke in the posi
32. closed 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 Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the reach of children 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 Iffuelis 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 a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer
33. cumulation of grass leaves excessive grease ot oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and do not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s or 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 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
34. d position as shown in Figure 4 Release the park brake and move the speed control lever to the mid speed position Note The OPC levers must be held down and the park brake must be disengaged whenever the speed control lever is moved out of neutral or the engine will kill 3 Squeeze the respective drive lever until an increased resistance is felt this is where neutral should be If the wheel turns while holding the drive lever in neutral the neutral control linkages need to be adjusted If the wheel stops then go to step 7 34 Maintenance N Neutral Control Linkage 5 Hydro Control Linkage 6 G006962 Figure 19 Viewed from Left Side of Unit Speed Control Linkage Adjust here rotate at approximately 1 4 turn increments and re check Drive Lever Linkage 7 Loosen nut Speed Control Crank 8 Yoke 4 Loosen the nut against the neutral control linkage yoke as shown in Figure 19 Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring neutral position Turn the adjusting bolt approximately 1 4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1 4 turn counterclockwise if the wheel is turning forward Release the drive lever to the forward drive position and squeeze back into the neutral position Check to see if the wheel stops If not repeat the above adjustment
35. e severe burns Allow the engine to cool completely before service or making repairs around the engine area Recommended Maintenance Schedule s Maintenance Service Interval Maintenance Procedure nec Before each use or daily Grease caster pivots C e C e C Every 25 hours C Check the mower blades Check the safety interlock system Check for loose hardware Grease the caster wheel bearings k the engine oil level Check the hydraulic oil level Check the tire pressures ean the engine and exhaust system area ean the grass and debris build up from the machine and cutting deck ean the grass build up from under the deck Service the foam element May need more often under severe conditions See the Engine Owner s manual for additional information Check the condition of the belts Every 40 hours Grease the pump drive idler pivot Grease the clutch arm pivot Grease the pump control bearings Grease the mower deck idler pivot Inspect PTO clutching belt tension Service the paper element May need mote often under severe conditions See the Engine Owner s manual for additional information Change the engine oil May need more often under severe conditions Remove engine shrouds and clean cooling fins Every 160 hours Check the spark plugs Every 200 hours Replace the paper element Every 100 hours 24 Maintenance Maintenance Service
36. e the PTO 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 whizlock nut and spring disc washer 6 Adjust anti scalp rollers for Normal Operating Conditions Place rollers in one of the positions shown in Figure 8 Rollers will maintain 3 4 inches 19 mm clearance to the ground to minimize gouging and roller wear or damage Note For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 inch 6 35 mm clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts are installed with the spring disc washer between head of the nut and mounting bracket 1 2 d 2 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm OOOO Figure 8 For cutting heights above 3 5 inches 38 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller 2 Outting height mounting bracket 7 Torque the 3 8 16 whizlock nut to 30 35 ft lb 41 47 N m Figure 9 8 If the 3 8 nyloc nut has been removed reinstall and torque to 30 35 ft lb 41 47 N m Figure 9 22 Operation G006758 Figure 9 1 Spring disc washer 3 3 8 nyloc torque to 30 35 cone towards nut ft lb 41 47 N m 2 Front right anti scalp 4 3 8 16 whizlock nut bracket shown torque to 30 35 ft Ib 41 47 N m
37. ed 4 Reinstall the blades if they were removed in the following order A Install bushing through blade with bushing flange on bottom grass side of blade G006780 Figure 11 1 Install bushing in blade prior to installing bushing in spindle B Install bushing blade assembly into spindle G006781 Figure 12 2 Torque to 55 60 ft Ib 75 81 N m Apply lubricant to threads as needed to prevent seizing Copper based anti seize preferable Grease acceptable substitute 1 Use wrench here for blade installation This nut has been torqued to 140 145 ft lb 190 197 N m C Apply lubricant to threads of blade bolt as needed to prevent seizing Copper based anti seize preferable Grease acceptable substitute Install blade bolt finger tight Place wrench on the top spindle nut then torque the blade bolts to 55 60 ft lb 75 81 N m A 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 Replacing the Discharge Deflector Service Interval As required A DANGER An uncovered discharge opening could allow the lawn mower to throw objects in the operator s or bystander s di
38. ed tight Drive or pump belt is worn loose or broken Drive or pump belt is off a pulley Blade s not sharp Cutting blade s is are bent Mowet deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Cutting blade s is are bent or unbalanced Blade mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Belt is damaged Drive belt is worn loose or broken Drive belt is off pulley Deck belt is worn loose or broken Deck belt is off pulley Broken or missing idler spring PTO clutch does not engage 40 Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust the tracking by turning knob on the right hydro control linkage in the direction that the mower needs to be adjusted to Turn the knob in 1 4 turn increments until the mower tracks correctly Adjust tire pressure in the drive tires Tighten the bypass valve Change the belt Change the belt Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to reat Clean the underside of the mower Adjust tire pressure in the drive
39. efore operating Do NOT operate unless trained to safely operate this machine Do NOT operate without shields guards and safety devices in place and working dt alr Clear area of debris before mowing DAN R Before leaving operator s position Thrown objects or blade contact can Lock drive levers in neutral lock position cause serious injury or death gt Disengage Keep all people and pets out of Shift speed control lever to neutral area when mowing Engage park brake Shutoff engine and remove key before Avoid blades unless blades and 20 adjusting servicing or cleaning Use extreme caution when operating on slopes Do NOT operate on slopes greater than 20 Mow across slope NOT up and down A G U aeta AUTION n Hearing protection recommended 103 1977 16 HP and 18 HP Kawasaki Manual Start ENHANCED CONTROL SYSTEM 103 2242 HOT SURFACE 103 2076 103 2076 P m ENGAGE PARK BRAKE ENHANCED CONTROL SYSTEM R RELEASE 103 2243 m 103 2103 103 2103 DRIVE WHEEL RELEASE ci Eh TOL Use 5 8 wrench One turn counterclockwise to release Do not over tighten V 103 4935 103 4935 12 Safety Lubricate Blade Bolt threads with copper based antiseize or grease and torque to 55 60 ft lbs 75 81 N m 109 3148 109 3148 ONLY
40. er clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 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 Stop engine and recheck oil level Check Hydraulic Oil Level Service Interval Every 40 hours 1 Stop engine and wait for all moving parts to stop and remove key Engage parking brake Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use Exmark Premium Hydro Oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Note The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tire pressure in drive ti
41. ess deadly poison that can kill you Do Not run engine indoors 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 Be sure all drives are in neutral and parking brake is engaged before starting engine Never raise deck with blades running Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine e Park machine on 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 patking brake Before refueling Before dumping the grass catcher Before making height adjustments WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Con
42. ever to the mid speed position and then back to the neutral position Recheck the left drive wheel rotation to see if further adjustment is necessaty be sure the speed control lever is in the neutral position Important If inconsistent neutral occuts check to be sure both springs are properly tightened on the speed control lever under the console especially the rear pivot spring Repeat above adjustments if necessary Place the speed control lever in neutral Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward Begin to retighten the knob clockwise about 1 4 turn at a time stopping to move the speed control forward and back Maintenance to neutral Recheck the drive wheel rotation to see if further adjustment is necessary The spring that keeps tension on the knob should normally not need adjustment However if adjustment is needed adjust to where length of spring is about 1 inch 2 5 cm between the washers Adjust spring length by turning nut at front of spring Drive Lever Linkage Adjustment 1 With rear of machine still on jack stands and engine running at full throttle disengage the park brake and move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches Figure 21 If the tire rotates in either direction the length of the drive lever link
43. ghly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Fill the fuel tank Open the fuel shutoff valve 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 electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mower pulls left or right with levers fully forwatd Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate Engine load is excessive Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Tracking needs adjustment Tire pressure in drive tires not correct Bypass valve is not clos
44. his 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 Electric Start Units Engine will not start starts hard or fails to keep running Engine loses power PTO is engaged Speed control lever is are not in neutral lock position OPC levers are released Battery does not have a full charge Electrical connections are corroded loose ot faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Ait cleaner is dirty Electrical connections are corroded loose ot faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Engine load is excessive Ait cleaner is dirty Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt watet or stale fuel is in the fuel system 39 Disengage the PTO Ensure the speed control lever is in the neutral lock position Depress OPC levers 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 thorou
45. htm All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and ate equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 Model and serial number location Model No Serial No Contents tes teg E ERR 3 Mov dp 5 Safety Alert si 5 Safe Operating e og d 5 Safety and Instructional Decals 10 Specifica ONS tte aatan 14 Model p i dea tt 14 Erden Erie PE dd 14 Dimensions oet tc matur E REA 15 Torque Requirements edt ttes 16 Product Overview A 16 Operat E a EEEE EEA 17 E 1
46. ic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Hydraulic System Air Purge Service Interval As required Air must be purged from the hydraulic system when any hydraulic components including oil filter are removed or any of the hydraulic lines are disconnected 31 The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump Figure 14 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed 1 G006192 Figure 14 Charge pump cap 2 Loosen 1 1 2 turns only 1 Stop engine and wait for all moving parts to stop Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground Check oil level as stated in Check Hydraulic Oil Level section Start engine and move throttle control ahead to full throttle position Move the speed control lever to the middle speed position and place the drive levers in the drive position If either drive wheel does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position Note It is necessary to lightly touch the
47. ine Serial No E No Serial No 2010 Exmark Mfg Co Inc Part No 4500 696 Rev B Industrial Park Box 808 402 223 6300 Cf Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
48. ive Linkage Adjustment 34 Tracking 36 Hydro Pump Spring Tension Setting 36 PTO Safety Switches gainer o ins 37 37 Clean Engine and Exhaust System PEA S eds E 37 Remove Engine Shrouds and Clean Cooling EID oisi eeu aa 37 Clean Debris From Machine 38 Clean Grass Build Up Under Deck 38 Maste DISDOBAL a iuto s tidie tte reve argen 38 t vr te aic 39 Schematics 41 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 injuty This Safety Alert Symbol Figure 2 1s used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 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 CAUTION DANGER White lettering Red background Indicates an imminently hazardous situa
49. k Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations Between the cutter housing spindle and bearings Between the cutter housing spindle and sheave Under top cutter housing bearing guatd Copper Based Anti seize Copper based anti seize is used in the following locations On threads of Blade Bolts See Check Mower Blades section Between engine crankshaft and pump and blade drive sheaves Onclutch arm assembly between bearings and shaft and between lower sheave and shaft Between pump shafts and sheaves Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Maintenance Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit Deck Leveling See Adjusting the Cutting Height section in Operation Pump Drive Belt Tension Self tensioning No adjustment necessary PTO Clutching Belt Tension See Inspect PTO Clutching Belt Tension section Deck Belt Tension Self tensioning No adjustment necessary Park Brake Adjustment 1 Shut off engine and wait for all moving parts to stop 2 Disengage the park brake Remove the hairpin in the park brake linkage Turn the linkage in the yoke until there is
50. lter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn 4 Fill reservoir as stated in Check Hydraulic Oil Level Maintenance 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 5 Loosen filter 1 2 tutn and allow a small amount of oil to leak from the oil filter this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir Turn filter clockwise until rubber seal contacts the filter adapter Then tighten the filter an additional 2 3 to 3 4 turn 6 Raise the tear 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 for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 7 If either drive wheel does not rotate one or both of the charge pumps located on the top of the main pump as shown in Figure 14 may have lost their prime Refer to Hydraulic System Air Purge section Note Do Not change hydraul
51. n 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 A 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 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 NOaARWN gt 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 are tight and level Place a damp
52. nder the mower or mower deck when the blades are engaged A DANGER An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO switch engages the cutting blades Be sure that all persons are clear of mower deck and discharge area before engaging the PTO 1 Set throttle to MIDWAY position 2 Push the PTO engagement arm forward and down to engage blades 3 Place the throttle in the FAST position to begin mowing For manual start engines The park brake must be disengaged before the PTO is engaged or the engine will kill Disengaging the PTO 1 Set throttle to MIDWAY position 2 Pull upward and back completely on the PTO engagement arm to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Lock drive levers in neutral 3 Disengage the PTO 4 Move speed control lever to neutral 5 Engage the parking brake 6 Place the throttle midway between the SLOW and FAST positions 7 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 8 Remove the key to
53. ntrol lever to the neutral position Driving in Reverse To move rearward in a straight line squeeze drive levers into the reverse position To turn left or right squeeze the right hand drive lever to turn left and the left hand drive lever to turn right To make a zero turn squeeze either the left hand ot the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed Note For smooth operation of this machine avoid quick jerky movements of the drive levers Move the drive levers smoothly and deliberately stop squeeze drive levers back to the neutral position Move the neutral lock latches into the neutral lock position and release drive levers Move the speed control lever to the neutral position Adjusting the Cutting Height WARNING When the two front support rod hairpins are removed from the mower deck the weight of the tractor section may cause the front frame of the unit to rise suddenly If the unit rises suddenly injury may occur Securely hold down the front of the unit when the front support rod hairpins are removed The cutting height of the mower deck is adjusted from 1 1 2 to 4 1 2 inches 3 81 cm to 11 4 cm in 1 2 inch increments 1 Stop the machine and move the drive levers to the neutral locked position 2 Disengage the PTO Engage the park brake Stop the engine remove the key and w
54. o products manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2010 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT If your Exmark dealer does not have the Exmatk 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 mowet BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact yout authorized Exmatk equipment dealer or distributor Exmark parts manuals are available online at http www exmark com manuals
55. of the fuel tank support The knob can be adjusted so that machine will track straight ahead with the drive levers released PTO Engagement Located on the left side of the upper handle To engage the blades push the lever forward or away from the operator until the linkage locks over center To disengage the blades pull the lever to the rear ot towards the operator For manual start engines The park brake must be disengaged before the PTO is engaged or the engine will kill Cold Start Kit Manual Start Only Located below the hydro control shield The cold start kit is used to ease the starting of the unit in cold weather or when the unit has not been operated for a period of time The cold start kit moves the idler pulley away from the pump belt releasing the tension on the belt which allows the engine to turn over with less resistance see Starting the Engine Manual Start section in Operation 18 Operation Pre Start Fill fuel tank on level ground For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Important Never use methanol gasoline containing methanol gasohol containing more than 10 ethanol premium gasoline or white gas because the fuel system could be damaged 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 Ove
56. re located under the engine deck on the left and right hand sides Note In medium or heavy duty positions the drive lever forces at the upper handle will also be increased OT 1 rr 2 3 Sec oe G006188 Figure 22 Heavy duty 3 Standard Medium duty 4 Retaining bolt 36 Maintenance PTO Safety Switch Mounted to a tab on the inside left side of the fuel tank support 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove ignition key or spatk plug wire s 2 With PTO disengaged and the bellcrank touching the rear of the slot in the engine deck adjust the PTO safety switch if needed until the bellcrank arm is 5 16 inch 7 9 mm from the switch body 3 Be sure the bellcrank Does Not touch the switch body or damage to the switch could occur 4 Retighten PTO switch mounting hardware Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions 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 debtis from rotating engine air intake screen around engine shrouding and exhaust system
57. rection and result in serious injury Also contact with the blade could occur Never operate the lawn mower unless you install a mulch plate discharge deflector or grass collection system 1 To remove a damaged or worn discharge deflector lift the leg of the spring with the loop out of the notch in the discharge deflector and slide the rod out of the discharge deflector brackets and discharge deflector To install new discharge deflector orient the spring on the rod as shown in Figure 13 Slide the rod through the front discharge deflector bracket discharge deflector and rear deflector bracket 27 Maintenance G010195 Figure 13 1 Rod 4 Mower deck 2 Spring 5 Discharge deflector bracket 3 Discharge deflector Assembled view 3 Hook the bent end of the rod around the front discharge deflector bracket to retain it from sliding out Place the leg of the spring with the loop in the notch in the discharge deflector to hold the discharge deflector in the down position see Figure 13 Important The discharge deflector must be spring loaded in the down position Lift the deflector up to test that it snaps to the full down position Check Safety Interlock System Service Interval Before each use or daily 1 For Electric Start Units Only Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and PTO disengaged Try to sta
58. res Inflate drive tires to 12 16 psi 83 110 kPa Inflate tires to pressures stated above Measure the circumference of each drive tire Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible Semi pneumatic caster tires do not need to be inflated Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove the mower deck belt shield to check mower blade drive belt condition 3 Look under engine deck to check the pump drive belt condition 4 Check all idler arms to be sure they pivot freely Disassemble clean and grease pivot bushings if necessary Lubricate Grease Fittings Note See chart for service intervals 29 Maintenance 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Service Fitting Initial Locations Pumps Interval 36 inch 48 inch 52 inch Deck Deck Deck Number of Places Wheel Bearings 2 Caster Daily Pivots 3 PTO Engagement Bellcrank 4 Pump Drive Idler Pivot 5 Clutch Arm Pivot poe hours E ad hours 6 Pump Control Ed hours Bearings 7 Mower Yearly Deck Idler Pivots
59. rfilling may result in fuel leakage or damage to the engine or emission system if equipped 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 Note After starting the engine and engaging the hydro drive if either of the drive wheels acts sluggish or will not rotate at all stop engine and refer to the Hydraulic System Air Purge Procedure in Maintenance Operating Instructions Open the Fuel Shut Off Valve Rotate the valve 1 4 turn counterclockwise to turn fuel on Starting the Engine Manual Start Note Operator must have PTO disengaged and speed control lever in neutral position when starting the engine 1 Lock drive levers in neutral and engage park brake Note A cold weather starting kit has been added for ease of starting in either cold weather or when the unit has not been run for a period of time To use cold statt kit A Pull split ring straight out the side of the unit and hook the ring over the lower rear hydro control shield bolt B Start engine Refer to the following guidelines for further starting suggestions To engage pump drive disengage cold start kit A Pull chain straight out from the side of the unit until the split ring can be removed from the bolt B Slowly release tension on chain 2 Pull out the choke control Place the
60. rt the engine with OPC levers disengaged speed control lever in neutral and PTO disengaged starter must not crank Try to start with OPC levers depressed speed control lever in any speed but neutral and PTO disengaged starter must not crank Try to start with OPC levers depressed speed control lever in neutral and PTO engaged starter must not crank For All Units Check OPC circuits Clear the area Disengage the park brake Run engine at one third throttle then with drive levers and neutral lock latches in neutral lock position move the speed control lever out of neutral and release OPC levers engine must stop Again run engine at one third throttle move the speed control lever to neutral engage PTO and release OPC levers engine must stop Note Park brake must be disengaged before the speed control lever is moved out of neutral or engine will kill For Manual Start Engines The park brake must be disengaged before the PTO is engaged or the engine will kill Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check 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 Visually inspect machine for any loose hardware or an
61. s to and from any authorized Exmark Service Dealer Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage 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 44 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 Be
62. st 2 hours Check every 2 hours for the first 8 hours of operation Every 40 hours thereafter 1 Stop engine and wait for all moving parts to stop 2 Engage PTO lever 3 Look through the round hole in the left rear corner of the engine deck to inspect blade clutching belt tension Bolt on blade engagement linkage bellcrank and indicator arm should align within 1 16 inch 1 6 mm see Figure 17 Refer to PTO Engagement Linkage for adjustment G007007 3 Figure 17 1 Engine deck 3 Align bolt to indicator within 1 16 inch 1 6 mm 2 Indicator 4 Turnbuckle Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners Pump sheave setscrews Square head setscrews on hydro pump control arms e OPC lever setscrews Lower sheave retaining bolt on clutch arm Shoulder bolts in ends of speed control crank 33 Sheave retaining bolt in end of engine crankshaft Fuel tank bulkhead fitting threads Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining IT are used on the following OPC lever hubs and ctoss shaft Note Care must be used not to bond the beating next to each OPC hub to the cross shaft which could cause binding of the OPC levers and erratic operation Fuel tank studs where studs are inserted into tan
63. tact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts DO NOT operate the mower when people especially children or pets are in the area Be alert slow down and use caution when making tutns 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 e 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 Loss of control and or loss of operator s footing could result in a fall with an arm or leg getting under the mower ot engine deck which may result in serious injury death or drowning Mow across slopes never up
64. ter from the vent hose 3 Insert a new filtet into the end of the vent hose Wheel Hub Slotted Nut Torque Specification Service Interval After the first 100 hours Every 500 hours thereafter See Figure 15 to determine which slotted nut has been installed on the unit 1 2 1 3 1 H 2 3 4 e Figure 15 dd Style A black finish 3 Style B yellow zinc 03 inch 76 mm 4 24inch 6 mm 1 Style A black finish Torque the slotted nut to 140 155 ft Ib 190 210 N m Note Do Not use anti seize on wheel hub Style B yellow zinc 1 Remove and discard the cotter pin 2 Torque the slotted nut to 100 ft lb 136 N m 3 Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 inch or less should be showing 6011816 Figure 16 0 1 inch max 2 No more than two threads 0 1 inch max should be showing here 32 4 If more than two threads 0 1 inch are showing remove nut and install washer P N 1 523157 between hub and nut 5 Torque the slotted nut to 100 ft Ib 136 N m 6 Then tighten nut until the next set of slots line up with the cross hole in shaft Do Not loosen nut to align the slot If required tighten to the next set of slots 7 Install new cotter pin P N 1 806800 Note Do Not use anti seize on wheel hub Maintenance Inspect PTO Clutching Belt Tension Service Interval After the fir
65. tion Throttle Control Located on the control console s right side The throttle is used to control engine speed Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed Moving the throttle forward into the detent is full position Speed Control Lever Located in middle of control console The speed control lever controls the maximum forward speed and is infinitely variable from neutral 0 6 2 mph 10 0 km hr Park brake must be disengaged to move speed control out of neutral or engine will kill 17 Operation Park Brake Lever Located on the left side of the unit above the hydraulic tank The brake lever engages the park 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 When parking on a steep slope the wheels must be chocked or blocked in addition to the brake being engaged The unit must be tied down and brake engaged when transporting The park brake must be disengaged to move speed control out of neutral or engine will kill For manual start engines The park brake must be disengaged before the PTO 1s engaged or the engine will kill Off Run Switch Manual Start Only Located on the console Turn key to the Run position to allow the engine to be started Turn key to the Off position to shut engine off Operator must have speed
66. tion which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read the Operator s Manual and other training material If the operatot s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users e Never let children or untrained people operate ot service the equipment Local regulations may restrict the age of the operator 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 mature to use caution and 3 is of sufficient size and weight to operate the controls comforta
67. tires Contact an Authorized Service Dealer Replace blades spindles and or check for damage to mower deck Install new cutting blade s Tighten the blade mounting bolt Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Contact an Authorized Service Dealer Install new belt Check the belt tension Check belt for damage replace if necessary Install drive belt and check adjusting shafts and belt guides for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Replace the spring Contact an Authorized Service Dealer Schematics Schematics Electrical Diagram TRANSMISSION 16 amp 18 HP KAWASAKI SAFETY INTERLOCK MODULE SWITCH N O YELLOW RED BLACK BROWN CONNECTORS ARE VIEWED FROM WIRE END N C NORMALLY CLOSED N O NORMALLY OPEN G012193 GROUND ENGINE KILL Q ENGINE PARK BRAKE BLADE SWITCH N O SWITCH N O D OPC SWITCH d N O En n 8 KEY SWITCH 41 Schematics IGNITION SWITCH TERMINAL CONNECTIONS TERMINAL A ENGINE KILL TERMINAL B BATTERY TERMINAL PTOINEUTRAL SAFETY CIRCUIT TERMINAL 8 START TERMINAL X REGULATOR TERMINAL Y BATTERY TERMINAL 8 TERMINAL
68. tor 45 9 inches 57 9 inches 62 8 inches Down 116 6 cm 147 1 159 5 cm Overall Length Pressure 14 psi 97 kPa Cutting Deck 36 inch Deck 48 inch Deck 52 inch Deck 77 7 inches 73 7 inches 75 9 inches 197 4 cm 187 2 cm 192 8 cm 16 x 6 50 8 9 x 3 50 4 Cutting Width 36 inch Deck 35 25 inches 89 5 cm 48 inch Deck 47 25 inches 120 0 cm Overall Height 52inch Deck 52 00 inches 132 1 cm 36 inch Deck 48 inch Deck 52 inch Deck Blade Size 106 7 cm 106 7 cm 106 7 cm 36 inch Deck 18 00 inches 45 7 Tread Width Outside to Outside of 48 inch Deck 16 25 inches 41 3 em Tires Widthwise Quantity 3 36 inch Deck 48 inch Deck 52 inch Deck 52 inch Deck 18 00 inches 45 7 cm 35 0 inches 39 4 inches 39 4 inches Quantity 3 88 9 cm 100 1 cm 100 1 cm Deck Drive Manual engagement of belt with over center lock Blade belt tension is adjustable Curb Weight Deck Mounting Full floating deck is attached to out front support frame removable for service Deck Depth Note Weights will vaty slightly depending on engine 36 inch Deck 5 0 inches 12 7 era ARCISOUICSOTUODUONS 48 inch Deck 5 0 inches 12 7 cm 52 inch Deck 5 0 inches 12 7 cm Cutting Height Adjustment Adjusts from 1 1 2 inches 3 8 cm to 4 1 2 inches 11 4 cm in 1 2 inch 1 3 cm increments Mulching Kit Optional Bagger Optional 15
69. ts and blades with original Exmark parts A WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result 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 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 Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 A
70. tteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Maximum Charger Settings 16 volts 7 amps Voltage Reading 12 6 ot 100 greater 124 12 6 75 100 16 volts 7 30 Minutes amps 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 117 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours or amps More 25 Maintenance Recommended Jump Starting Procedure Electric Start Units Only 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 Clea
71. vailable from your local Exmark dealer Find your closest dealer at exmark com 46 G011841 Figure 23 This page may be copied for personal use 1 The maximum slope you can safely operate the machine on is 20 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 20 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 47 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 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Eng
72. y other possible problem Tighten hardware or correct the problem before operating Service Air Cleaner Service Interval Every 25 hours Service the foam element May need more often under severe conditions See the Engine Owner s manual for additional information Every 100 hours Service the paper element May 28 Maintenance need more often under severe conditions See the Engine Owner s manual for additional information Every 200 hours Yearly whichever comes first Replace the paper element 1 Stop engine wait for all moving parts to stop and remove key or spark plug wire s Engage parking brake See the Engine Owner s Manual for maintenance instructions Change Engine Oil Service Interval After the first 5 hours Every 100 hours May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Drain oil while engine is warm from operation 3 The oil drain hose assembly is located on the left side of the engine Place pan under machine to catch oil Remove oil drain plug Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft lb 27 33 N m Replace the oil filter per the Engine Owner s Manual Clean around oil filter and unscrew filter to remove Before the new filter is installed apply a thin coating of Exmark 4 Cycle Premium Engine Oil on the surface of the rubber seal Turn filt

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