Home

Husqvarna 115 13 81-96 Chainsaw User Manual

1. AV Hd Lav1S AV TIJ di JINUJ HIX NOTI LIOW Hd Era E Eg 3 l G3MJIA S ULJJNNOJ FON l na LE DAN E LE ou SE Bou g er gl ETa 8 E xo vw E a ad x S Za Te hee ele T J Bi I DE 13 DIA OF JFIINLT 1 3 WEY fi 5 Nd JIHAD 079 awa NYA a 318 y0 Souvan 038 q FI THKODY 18 Sot Inta LAVIS E A X V 1 8 Nod a 3L1HA 2208 JONY D NON 430 1 038 40 1134 AIVIEANIA JAvwW LIN JIJ NDILISOd 339 YO a Aww J Mi _ 3389 YO MS Fates bas 1309 om w HJLIMS a AJA ld 3118 DO JONYAD X IVNINW331 i 4389 OL NYAD LAD HOLIAS JOWA WANT OL JANY D NI KOLIAS A TIUNIMO3L ai AVIS 0 s ae _ O F we 034 CNO i Y TIVNINSI1 ma N 3118 A HUH a E MEN WS g IVNIWAJI as e a NVA S WNIWASL JND MENI ONYAN I TIVWNINAI31 sn L JLINS 0 13 TA ILIN VL HILIAS Old JILIN SMOH A ININ83 Te ANId ATJ HILIMS LLL AVTSO LYAS X MWN IW 3 H Dva 03 i AVIAN LAVLS S WNIWSI Sus BB BH LE z a A a HILIAS Old 8313H SNH IT VNIWAS l n pu A AJILLY9 O WNINYS A AAA AV BI NYA WNIWSI a AV BO LVS SADILJFNNDD WNIWSAI ONNOSO HINT FTIOON FI J 1931 ANTHIWW 3 1V35 NI JO V 3dO KLIM CASO 34 SSHOLTAS
2. NOTLTSOd 2001 IVaLM N NI S JAJI TOJJNDJ KLIM 035019 JAV SFKILIAS TDJINOJ NOTLOW H108
3. 48 9 HYDRAULIC DIAGRAM AS VIEWED FROM REAR OF UNIT HIGH PRESSURE FORWARD UN HIGH PRESSURE CHARGE PUMP INLET CASE DRAIN HIGH PRESSURE FORWARD ON BYPASS VALVE HIGH PRESSURE REVERSE HIGH PRESSURE REVERSE 49 10 Limited Warranty Exmark Turf Equipment Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part manufactured by Exmark and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship This warranty applies to Exmark turf equipment sold in the US or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Products e All Products except as noted below 90 days for rental
4. f Check that the PTO is disengaged g Check that the spark plug wires are properly connected h Check for loose or faulty wiring connections 1 Check for corrosion at all wiring connections Even minor corrosion may cause a faulty connection Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect NOTE When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors NOTE After carefully checking the above steps attempt to start the engine If it does not start contact your authorized Exmark service dealer IMPORTANT It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer ENGINE TROUBLESHOOTING TABLE EVE E AER LEVEL SCREEN CHARGE warm xt x E x E x Hardstarting X x x xX xX x x Stopssuddenty X xX xX x x x X Lacks power xX xX Operates erratically xX x X X x Xx x Kmocksorpings Jx x xX Skipsormistires x
5. 93 6 in 237 7 cm 2 11 3 Overall Height Roll Bar Up Roll Bar Down 71 9 in 182 6 cm 53 8 in 136 7 cm 2 11 4 Tread Width center to center of tires widthwise w 60 Deck w 72 Deck 41 9 in 106 4 cm 45 9 in 116 6 cm Caster wheels 39 0 in 99 1 cm 47 6 in 120 9 cm 2 11 5 Wheel Base center of caster tire to center of drive tire w 60 Decks w 72 Deck 50 3 in 127 8 cm 54 5 in 138 4 cm 2 11 6 Curb Weight w 60 Deck w 72 Deck 1403 Ibs 636 kg 1408 Ibs 639 ko 2 12 TORQUE REQUIREMENTS Bolt Location Torque Cutter Housing Spindle Nut occocccccccccccccccnconcnconos 140 145 ft lbs 190 197 N m Blade Mounting Bolt ccooccccocccocnoconiconnccanicunoss 115 120 ft lbs 156 163 N M Engine Deck Front Frame Mount Bolts 30 35 ft lbs 41 47 N M Anti Scalp Roller Bolts is ci 40 45 ft lbs 54 61 N M Engine Mounting Bolts ooccooccocccocncncncccnnaconanonanonanos 25 30 ft lbs 34 41 N M Wheel Lug NUS ocio ets uri bb ki 90 95 ft lbs 122 129 N M Wheel Motor Mounting BoltS oocccoccooccooccooconooo 72 77 ft lbs 98 104 N M Wheel Hub Slotted Nut occcoocccccncccccccccccacccncncnoo minimum125 ft lbs 169 N M Rollover Protection System roll bar Mounting Bolts 30 35 ft lbs 41 47 N M 14 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE MOWER 3 2 I
6. Hinged to tilt up for access to hydraulic pumps battery and other components Held in tilted position with prop rod Adjustable fore and aft seat track Armrests Standard seat foam padded flip up armrests with height adjustment Optional suspension seat molded adjustable flip up armrests Seat Safety Switch Incorporated into the Safety Interlock System Time delay seat switch eliminates rough ground cut outs 2 8 HYDROSTATIC GROUND DRIVE SYSTEM 2 8 1 2 8 2 2 8 3 2 8 4 2 8 5 2 8 6 2 8 1 2 9 TIRES Quantity Tread Size Ply Rating 13 psi Sora 13 psi 0 KPa a Hydrostatic Pumps Two Hydro Gear BDP 10A variable displacement piston pumps Wheel Motors Two Parker Ross with 1 1 4 tapered shafts Hydraulic Oil Type Synthetic Mobil 1 15W 50 Hydraulic Oil Capacity 2 1 qt 2 0 L Hydraulic Filter Replaceable cartridge type P N 1 513211 10 microns 18 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C Speeds 0 9 8 mph 15 8 km hr forward 0 6 3 mph 10 1 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running Front Caster Pneumatic Air Filled Pneumatic Air Filled 2 2 2 Multi Trac C S 2120012 13x650 13 x 6 50 6 2 10 CUTTING DECK 2 10 1 2 10 2 2 10 3 2 10 4 2 10 5 2 10 6 Cutting Width 60 in 152 4 cm 72 in 182 9 cm Discharge Side Blade Size 3 ea w 60
7. Remove seal guards from the wheel hub d Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the SPACER NUT WITH axle Remove the axle with the other Goose WRENCH FLATS spacer nut still assembled to it from the wheel assembly FIGURE 9 e Pry out seals and inspect bearings for CASTER WHEEL ASSEMBLY wear or damage and replace if necessary f Pack the bearings with a NGLI grade 1 multi purpose grease g Insert 1 bearing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced h Ifthe axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to 1 spacer nut and thread onto the axle with the wrench flats facing outward Do not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 1 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing h With the open end of the wheel facing up fill the area inside the wheel around the axle full of NGLI grade 1 multi purpose grease 1 Insert the second bearing and new seal into the wheel j Apply a thread locking adhesive to the os Spacer nut and thread onto the axle with the wrench flats facing outward k Torque the nut to 75 80 in lbs 8 9 N m
8. operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance TABLE OF CONTENTS 1 SAFETY PAGE TT Salen ALONE SY DON b dio ass bi bak a poin e Dl ab bn ko bn oi a oi fo bk bebe al 1 N MONN it ie a n ee l pi l a E tty ema e pa a a errs e ke ti pie ek e aka 1 to A A 1 3 t4 DST ALON ei tit rt koka lit ak n a ka ia e a kk a n n ka a 4 7 1 5 Maintenance amp Storage ooccccccccocccccnncncnnoonononnnnnnonnnnonanonnnnonanonannonaninnnnnnnns 7 8 NS A A A 9 11 2 SPECIFICATIONS 2 1 Model NUMDELS eiii ideas 12 22 E o a 12 2 3 SA A 12 24 ME
9. AN WARNING ger paus ca betay i apode q FR N illness al PA rae rng In evento nection n acida nifun f N R and always shield eyes race skin es wan va dia iately oa ep a aa dit n oh of children Use 5 8 wrench R One turn counterclockwise to release Y Do not over tighten Y PART NO 103 4973 LOCATION Top of console A CAUTION HOT SURFACE 103 2076 2 Js Q PART NO 103 2076 LOCATION Top of Radiator Trim Plate LH amp RH Sides AWARNING DISENGAGE BLADE CLUTCH SHUT OFF ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR CLEANING DECK 1 633313 PART NO 1 633313 LOCATION RH Side on Top Front of Mower Deck PART NO 103 0262 LOCATION RH Front of Console ACAUTION f A WARNING BOTATING BLADES te ROTATING MECHANICAL DEVICES AA NS gt Ata en Fak REACHING UNDERNEATH p g p 3 A 1 643253 a e Stop engine before opening oe vo PO en PART NO 103 0368 LOCATION LH and RH Sides of Radiator Mount Plate LOCATION Rubber Heat Shield Flap behind Seat 10 rai HYDRAULIC OIL USE ONLY MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILL TO TOP OF BAFFLE 7 SN A CAUTION AN HOT as SURFACE 1 523552 PART NO 1 523552 LOCATION Top of Hydraulic Reservoir Under the Seat This cooling system protected by Y Shell DEX COOL Extended Life Anti Fr
10. DISPOS AN E Ea 45 64 BatetADISPOSA vcd tj at de oi jen et tin a a l po e eed seki pay 46 E TROUBLE SHOOTING oia lic 46 47 8 ELECTRICAL DIAGRAMS 2 0 00 000llllllivvveeeeeertttrreroooeooooooooooooseeeeoseoeooooooooooooon 48 9 HYDRAULIC DIAGRAM cuidas rada 49 10 WARRANTY ia Baer ecg cn e a n ak eka e ae nad cons dade tera kn ei ake sa 50 1 SAFETY 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL 4h is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the prop
11. Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we shall have no liability or responsibility for e Expenses related to gasoline oil or lubricants e Travel time overtime after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer 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 e Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment which is the s
12. To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage a Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage rere kn Saki Charging Interval Reading Charge Charger Settings ik 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps 1 Hour 12 0 12 2 25 50 14 4 volts 4 amps 2 Hours 11 7 12 0 0 25 14 4 volts 4 amps 3 Hours 11 7 or less 0 14 4 volts 2 amps 6 Hours or More 27 9 1 4 Clean engine cooling system Service Interval Daily or more often in dry conditions A CAUTION POTENTIAL HAZARD Excessive debris and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat WHAT CAN HAPPEN Excessive debris around the engine cooling a
13. disconnect battery cables in the reverse order after starting 1 5 MAINTENANCE AND STORAGE 1 5 1 1 5 2 1 0 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 9 9 1 5 10 1 5 11 1 5 12 For engine maintenance follow the engine manufacturer s recommendations precisely as stated in the engine manual Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Keep engine engine area and pump drive belt compartment free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Store fuel in a container specifically designed for this purpose in a cool dry place Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present Maximum mowing results and safety can only be ach
14. may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD 4 DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support a This adjustment must be made with the drive wheels turning First raise the frame and block up so that drive wheels can rotate freely b Remove the electrical connection from the seat safety switch located directly to the left of the seat switch assembly beside the hydraulic oil reservoir Temporarily install a jumper wire across the terminals in the connector of the wiring harness c Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature d Unhook seat latch and tilt seat forward e Loosen lock nuts from the ball joints at each end of the LH pump control linkage See Figure 18 LOOSEN HERE RIGHTHAND THREAD TURN HERE TO ADJUST LOOSEN HERE LEFTHAND THREAD AS NS MAN A PEE TURN RH TRACKING ADJUSTMENT KNOB y DO NOT LOOSEN ANY ee LEFT HAND SIDE OF UNIT RIGHT HAND SIDE OF UNIT NUTS ON RH SIDE NOTE The nut to the front of the unit on the LH rod has left hand tnreads FIGURE 18 MOTION CONTROL ADJUSTMENT 43 j Start engine Brake must be engaged and motion control levers out to start engine Operator does not have to be in the seat because of the jumper wire being used Run en
15. oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example lf 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 5 1 15 Check tire pressures Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Check tire pressure in drive tires c Inflate drive tires to 13 psi 90 kPa For units with Pneumatic Caster tires with a valve stem d Check tire pressure in Caster tires e Inflate caster tires to 13 psi 90 kPa For units with Semi Pneumatic Caster tires without a valve stem d Caster tires do not need to be inflated 33 NOTE Do not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty 5 1 16 Check condition of belts Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up Lift the rubber flap on front side of the engine to check pump drive belt c Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt d Check under machine to inspect the mule drive belt e See Sections 5 2 3 through 5 2 5 for belt ad
16. ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible DO NOT attempt to turn the unit while on the ramp you may lose control and drive off the side 25 Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 9 MAINTENANCE amp ADJUSTMENTS WARNING POTENTIAL HAZARD While
17. x X xX Tx _A gt A ld ee A O CO EC a KAN Check for dirty radiator core 7 4 ENGINE WARNING SYSTEMS 7 4 1 Warning Buzzer Located behind the seat on the right hand side When the engine is running and the buzzer emits a beep the buzzer is warning signal the user that the engine is overheating Perform the following step gt lt gt gt lt gt gt lt pi x txt xixi x xxx X gt lt gt gt lt X X gt x Z 1 Disengage the mower blade and idle down the engine 2 Look at the temperature gauge to determine if the temperature continues to increase If it does turn the unit off and allow the engine and engine components to cool 3 Check the coolant level If necessary fill with coolant as described in Section 5 1 2 4 Remove any debris on or around the radiator that may restrict airflow 47 0304903 FAVJB HLIM Nad 030V3N3 3148 KLIK 03500 8 ELECTRICAL DIAGRAM
18. 0 51 2 5 64 3 0 76 3 5 90 an ee BRACKET BE EFFECTIVE AGAINST SHOWN SCALPING P a ANTI SCALP ROLLER MOUNTING BRACKET TORQUE TO 40 45 ft Ibs 54 61 N M FIGURE 11 ANTI SCALP ROLLER ADJUSTMENT tt Deck Leveling a b c Position mower on a flat surface Stop engine wait for all moving parts to stop and remove key Check tire pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary For units with Pneumatic Caster tires with a valve stem Check tire pressure in Caster tires Proper inflation pressure for tires is 13 psi 90 kPa For units with Semi Pneumatic Caster tires without a valve stem Caster tires do not need to be inflated Set anti scalp rollers to top holes or remove them completely for this adjustment 38 For 72 Deck Apply downward pressure here i Raise the deck to the 5 12 7 cm height position also transport position and take all force off of the two large deck lift springs by loosening the nuts at the front of each spring See Figure 12 For 60 units Lower the deck to the 1 1 2 3 81 cm height position For 72 units Lower the deck to the 1 1 2 3 81 cm height position Force the left rear deck support arm downward about 1 4 6 4 mm to get the deck to rest at the 1 1 2 height position Place locking pliers between the rear swivel and spring stop to hold the deck in this position See Fig
19. 107 2102 Inside Surface of Upper Roll bar LOCATION G 44 WARNING Disengage PTO a Move drive levers out to neutral lock position l Engage park brake Uj f Stop engine 103 3794 l J N i of AN PART NO 103 3979 LOCATION RH Side of Console ON WARNING E Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning To avoid loss of control and possibility of rollover Do NOT operate near drop offs or near water Do NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes There is no rollover protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warning Q E o 107 2112 t mXxXozro PART NO 107 2112 LOCATION Top Center of Floorpan mr 0I 103 4930 PART NO 103 4930 LOCATION Right of Choke Control on RH Fuel Tank far 103 1798 PART NO 103 1798 LOCATION Right of Throttle Control on RH Fuel Tank Gyr a aw Engage IMPORTANT Before starting engine clean grass from pump drive belt compartment Check more often in dry conditions ADANGER COVER IS MISSING
20. DO NOT OPERATE mm THIS UNIT WHEN COVER IS NOTIN PLACE PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s 103 4474 PART NO 103 4474 LOCATION Top Front of RH Fuel Tank 9 DANGER KEEP HANDS and FEET AWAY FD Na PART NO 1 403005 LOCATION Left and Right Corners of Mower Deck BELT ROUTING BLADE BELT 1 643052 72 1 633127 60 1 633366 52 1 43222 PART NO 1 643222 LOCATION Left of Center on Mower Deck Under Floor Pan ACAUTION EZ SWITCH PART NUMBER 1 633782 SEE DO NOT OPERATE OPERATOR S MANUAL FOR DISPOSAL INSTRUCTIONS 1 643401 WITHOUT GUARD IN PLACE PART NO 1 643401 LOCATION On Tilt Switch 1 513748 PART NO 1 513748 LOCATIONS Bottom Side 103 3510 of Floorpan 3120 20 uo 1039 EUGIUG Kb A N O STE P PART NO 103 3270 PART NO 1 513742 LOCATION Rear RH Side of LOCATION Top of Mower Deck Belt Radiator Mount Shields Left and Right Sides Plate 4 CAUTION Loose or Damaged Blade Bolt may allow blade to come out from under deck at HIGH SPEED e Replace Blade Bolt after striking a foreign ob ject e Torque Blade Bolt to 115 120 F T LBS 156 163N m SEE OPERATOR S MANUAL 103 1077 PART NO 103 1077 LOCATION LH Side on Top Front of MOTION M ower Deck MOTION CONTROL CONTROL a 103 4973 aj ME A CAUTION DRIVE WHEEL RELEASE PO cojo t re L
21. Deck 20 5 in 52 1 cm w 72 Deck 24 5 in 62 2 cm Blade Spindles Solid steel spindles with1 I D bearings Deck Drive Electric clutch mounted on horizontal engine shaft B Section belt with self tensioning idler from electric clutch to transfer shaft mounted on deck Blades are driven by one B Section belt w self tensioning idler from transfer shaft on deck to blade spindles Deck Full floating deck is attached to out front support frame Six anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge 13 Deck Depth 60 Deck 5 5 14 0 cm 72 Deck 5 5 14 0 cm 2 10 7 Cutting Height Adjustment an extra long cushioned lever is used to adjust the cutting height from 1 1 2 3 8 cm to 5 10 2 cm in 1 4 64 cm increments The cutting height adjustment handle has a transport position and all adjustments can be made while the operator remains seated Units also have a foot operated deck lift assist lever to aid in raising the deck 2 10 8 Mulching Kit Optional 2 11 DIMENSIONS without deck deflector up deflector down 2 11 1 Overall Width w 60 Deck 53 5 in 135 9 cm 61 4 in 156 0 cm 72 2 in 183 4 cm w 72 Deck 57 3 in 145 5 cm 73 4 in 186 4 cm 84 3 in 214 1 cm 2 11 2 Overall Length w 60 Deck w 72 Deck Roll Bar Up 80 7 in 205 0 cm 84 8 in 215 4 cm Roll Bar Down 89 2 in 226 6 cm
22. ENGAGED FIGURE 15 BRAKE ADJUSTMENT 5 2 9 Brake Adjustment a Check for brake link 2 75 7 0 cm measurement as described in section 5 2 8 b Engage brake lever lever up c Measure the distance between the trunion roller and the rod collar Measurement should be 3 16 4 8 mm to 1 4 6 4 mm See Figure 15 d If adjustment is necessary loosen the nut directly below the yoke Turn the bottom nut below washer until the correct measurement is obtained See Figure 15 turn nut clockwise to lengthen the gap screws rod into yoke and turn counter clockwise to shorten the gap screws rod out of yoke Tighten nut against yoke and check opposite side of unit repeat if necessary 5 2 10 Adjust Throttle Lever Tension a Stop engine wait for all moving parts to stop and remove key b Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt which is located under the console See Figure 16 41 a Yi TAB WASHER BELLEVILLE WASHERS gt BOLT FIGURE 16 THROTTLE TENSION 5 2 11 Electric Clutch Adjustment No adjustment necessary 5 2 12 Reverse Indicator Adjustment a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat forward c Begin with either the left or right motion control lever Move lever to the neutral position and pull lever back until the clevis pin on arm below pivot shaft contacts the end of the slot
23. For Serial Nos 440 000 amp Higher ank MFG CO INC OPERATOR S MANUAL LAZER Z LIQUID COOLED MODELS CONGRATULATIONS on the purchase of your new Exmark mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the part number description and quantity of the part needed The Serial No plate is located on the right side of the console For ease of ordering and reference we suggest that you record the information requested in the following identification table Place Model No and Serial No Label Here Engine Model No and Spec No Code Included in Literature Pack or Fill in Below Engine Serial No E No Model No Date Purchased Serial No Part No 103 5505 Rev A WARNING POTENTIAL HAZARD This product is a piece of power equipment WHAT CAN HAPPEN Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD Keep all shields guards and safety devices especially the grass discharge system in place and in proper working condition Stop engine and
24. ID THE HAZARD Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging PTO IMPORTANT Operator must be in seat before the PTO can be engaged Set throttle to midway position Pull outward on the switch to the ROTATE position Accelerate to full throttle to begin mowing 4 3 5 Stopping PTO Set throttle to the midway position Push in on the switch to the STOP position stopping the PTO 4 3 6 Stopping Engine Bring unit to a full stop Disengage the PTO move motion control levers out to the neutral lock position and set parking brake Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engine Rotate ignition switch to OFF position Remove the key to prevent children or other unauthorized persons from starting engine Close fuel shut off valve when machine will not be used for a few days when transporting and when the unit is parked inside a building 4 4 TRANSPORTING 4 4 1 Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps
25. IN A MINIMUM OF 1 4 GROUND CLEARANCE NEVER POSITION 1 833922 4 PART NO 1 633922 LOCATION Front Center on Top CHECK SERVICE REFERENCE AID Da GREASE LUBE POINTS AT INTERVALS SHOWN 1 CHECK HYDRAULIC FLUID ATINTERVAL SHOWN USE ONLY MOBIL 1 15W 50 SYNTHETIC MOTOR OIL SEE ENGINE OPERATORS MANUAL FOR SERVICING ENGINE CHECK TIRE PRESSURE IN PNEUMATIC TIRES 13 PSI AT INTERVAL SHOWN SEE OPERATORS MANUAL FOR ADDITIONAL DETAILS YEARLY UNDER ENGINE DECK of Mower Deck For Units with S N 465 000 and Higher PART NO 103 6319 LOCATION Bottom Side of Floor Pan 11 25 HOURS lt 40 HOURS W ZERK YEARLY W O ZERK YEARLY X PART NO 1 303508 LOCATION RH Side on Top Rear of Mower Deck IMPORTANT BEFORE STARTING ENGINE CLEAN GRASS FROM PUMP DRIVE BELT COMPARTMENT CHECK MORE OFTEN IN DRY CONDITIONS PART NO 1 633462 LOCATION Rubber Heat Shield Flap behind Seat 1 633462 KILL RELAY 103 1027 START RELAY FAN RELAY PART NO 103 1027 LOCATION RH Radiator Side Plate PART NO 1 633706 LOCATION LH Side of Cutting Height Adjustment Plate CHECK SERVICE REFERENCE AID lt A GREASE LUBE POINTS AT INTERVALS SHOWN 1 CHECK HYDRAULIC FLUID AT INTERVAL SHOWN USE ONLY MOBIL 1 15W 50 SYNTHETIC MOTOR OIL 2 SEE ENGINE OPERATORS MANUAL FOR SERVICING ENGINE CHECK TIRE PRESSURE 13 PSI ATINTERVAL SHOWN SEE OPERATORS MANUAL FOR ADD
26. ITIONAL DETAILS 25 HOURS UNDER ENGINE DECK 25 HOURS 40 HOURS W ZERK YEARL Y W O ZERK lt A YEARLY 25 HOURS 25 HOURS 1 833702 For Units with S N 464 999 and Lower PART NO 1 633702 LOCATION Bottom Side of Floor Pan 2 SPECIFICATIONS 2 1 MODEL NUMBER Serial Nos 440 000 and Higher LZ27LKAG04 LZ27LKA 24 2 2 ENGINE 2 2 1 2 2 2 Engine Specifications See your Engine Owner s Manual RPM Full Speed 3750 RPM No Load Idle 2200 RPM 2 3 FUEL SYSTEM 2 3 1 Capacity 13 5 gal 51 L 2 3 2 Type of Fuel Regular unleaded gasoline 87 octane or higher 2 3 3 Fuel Filter In line 40 Micron Kawasaki P N 49019 1055 2 3 4 Fuel Shut Off Valve 1 4 turn increments left tank OFF right tank 2 3 0 Fuel gauge in left hand fuel tank 2 4 ELECTRICAL SYSTEM 2 4 1 Charging System 3 Phase Flywheel Alternator 2 4 2 Charging Capacity 10 amps minimum 30 amps charging less 15 20 amps for electric fan 2 4 3 Battery Type BCI Group U1 2 4 4 Battery Voltage 12 Volt 2 4 5 Polarity Negative Ground 2 4 6 Fuses One 20 amp and two 30 amp blade type 2 4 7 Safety Interlock System PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine lt is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO Is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if
27. NE TOWARDS BOLT HEAD HT kid TORQUE TO l po 115 120 ft lbs 156 163 N m G0089 FIGURE 7 BLADE BOLT INSTALLATION 5 1 7 Check safety interlock system a Service Interval Daily Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank 29 9 1 10 b Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must stop after approx 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must stop after 1 2 second has elapsed Run engine at one third throttle with brake disengaged move levers in and r
28. NSTALL ROLLOVER PROTECTION SYSTEM ROLL BAR 3 2 1 3 2 2 3 2 3 3 2 4 Disassemble roll bar from the crate a Remove roll bar tubes from sides of crate and remove screws that attach the wheel hub retaining plate to the bottom of the crate b Remove the two brackets used to mount the bottom of the upper roll bar tube to the crate Remove the 1 2 13 x 3 1 4 capscrews and 1 2 13 hex flange lock nuts from the two brackets at each end of the upper roll bar tube and retain for later use Raise the rear of the unit and support it with jack stands or equivalent support CAUTION POTENTIAL HAZARD Raising the rear of the unit for assembly relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Remove the wheel nuts from both sides of the unit and retain for later use Install the two lower roll bar tubes a Locate the left and right lower roll bar tubes b Align lower roll bar tubes along wheel motor channels as shown in Figure 2 c LOOSELY install the lower roll bar hardware from the bolt bag to the tubes in the following order Reference Figure 2 for alignment and installation instructions below 1 Install one 3 8 16 n
29. ack stands or equivalent support just high enough to allow drive wheels to turn freely g Start engine and move throttle control ahead to full throttle position Move the speed control levers to the full soeed and run for several minutes Shut down machine and recheck oil level 36 9 1 26 9 1 27 9 1 28 9 1 29 9 1 30 Do not change hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Wheel hub slotted nut torque specification Service Interval 500 hrs When tightening the slotted nut on the wheel motor tapered shaft a Torque the slotted nut to 125 ft Ibs 169 N M b Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 or less should be showing c If more than two threads 0 1 are showing remove nut and install washer PN 1 523157 between hub and nut d Torque the slotted nut to 125 ft lbs 169 N M e Then tighten nut until the next set of slots line up with the cross hole in shaft f Replace cotter pin NOTE Do not use antisieze on wheel hub Fuel Tank mounting hardware specification When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperatur
30. aise off seat but do not get off of machine engine must stop after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever in engine must stop Repeat again moving the right lever in then moving both levers in engine must stop whether operator is on seat or not NOTE If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER IMPORTANT It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check rollover protection system roll bar pins Service Interval Daily a Make sure latch pin and hair pin are fully installed and lanyard is in good condition Check for loose hardware Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service air cleaner Service Interval 50 hrs More often under severe conditions See Engine manual for additional information a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch tilt seat up and tilt hood forward to gain access to the air cleaner c Loosen retaining clips and remove air cleaner compartment cover d Remove paper element Check the condition of the paper element Replace if dirty bent or d
31. alent support c Clean out any grass build up from underside of deck and in discharge chute Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 5 1 5 28 Inspect blades and sharpen or replace as required Re install the blades if they were removed by placing a block of wood between the front or rear baffles and the blade then torque the blade bolts to 115 120 ft lbs 156 163 N m Be sure the spring disk washer cone is installed toward the bolt head See Figure 7 CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck causing serious injury or property damage HOW TO AVOID THE HAZARD Replace the blade bolt after striking a foreign object Use only the following replacement parts Blade bolt PN 103 0862 Spring disc washer PN 103 0865 DO NOT lubricate the threads of the bolt or spindle before assembly Torque the blade bolt to 115 120 ft Ibs 156 163 N m BLOCK OF WOOD BETWEEN FRONT OR REAR BAFFLES amp BLADE if 156 163 N m Ni ee gt oy T w l Xx DO NOT USE WRENCH HERE FOR b s NIL BLADE INSTALLATION MAINTAIN 140 145 ft lbs 190 197 N m TORQUE ON THIS NUT CO
32. amaged e DO NOT wash or use pressurized air to clean paper element or inner element f Reinstall element Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips 30 9 1 11 9 1 12 9 1 13 Check Spark Arrester Service Interval 50 hours Ah WARNING POTENTIAL HAZARD Hot exhaust system components may ignite gasoline vapors even after the engine is stopped Hot particles exhausted during engine operation may ignite flammable materials WHAT CAN HAPPEN 4 Fire may result in personal injury or property damage HOW TO AVOID THE HAZARD Do NOT refuel or run engine unless spark arrester is installed a Shut off engine remove key and wait for all moving parts to stop Wait for muffler to cool c If any breaks in the screen or welds are observed replace arrester If plugging of the screen is observed remove arrester and shake loose particles out of the arrester and clean screen with a wire brush soak in solvent if necessary Re install arrester on exhaust outlet Change engine oil Service Interval 100 hrs NOTE Change oil and filter after first five 5 hrs of operation a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch tilt seat up and tilt hood forward to gain access to the engine area c Drain oil while engine is warm from operation d The oil drain valve is located on left hand side of engine P
33. and blades are stopped 1 before using this machine j Do NOT operate unless trained to safely use 7 mn Nom this machine Q m Gs J PARK Do NOT operate under the influence of i CUTTING BRAKE alcohol or drugs HEIGHT Do NOT operate without shields guards and safety devices in place and working e Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC Ya system PY Stop engine and remove key before adjusting servicing or cleaning machine and attachments e Hearing protection is recommended A WARNING To avoid serious injury or death I Pick up objects that could be thrown by the blades Do NOT mow when people and pets are in the area No Do NOT carry passengers mii Look behind and to the side before changing directions Before leaving the operator s position 103 3979 ENGAGE A s PART NO 103 3794 LOCATION LH Side of Console k TO AVOID INJURY OR A FROM ROLLOVE Keep roll w in the raised and locked position and use seat belt ka THERE IS NO ROL WH BAR IS DOWN Lower the roll bar only when absolutely necessary Do not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Read and follow slope operation instructions and warnings po 107 2102 PART NO
34. ary loosen the idler pulley on the right hand side so it can move up and down in the slot Place a wrench on the 3 8 nut in the center of the spring loaded pulley and apply upward pressure to relieve tension on the spring a 1 2 drive breaker bar and 9 16 socket works best Reposition the adjusting pulley to the bottom of the slot NOTE When installing a new belt it is necessary to reposition the right adjusting pulley upward in the slot in order to position the center of the spring loaded pulley between the alignment holes FRONT A SPRING OF RIGHT SIDE er M IDLER PULLEY E ADJUSTABLE N zi N ep ALIGNMENT Il so O FRONT OF UNIT G0073 FIGURE 13 MULE DRIVE BELT ADJUSTMENT 5 2 5 Deck Belt Tension a The deck belt is tensioned by a self tensioning idler no adjustment is necessary 5 2 6 Adjust Seat Switch a If necessary adjust the seat actuator rod length to where the machine will shut off when the operator raises off the seat with brake disengaged or PTO engaged but will continue to run with operator in seat a slight shift in weight should not shut machine off Normal adjustment is when length of spring is 2 09 5 3 cm with seat up NOTE To prevent rough ground cut outs the unit is equipped with a time delayed seat switch When the operator raises off the seat with either the brake disengaged or the PTO engaged the engine should stop after 1 2 second has elapsed b To adjust seat
35. attempt to open or repair the tilt switch Avoid contact with the mercury The tilt switch PN 1 633782 on this unit contains mercury a hazardous material Mercury that is outside a sealed container vaporizes at room temperature The vapors are harmful Mercury can be absorbed through the skin Do not attempt to open or repair this switch A very small amount of mercury is contained in a hermetically sealed body The steel switch is then potted in a hard epoxy in a plastic case It is unlikely that the mercury will ever escape from the enclosure These high performance and reliable inexpensive switches are recyclable Mercury is an important and beneficial compound but requires special care in handling and disposal When used and managed properly mercury is not a threat to people or the environment This information is presented to users so that they are aware that these switches contain mercury and will apply sound disposal practices when these devices reach their normal end of life or are damaged Several states have passed laws concerning the disposal of devices containing mercury In all the remaining states it is advisable to follow similar procedures The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused recycled or otherwise managed to insure that it does not become part of solid waste or waters Management and disposal practices must be within relevant fede
36. bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely necessary Do not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits e Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water e Check carefully for overhead clearances i e branches doorways and electrical wires before driving under any objects and do not contact them Use EXTREME caution when backing up LOOK BEHIND YOU Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition DO NOT change the engine governor settings or overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury Disengage PTO before starting engine Start the engine carefully with feet well away from the blades Keep hands feet and clothing away from rotating parts while the mower is being operated Stop engine wait for all moving parts to stop and remove key e Before checking cleaning or working on the mower e After striking a foreign object inspect the mower for damage and make repairs before restarting and operating the mower e Before clearing blocka
37. chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain 24 4 4 2 4 CAUTION POTENTIAL HAZARD 4 This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem These items are required to drive on a public street or roadway WHAT CAN HAPPEN Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines HOW TO AVOID THE HAZARD Do not drive a unit on a public street or roadway Ah WARNING POTENTIAL HAZARD Loading a unit on a trailer or truck increases the possibility of backward tip over WHAT CAN HAPPEN Backward tip over of the unit could cause serious injury or death HOW TO AVOID THE HAZARD Use extreme caution when operating a unit on a ramp Use only a single full width ramp DO NOT use individual ramps for each side of the unit If individual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit DO NOT exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a
38. ck springs by loosening nuts here O O O O g A TI Yo i IO e OL l Front of Unit Socket head adjusting screw eg FIGU RE 1 2 W gt 9 2 3 9 2 4 SWIVEL ADJUSTMENT SPRING COMPRESSION ADJUSTMENT Raise deck lift lever to the 5 12 7 cm cutting height position See Figure 10 Adjust spring compression until proper distance is obtained between the two large washers See Figure 12 Adjustment is made by turning the nut at the front of each spring clockwise will shorten the spring counter clockwise will lengthen the spring Lock in position with jam nuts NOTE When above adjustments have been made the front of the deck will be slightly lower than the rear of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary Mule Drive Belt Tension Adjustment Self tensioning idler adjust as follows 39 a Stop engine wait for all moving parts to stop and remove key b Check to make sure the center of the bolt head in the center of the spring loaded pulley on left side engine deck support is positioned between the centers of the two alignment holes in the left support plate See Figure 13 It is necessary to adjust the belt tension when the center of the bolt head is at or below the center of the bottom alignment hole c When adjustment is necess
39. cooling system and touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system CAUTION POTENTIAL HAZARD Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets 1 6 SAFETY SIGNS 1 6 1 1 6 2 1 6 3 1 6 4 1 6 5 1 6 6 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Safety signs must be replaced if they are missing or illegible When new components are installed be sure that current safety signs are affixed to the replaced components 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 air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower RELEASE l n Sa WARNING DANGER Da LI v Y To avoid serious injury or death To avoid serious injury or death Read and understand the operator s manual Jj e Avoid blades unless engine
40. djustment gt a Remove dust cap from caster and tighten nyloc nut until washers are flat and back ini off 1 4 of a turn to properly set the pre load on the bearings If disassembled RNS make sure the spring washers are reinstalled as shown in Figure 19 gt FIGURE 19 CASTER ADJUSTMENT 5 2 15 Seat armrest adjustment a Lift armrest on seat Locate square tab marked with the numbers 1 through 4 Rotate square tab 1 4 turn to raise or lower the armrest in approximately 1 4 6 4 mm increments See Figure 20 MW Armrest Adjustment Tab Rotate Turn FIGURE 20 ARMREST ADJUSTMENT 44 6 WASTE DISPOSAL 6 1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 6 2 ENGINE COOLANT DISPOSAL 4A CAUTION POTENTIAL HAZARD Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets Dex Cool contains ethylene glycol Ethylene glycol is a pollutant Dispose of used engine coolant according to your state and local regulations 6 3 MERCURY SWITCH DISPOSAL CAUTION POTENTIAL HAZARD The mercury contained in the tilt switch is poisonous WHAT CAN HAPPEN Exposure to mercury can cause severe illness HOW TO AVOID THE HAZARD Never
41. e and in proper working condition DANGER POTENTIAL HAZARD 4 In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN A static charge can ignite gasoline vapors A fire or explosion from gasoline can burn you others and Cause property damage HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or ona truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Ah WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks or hot engine exhaust components WHAT CAN HAPPEN Explosion and fire may occur resulting in property damage personal injury and or death HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer t
42. e and fuel levels Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners a Pump drive sheave set screws b Square head setscrews on Hydro pump control arms Cc Sheave retaining bolt in the end of engine crankshaft d Caster wheel spacer nuts e Fuel tank bulkhead fitting nuts Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining or Retaining ll are used on the following a Fuel tank studs where studs are inserted into tank Mobil HTS grease or food grade antisieze is used in the following locations a Between the cutter housing spindle and bearings b Between the cutter housing spindle and sheave c Under top cutter housing bearing guard d Between jackshaft and bearings and jackshaft and sheaves Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 5 2 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine wait for all moving parts to stop and remove key before servicing cleaning or making any adjustments to the unit 9 2 1 Cutting Height Adjustment a Stop machine and move drive levers out to neutral lock position b Disengage PTO c Raise the deck lever to the transport position also the 5 12 7 cm cutting height position See Figure 10 SAT 9 2 2 The deck can be raised by pulling the deck lever up and or by pushing on the deck li
43. e temperature continues to increase If it does turn the unit off and allow the engine and engine components to cool 3 Check the coolant level If necessary fill with coolant as described in Section 5 1 2 4 Remove any debris on or around the radiator that may restrict airflow 4 2 PRE START 4 2 1 Fill fuel tanks For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Regular grade leaded gasoline may also be used however combustion chamber and cylinder head will require more frequent service See Engine Owner s Manual DO NOT add oil to gasoline DO NOT overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 4 2 2 Make sure you understand the controls their locations their functions and their safety requirements 4 2 3 Refer to Maintenance Section 5 and perform all the necessary inspection and maintenance steps 4 3 OPERATING INSTRUCTIONS 4 3 1 Operate units with the roll bar in the raised and locked position and use seat belt There is no rollover protection when the roll bar is down If it is necessary to lower roll bar do not wear the seat belt Raise the roll bar as soon as clearance permits 4 3 2 Open fuel shut off valve left or right tank 4 3 3 Starting Engine Brake must be engaged motion control levers out neutral
44. eeze Coolant e Top off only with Shell DEX COOL Extended Life Anti Freeze Coolant e Suggested change interval is at 4 years or 4 000 hours of service e Do not mix with conventional coolants e Shell DEX COOL Extended Life Anti Freeze Coolant is available at your local auto parts store Dex Cool is a registered trademark of General Motors Corp Another Product Innovation From D Mank YO 103 0223 PART NO 103 0223 LOCATION LH Side on Top Ne PART NO 1 643339 LOCATION Top of Right Engine Baffle i of Radiator THE ROLLERS TO SUPPORT THE MOWER DECK S PUMP BELT ROUTING Q O 1 643339 P C WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 Y ITEM NAME 1 ROLLER 2 BUSHING 3 SPRING WASHER 4 3 8 16 X 4 BOLT 5 MOUNT BRACKET 6 FLAT WASHER 7 WHIZLOCK NUT lt 2 MUST BE GRADE 8 BOLT AND WASHERS MUST BE INSTALLED AS SHOWN IN DIAGRAM TORQUE NUT TO 35 45 FT LBS imd 1 323540 PART NO 1 323540 LOCATION Left Rear Corner Top of Mower Deck ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 GROUND CLEARANCE CUTTING HEIGHT INCHES mm FOR MAXIMUM FLOTATION ROLLERS MAY BE POSITIONED LOWER BUT MUST MAINTA
45. either the left the right or both levers are moved from neutral lock position while brake is engaged 2 4 8 Tilt Switch Shuts off the engine when the unit is tilted more than 60 from horizontal 2 5 COOLING SYSTEM 2 5 1 Fan Electric with continuous operation with engine running 2 02 Coolant Liquid 50 50 mix of DexCool extended life antifreeze and water 2 5 3 Coolant Capacity 4 quarts 2 6 OPERATOR CONTROLS 2 6 1 Steering and Motion Control Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the position of the levers relative to each other Moving motion control levers outward in slots locks the drive system in neutral NOTE Motion control levers are adjustable to two heights 2 6 2 PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades 2 6 3 Parking Brake Lever Engages parking brake 2 6 4 Deck Height Adjustment Lever Sets cutting height to desired position 2 6 5 Deck Lift Assist Lever Foot pedal that assists in raising the deck 2 7 SEAT 2 7 1 212 2 7 3 2 1 4 Type Standard seat with high back foam padded internal suspension and armrests Optional seat accessories e Custom ride suspension system to enhance Standard Seat e Deluxe suspension seat with high back low profile foam in place cushion dampened adjustable spring suspension and armrests Mounting
46. ems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication EXMARK PARTS PLUS PROGRAM EFFECTIVE DATE September 1 1995 Program If your Exmark dealer does not have the Exmark part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed How the Program Works 1 If dealer does not have part in stock for a down unit at the time of request by customer the dealer contacts his distributor by 1 00 p m local time and requests Exmark Parts Plus shipment of six 6 line items or less 2 Distributor ships part s to dealer or customer as E X M A R K P A R T S P L T 15 requested by dealer same day overnight UPS Distributor bills dealer for part and freight charges where applicable 3 If distributor does not have the part s in stock to satisfy Exmark Parts Plus order he contacts Exmark by 3 00 p m central time w
47. ep sparks flames or cigarettes away from battery Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid 3 3 2 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see the following chart for recommended charger settings Reading Charge Charger Settings ging 12 6 or greater 12 4 12 6 12 2 12 4 12 0 12 2 11 7 12 0 11 7 or less 16 volts 7 amps 16 volts 7 amps 16 volts 7 amps 14 4 volts 4 amps 14 4 volts 4 amps 14 4 volts 2 amps 17 No Charging Required 30 Minutes 1 Hour 2 Hours 3 Hours 6 Hours or More 3 3 3 Ah CAUTION POTENTIAL HAZARD 4 Ifthe ignition is in the ON position there is potential for sparks and engagement of components WHAT CAN HAPPEN Sparks could cause an explosion or moving parts could accidentally engage causing personal injury HOW TO AVOID THE HAZARD Be sure ignition switch is in the OFF position before charging the battery Connect the negative battery cables NOTE
48. er use of the equipment If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property 1 3 PREPARATION 1 3 1 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark 1 3 2 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended CAUTION POTENTIAL HAZARD This machine produces sound levels in excess of 85 dBA at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine 1 3 3 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals A 1 3 4 Thoroughly inspect the area where the equipment is to be used and remo
49. forward move the right lever back toward neutral to slow the right drive wheel To make a zero turn to the left pull the left lever back beyond neutral while holding the right lever slightly ahead of neutral To make a zero turn to the right pull the right lever back beyond neutral while holding the left lever slightly ahead of neutral Pulling the fevers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction spring tension can be felt when moving into reverse from neutral To turn to the left while backing move the left lever forward toward neutral To turn to the right while backing move the right lever forward toward neutral CAUTION POTENTIAL HAZARD Machine can spin very rapidly by positioning one lever too much ahead of the other WHAT CAN HAPPEN Operator may lose control of the machine which may cause damage to the machine or injury HOW TO AVOID THE HAZARD Use caution when making turns Slow the machine down before making sharp turns Tracking Adjustment Knob Located under the seat on the RH pump control link Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position Stop machine and wait for all moving parts to stop Engage park brake Unhook seat latch and tilt seat forward to gain access to the tracking knob Rotate the knob clockwise as viewed from the rear of the mach
50. ft assist lever NOTE When changing cutting height positions always come to a complete stop and disengage the PTO LEVER IN TRANSPORT AND 5 12 7 cm CUTTING HEIGHT POSITION GU FIGURE 10 CUTTING HEIGHT POSITION Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter See decal on the side of the deck lift plate Move lever out of transport or 5 12 7 cm cutting height position and down onto height adjustment pin to mow at selected height To transport move lever back up to transport or 5 12 7 cm cutting height position Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure that PTO is disengaged Adjust anti scalp rollers for Normal Operating Conditions Stop engine wait for all moving parts to stop and remove key Place rollers in one of the positions shown in Figure 11 Rollers will maintain 3 4 in 19 mm clearance to the ground to minimize gouging and roller wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm minimum clearance to ground Do Not adjust rollers to support the deck Be sure bolt is tightened properly or loss of anti scalp roller may result SPRING DISC WASHER FOR CUTTING HEIGHTS ABOVE CONE TOWARDS 3 5 38 mm USE THE BOTTOM BOLT HEAD HOLE THE ROLLERS WILL STILL CUTTING HEIGHT INCHES mm 2
51. gers hands and clothing clear of rotating components Shut off engine remove key and wait for moving parts to stop before performing maintenance e With the cap off the radiator tilt hood closed and put the seat down Start the engine Refer to Section 4 3 3 Return the seat up and hood forward to the open position f Operate engine until the engine thermostat opens and coolant is circulating through the radiator core As air is purged from the engine block and the coolant level drops add additional coolant to the radiator g When the radiator is completely full and no additional coolant can be added continue running and install the radiator cap Make sure that the cap is completely seated by pressing down firmly while turning until the cap stops Once the cap is installed the engine may be stopped 5 1 14 Check hydraulic oil level Service Interval 40 hr a Stop engine and wait for all moving parts to stop b Unhook seat latch and tilt seat up c Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use only Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do not overtighten NOTE The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the
52. ges e Whenever you leave the mower Stop the engine and wait for all moving parts to stop e Before refueling e Before dumping the grass catcher Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engine The fuel system is provided with a shut off valve Shut off the fuel e When the machine will not be used for a few days e During transport to and from the job e When parked inside a building This mower was designed for one operator only Keep all others away from mower during operation 1 4 17 1 4 18 1 4 19 1 4 20 1 4 21 Do Not mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Be aware of the mower discharge and direct discharge away from others Do Not operate mower under the influence of alcohol or drugs Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision If jump starting is required a connect the positive power cable from the positive post on the booster battery to the positive terminal post on the starter solenoid switch this post has the positive battery cable attached to it b connect the negative or ground cable from the negative post on the booster battery to the engine block as far away from the battery as possible c
53. gine at full throttle and release brake The reverse indicator spring must be correct before the following adjustments can be made See Section 5 2 12 NOTE The motion control lever needs to be in neutral while making any necessary adjustments The left rod assembly controls the left wheel and the right rod assembly controls the right wheel Bring the LH motion control lever into the neutral position Adjust LH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse See Figure 18 Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral The wheel must stop turning or slightly creep in reverse When adjustment is complete tighten lock nuts onto ball joints Bring the RH motion control lever into the neutral position Adjust the RH pump control rod length by rotating the tracking adjustment knob in the appropriate direction until the wheels slightly creep in reverse Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral The wheel must stop turning or slightly creep in reverse See Figure 18 Shut off unit Remove jumper wire from wire harness connector and plug connector into seat switch 5 2 14 Caster pivot bearings pre load a
54. gine coolant is toxic Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets Drain coolant when engine is cool Coolant may be drained from the radiator by loosening the drain cock in the right rear corner The engine block may be drained by removing the rear radiator hose and or by removing the drain plugs from the engine block The plug may be accessed from the bottom left hand side of the engine The plug may be identified as a hex head bolt with a black finish See Figure 8 O LES 2b a j AR on L CIS A COOLANT DRAIN PLUG LOCATED HERE HEX HEAD BOLT WITH BLACK FINISH VIEWED FROM REAR OF UNIT FIGURE 8 COOLANT PLUG LOCATION a Re install all drain plugs and hoses and tighten drain cock b Fill radiator with a 50 50 mix of water and Dex CoolO coolant as specified in Section 2 5 2 allowing some room approximately 1 2 12 7 mm for expansion Add 50 50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle a 44 WARNING POTENTIAL HAZARD Engine compartment contains open belt drives and fans Rotating components can cause injury WHAT CAN HAPPEN Fingers hands loose clothing or jewelry can get caught by the rotating fan and drive shaft HOW TO AVOID THE HAZARD Do not operate machine without the covers in place Keep fin
55. gine coolant level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure unit is on a level surface b Unhook seat latch tilt seat up and tilt hood forward to gain access to the cooling area c Check with engine cold d View coolant level in overflow bottle on the left side of the engine Coolant level should be at the indicator line on the overflow bottle 26 e Ifthe coolant level is low remove the cap to the overflow bottle and fill to the indicator line Use coolant specified in Section 2 5 2 NOTE Units should only be filled with Dex Cool extended life coolant which can be identified by its orange color AX WARNING POTENTIAL HAZARD Engine coolant is hot and pressurized Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system and touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system Ay CAUTION POTENTIAL HAZARD Engine coolant is toxic Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets Check battery charge Service Interval Monthly Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life
56. he amount of fuel in the left tank only Use the fuel from the right fuel tank first When the right fuel tank is empty switch to the left fuel tank Fuel gauge will monitor the remaining fuel Drive Wheel Release Valves Located on the top left front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Unhook seat latch and tilt seat up to gain access to pumps With a 5 8 wrench turn both valves one turn counter clockwise to release drive system Turn clockwise to reset system DO NOT overtighten DO NOT tow machine Coolant Temperature Gauge Located at the front of the left fuel tank The coolant temperature gauge monitors the temperature of the engine coolant An engine overheating condition is indicated by the red area on the gauge and an alarm will sound See Section 4 1 15 Voltmeter Located next to the Coolant Temperature Gauge at the front of the left fuel tank The voltmeter measures the voltage output of the alternator Both high and low voltages will potentially damage the battery DN 4 1 15 Warning Buzzer Located behind the seat on the right hand side When the engine is running and the buzzer emits a beep the buzzer is warning signal the user that the engine is overheating Perform the following step 1 Disengage the mower blade and idle down the engine 2 Look at the temperature gauge to determine if th
57. ieved if the mower is properly maintained and operated correctly Check all bolts frequently to maintain proper tightness Keep all guards shields and all safety devices in place and in safe working condition Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as or equivalent to the parts supplied as original equipment Ah WARNING POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrate skin and cause injury WHAT CAN HAPPEN Y Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system For Kawasaki Liquid Cooled units WARNING POTENTIAL HAZARD Engine coolant is hot and pressurized Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine
58. ine to cause the machine to track more to the right and counterclockwise to cause the machine to track more to the left Adjust in quarter turn increments until the machine tracks straight Check that the machine does not creep when in neutral with the park brakes disengaged IMPORTANT Do not rotate the knob too far as this may cause the machine to creep in neutral Refer to section 5 2 13 for control linkage adjustment PTO Engagement Switch Located on right fuel tank Switch must be pulled out to the ROTATE position to engage the blades Switch is pushed in to the STOP position to stop the blades Choke Control Located on right fuel tank Choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear will put the choke in the OFF position DO NOT run a warm engine with choke in the ON position 21 4 1 10 4 1 11 4 1 12 4 1 13 4 1 14 Throttle Control Located on right fuel tank Throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Brake Lever Located on left side of unit just to the front of the console The brake lever engages a parking brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake The u
59. ir intake and inside of the pump drive belt compartment can create a fire hazard HOW TO AVOID THE HAZARD Clean all debris from inside of pump drive belt compartment daily IMPORTANT Inf on d BEFORE STARTING ENGINE nformation located CLEAN GRASS FROM PUMP e On right fuel tank decal 103 4474 DRIVE BELT COMPARTMENT e On decal 1 633462 behind seat on CHECK MORE OFTEN IN DRY CONDITIONS ye rubber heat shield flap a Stop engine wait for all moving parts to stop and remove key b Clean all debris from inside of pump drive belt compartment c Wipe debris from screen in engine cover Rotate engine cover forward and wipe debris from radiator core as required Inspect seals in engine cover and replace as necessary Clean grass build up under deck Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Raise deck to the transport 5 12 7 cm cutting height position Lift the front of unit and support unit using jack stands or equivalent support Ah CAUTION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equiv
60. ith an Exmark Parts Plus order of six 6 line items or less 4 If order is received by 3 00 p m central time Exmark ships part s direct to dealer or customer as requested by distributor same day overnight UPS Exmark bills the distributor for parts and shipping charges where applicable 5 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program 6 Who pays for the part and freight if it fails to arrive overnight in accordance to the program A Under any circumstance the customer does not pay B Ifthe part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following restrictions apply The Exmark Parts Plus Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday Parts Plus ser
61. just beginning to put pressure on spring See Figure 17 d Check where lever is relative to notch in console should be centered allowing lever to pivot outward to the neutral lock position e If adjustment is needed loosen the nut against the yoke and while applying slight rearward pressure on the motion control lever turn the head of the adjustment bolt in the appropriate direction until lever is centered keeping rearward pressure on the lever will Keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position Tighten lock nut BRACKET l LOCKNUT FRICTION WASHERS f Repeat on opposite side of unit LEVER CENTERED IN NOTCH REVERSE INDICATOR TURN BOLT HERE LOOSEN HERE G0050 FIGURE 17 REVERSE INDICATOR ADJUSTMENT 42 5 2 13 Motion control linkage adjustment WARNING POTENTIAL HAZARD Engine must be running and drive wheels must be turning so motion control adjustment can be performed WHAT CAN HAPPEN Contact with moving parts or hot surfaces may cause personal injury HOW TO AVOID THE HAZARD Keep fingers hands and clothing clear of rotating components and hot surfaces 4 CAUTION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or
62. justment 5 1 17 Lubricate grease fittings Service Interval Refer to chart a Stop engine wait for all moving parts to stop and remove key b Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule LUBRICATION CHART FITTING INITIAL NO of SERVICE LOCATIONS PUMPS PLACES INTERVAL 1 Front Caster wheel hubs 4 Deck Drive Belt IdlerArm___ ______ ____ Y f6 Mule Drive Betieram T T Pump Drive Betidler Am D n See Section 5 1 16 c for special lubrication instructions on the front caster pivots and Section 5 1 17 for special lubrication instructions on the front casters wheel hubs 5 ie No 6 Mule Drive Belt Idler Arm 8 3 3 1 Located Under Engine Frame mi No 7 Pump Drive Belt Idler Arm Ca Y SD s HAD Located Under Engine Frame i No 4 6 amp 7 Idler Pivots For Units with S N 464 999 and Lower Monthly disassemble belt and spring and grease under a No Load condition 69076 34 c Lubricate front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thread plug back in Place cap back on 5 1 18 Lubricate caster wheel hubs Service Interval Once Yearly a Stop engine wait for all moving parts to stop and remove key b Remove caster wheel from caster forks c
63. lECMICAN o St Ms dad 12 2 57 GOOM gt SM E en ok le fk tea pite 12 2 6 Operator CONMO Sote ia tas de eko al ead a ee a a e nos a ala ei kai rada 12 E lead ia aa nati acho det Coa a A 13 2 8 Hydrostatic Ground Drive System ooccconcccccncoccccccncconicncnnonnnnonnnnnnnnnnnconcnnonnss 13 2 erezi titya iya bio ei kon bi ate a a Oar ek e ke at bb 13 210 CUNO DECK fi e ale a ay n a a n n e n ki a n n n a e a a a e a ak pe akote 13 14 ZAN DIMENSION Sr dida 14 2 12 Torque Requirements ers ita 14 3 ASSEMBLY INSTRUCTIONS SL nerale MOWON siii os 15 3 2 Install Rollover Protection System Roll Bar cocccoccccocicoccccocncono 15 17 29 A A 17 18 34 Install DAVE VYNCCIS naa e a 18 390 CHECK Tire ROSS Ud 18 3 6 Install Motion Control Levers oocoocccconnicccncocccconncconoconnconnnnncnnnnnnnnnnnnons 18 19 3 7 Position Discharge Chute ccooccccocnoconccocncconoconnocononanoonononanononnonanonannnnaninnnnns 19 9 6 SONMICE E NOUVO isine 19 3 9 Service Engine Cod rescata eed da ae koka ik e a ao k gi kal 19 20 9 10 SONVIGE Hydraulic Ollas dio 20 4 OPERATION INSTRUCTIONS AON SONO Saa 20 23 Ze WO E E A AT 23 43 Operating ANSMWUCHONS ici eli daa 23 24 AA Ta ns OOMING a e 24 26 5 MAINTENANCE 8 ADJUSTMENTS 9 1 Pernodic Maintenance 00d A ai 26 37 e PAGIUISUTICING nai tdi 37 44 6 WASTE DISPOSAL 6 1 Motor OIDISPOSAl pvp 45 6 2 Engine Coolant DISPOSA vesical dad 45 0 3 Mercury SWIC
64. lace pan under machine to catch oil and open valve with a 10 mm wrench Allow oil to drain then close valve e Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn f Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual DO NOT overfill g Start the engine and check for leaks Change engine coolant Service Interval 4 years 4000 hours Dex Cool extended life coolant orange color It is recommended to service at whichever interval happens first a Stop engine wait for all moving parts to stop and remove key Machine must be positioned on level surface b Unhook seat latch tilt seat up and tilt hood forward to gain access to the cooling area 31 WARNING POTENTIAL HAZARD Engine coolant is hot and pressurized Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system and touching a hot radiator may Cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system Ay CAUTION POTENTIAL HAZARD En
65. lf the positive cable is also disconnected connect the positive red cable and the red wire to the positive terminal on the battery first then connect the negative black cable and white white wire to the negative terminal on the battery red wire and white white wire are only on some units Slip insulator boot over the positive terminal NOTE If time does not permit charging the battery or if charging equipment is not available connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery We Y A WARNING BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN 3 4 INSTALL DRIVE WHEELS 3 4 1 Mount drive wheels with the valve stem to the outside of the unit Secure using four 4 1 2 20 wheel nuts installed on studs in hubs for each wheel Torque to 95 ft lbs 128 N M 3 5 CHECK TIRE PRESSURE 3 5 1 Check tire pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary For units with Pneumatic Caster tires with a valve stem Check tire pressure in Caster tires Proper inflation pre
66. lock position and PTO switch OFF to start engine It is not necessary for the operator to be in the seat to start the engine On a cold engine place the throttle midway between the SLOW and FAST positions and push choke lever forward to the ON position Turn ignition switch to the start position Release the switch as soon as the engine starts IMPORTANT DO NOT crank the engine continuously for more then ten 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor After starting a cold engine gradually return choke to the OFF position as the engine warms up On a warm engine place the throttle midway between the SLOW and FAST positions and leave the choke in the OFF position 23 4 3 4 Engaging PTO 4h DANGER POTENTIAL HAZARD 4 The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower deck when the blades are engaged A DANGER POTENTIAL HAZARD 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 WHAT CAN HAPPEN Thrown objects or blade contact can cause serious injury or death HOW TO AVO
67. loosen then re torque to 20 25 in lbs 2 3 N m Make sure axle does not extend beyond either nut l Re install the seal guards over the wheel hub and insert wheel into caster fork Re install caster bolt and tighten nut fully IMPORTANT To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Re apply threadlocking adhesive 5 1 19 Lubricate seat switch actuator Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up c Lubricate switch actuator rod with spray type lubricant or light oil 35 9 1 20 9 1 21 9 1 22 9 1 23 9 1 24 9 1 25 Lubricate brake handle pivot Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil Lubricate brake rod bushings Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up c Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings Lubricate motion control bronze bushings Service Inte
68. maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the ignition switch and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s WARNING POTENTIAL HAZARD The engine can become very hot Touching a hot engine can cause severe burns HOW TO AVOID THE HAZARD Y Allow the engine to cool completely before service or making repairs around the engine area 5 1 PERIODIC MAINTENANCE 9 1 1 Check engine oil level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure unit is on a level surface b Unhook seat latch and tilt seat up and tilt hood forward to gain access to the engine area c Check with engine cold d Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level e Ifthe oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual DO NOT overfill IMPORTANT DO NOT operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check en
69. nit must be tied down and brake engaged when transporting Ignition Switch Located on right fuel tank The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Brake must be engaged motion control levers out neutral lock position and PTO switch OFF to start engine lt is not necessary for the operator to be in the seat to start the engine Hour Meter Located on right fuel tank The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If the ignition switch is left on without engine running hour meter will not run NOTE This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve Located directly below right side of console next to cubby The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the job site and when parked inside a building The valve has three positions each position made in 1 4 turn increments FUEL FLOW VALVE HANDLE POSITION DOWN RIGHT TANK RIGHT LEFT TANK LEFT Fuel Gauge Located on the left fuel tank The fuel gauge monitors t
70. nty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department D Warranty Period 1 year 1 year 2 years The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense As a condition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions The sole liability of Exmark and
71. o prevent build up of gasoline vapors especially at floor level Refuel only outdoors never inside an enclosed trailer Be sure all fuel tanks and gasoline storage containers have proper caps installed to prevent spillage and minimize vapor escaping into the trailer Do not place any equipment that is leaking gasoline in an enclosed trailer 1 4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment these factors are also dependent upon the awareness concern prudence and proper training of the personnel involved in the operation transport maintenance and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing 1 4 1 1 4 2 1 4 3 1 4 4 WARNING POTENTIAL HAZARD Operating engine parts especially the muffler become extremely hot WHAT CAN HAPPEN Severe burns can occur on contact Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating pa
72. overtighten Make sure upper roll bar can pivot freely Notes e Make sure the capscrew and nuts are installed with the nut to the inside of the roll bar e Make sure the tab on the lanyard washer is installed as shown and points toward the front of the unit Raise the roll bar into the upright position and secure with the latch pin assemblies on each side Install latch pin from outer surface of roll bar assembly and secure with the hairpin to the inside Torque all lower roll bar hardware attached to the machine frame to 30 35 ft Ibs 41 47 N m Tighten the front knobs against the upper roll bar ends 16 UPPER ROLL 1 2 13X31 4 BAR TUBE CAPSCREW A OS LATCHPIN n ASSEMBLY Po gt APPLY OIL TO INSIDE SURFACE OF EAR SHAPED PLATES AR 124 La po WHIZLOCK NUTS LATCH PIN Yo ASSEMBLY 1213 X3 1 4 CAPSCREW G0087 FIGURE 3 a UPPER ROLL BAR INSTALLATION 3 3 SERVICE BATTERY WARNING Battery posts terminals and related accessories contain lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling The machine is shipped with a filled lead acid battery 319 1 Unhook seat latch and tilt seat up to gain access to the battery DANGER POTENTIAL HAZARD Charging the battery may produce explosive gasses WHAT CAN HAPPEN Battery gasses can explode causing serious injury HOW TO AVOID THE HAZARD Ke
73. r This area can be dangerous see Figure 1 G0075 Figure 1 SAFE ZONE FOR MOWING e Progressively greater care is needed as the slope increases e Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope e Avoid sudden starts when mowing uphill Mower may tip backwards e Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Use extreme care with grass catchers or attachments These can change the Stability of the machine and cause loss of control e Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability A Rollover Protection System roll bar is installed on the unit WARNING POTENTIAL HAZARD There is no rollover protection when the roll bar is down WHAT CAN HAPPEN 4 4 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 1 4 15 1 4 16 Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning HOW TO AVOID THE HAZARD Keep the roll
74. r and engine coolant until liquid level is as high as possible without overflowing Reinstall radiator cap making sure that the cap is completely seated by pressing down firmly while turning until the cap stops Add 50 50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle NOTE Units should only be filled with Dex Cool extended life coolant which can be identified by its orange color 3 10 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reservoir Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do not overtighten NOTE The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C Fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 4 OPERATION INSTRUCTIONS 4 1 CONTROLS 4 1 1 Familiarize you
75. ral state or local laws Return the switch to your Exmark dealer if it is faulty and is being replaced or if the unit containing the switch is no longer operating and is being scrapped If the switch is damaged or broken open use extreme caution in handling Call your local waste management authority or Exmark Customer Service for instructions 45 6 4 BATTERY DISPOSAL DANGER POTENTIAL HAZARD 4 Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified battery reseller 7 TROUBLE SHOOTING 7 1 MOWER PULLS LEFT OR RIGHT W LEVERS FULLY FORWARD a b c Refer to Tracking Adjustment Section 4 1 3 Check air pressure in tires 13 psi drive 13 psi pneumatic casters Note Some units have semi pneumatic casters withou
76. rself with all controls before operating the mower 4 1 2 Motion Control Levers Located on each side of the console The left lever controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor The right lever controls the flow of hydraulic oil from the right hydrostatic pump to the right drive wheel motor IMPORTANT To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will kill When levers are centered in the T slot the drive system is in the neutral position With levers moved out in the T slot the drive system is in the neutral lock position See Figure 6 FRONT OF FORWARD UNIT HANDLES IN NEUTRAL lia NEUTRAL LOCK NEUTRAL LOCK REVERSE RIGHT SIDE G0048 FIGURE 6 MOTION CONTROL POSITIONS 20 By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line Movement of the left lever forward will cause the left drive wheel to rotate in a forward direction Movement of the right lever forward will cause the right drive wheel to rotate in a forward direction To stop forward travel pull the levers back to the neutral position To turn left while moving forward move the left lever back toward neutral to slow the left drive wheel To turn right while moving
77. rts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working Keep hands feet hair jewelry or clothing away from rotating parts Give complete undivided attention to the job at hand Mow only in daylight or good artificial light keeping away from holes and hidden hazards NEVER carry passengers DO NOT operate the mower when children or others are in the area When feasible avoid operating the equipment in wet grass Use EXTREME caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes 1 4 5 DANGER POTENTIAL HAZARD Mowing on wet grass or steep slopes can cause sliding and loss of control WHAT CAN HAPPEN Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning HOW TO AVOID THE HAZARD Do not mow slopes when grass is wet Do not mow near drop offs or near water Do not mow slopes greater than 15 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes e See inside the back cover to determine the approximate slope angle of the area to be mowed e Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or wate
78. rval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up c Lubricate bronze bushings on flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant Check spark plugs Service Interval 160 hrs a Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Owners Manual Change fuel filter Service Interval As Required a A fuel filter is installed between the fuel tanks and the engine Replace when necessary NOTE Use Kawasaki Part No 49019 1055 for replacement filters Change hydraulic system filter Service Interval After First 250 hrs Then yearly thereafter NOTE Use only Exmark Part No 1 513211 for summer use above 32 F 0 C or Part No 1 523541 for winter use below 32 F 0 C a Stop engine wait for all moving parts to stop and remove key b Raise seat c Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system d Unscrew filter to remove and allow oil to drain from reservoir IMPORTANT Before reinstalling new filter fill it with Mobil 1 15W 50 and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn e Fill reservoir as stated in Section 5 1 13 f Raise the rear of machine up and support with j
79. ssure for tires is 13 psi 90 kPa For units with Semi Pneumatic Caster tires without a valve stem Caster tires do not need to be inflated 3 6 INSTALL MOTION CONTROL LEVERS 3 6 1 Loosen and remove the two 2 3 8 x 1 bolts and spring disc washers which attach the motion control levers to the control arm shafts for shipping and the two 2 3 8 x 1 bolts and spring disc washers which are screwed into the control arm shafts Install the left motion control lever onto the control arm shaft See Figure 4 on the left side of the console Place the lever with the mounting plate towards the rear on the outside of the control arm shaft and secure with the bolts and washers Position the lever so the bolts are in the center of the slots on the lever mounting plate and tighten until snug Repeat on opposite side of unit NOTE There are two lever height options available Place the levers in the top two holes to increase height of the levers or in the bottom two holes to decrease the height of the levers If the levers do not align with each other when in the neutral position See Figure 5 loosen the hardware and make the appropriate adjustment by sliding tilting the lever s forward or backward until properly aligned and tighten hardware 18 MOTION CONTROL LEVER a l Y N yo MOUNT PLATE TO THE REAR 8 OUTSIDE OF ARM SHAFT FIGURE 4 FIGURE 5 CONTROL ARM SHAFT LEVER ALIGNMENT b Ifthe ends of
80. switch loosen lock nut on bottom of the actuator rod 5 16 x 7 bolt and adjust the nuts to move the actuator plate up or down on the rod 5 2 7 Belt Guide Adjustment a Stop engine wait for all moving parts to stop and remove key b Remove the belt shield on the right side of mower deck c Note belt guide bolted to deck near the shield support stud and right hand pulley Guide should be 1 8 3 2 mm away from the belt with bolt end of guide near end of slot See Figure 14 d If adjustment is necessary loosen the bolt securing the belt guide and make proper adjustment Tighten hardware 40 G0090 FIGURE 14 BELT GUIDE POSITIONING 5 2 8 Brake Link Adjustment Check to make sure brake is adjusted properly a Disengage brake lever lever down b Measure the length of the spring Measurement should be 2 75 7 0 cm between washers see Figure 15 c If adjustment is necessary tighten the nut directly below the yoke and loosen the bottom nut bottom one of the two tightened together below the spring Turn the nut directly below the washer top nut of the two tightened together until the correct measurement is obtained Tighten the two nuts together and repeat on opposite side of unit Turn clockwise to shorten spring length and turn counter clockwise to lengthen the spring DETAIL A LEVER UP ENGAGED COLLAR 3 16 4 8 mm to 1 4 6 4 mm TRUNION ROLLER LEVER DOWN DIS
81. t a valve stem which do not require inflation Check reverse indicator and motion control linkage adjustment See section 5 2 12 and 5 2 13 7 2 MOWER CUTS UNEVENLY a Check air pressure in tires 13 psi drive 13 psi pneumatic casters Note Some units have semi pneumatic casters without a valve stem which do not require inflation A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation Higher pressures in front casters may cause them to shimmy on hard surfaces Check deck support chains Check deck leveling See Adjustments Section 5 2 2 Note The front of the mower deck will be approximately 1 4 lower than the back of the mower deck This is the rake of the deck Check blades tip to tip for straightness they should be within 3 16 or one blade width from being in line 7 3 ENGINE WILL NOT START a Make sure the battery has a full charge See section 5 1 3 for charging instructions 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 Make sure there is fuel in the fuel tank and that the fuel valve is open Be sure the seat switch is properly adjusted See Section 5 2 6 46 e Make sure the parking brake is set and motion control levers are moved out neutral lock position
82. the levers hit against each other while in the drive position levers rotated in as far as possible make adjustments by moving the levers outwards to the neutral lock position and carefully bend them outward Move them back to the drive position and check for clearance repeat if necessary 3 7 POSITION DISCHARGE CHUTE 3 7 1 Loosen two 2 5 16 nyloc nuts attaching discharge chute Lower the discharge chute into position Retighten nyloc nuts until chute is snug but can pivot freely 3 8 SERVICE ENGINE Engine is shipped with oil check oil level and if necessary fill to the appropriate level with oil as specified in Engine Owner s Manual 3 9 SERVICE ENGINE COOLANT Machine is shipped filled with engine coolant 4 WARNING POTENTIAL HAZARD Engine coolant is hot and pressurized Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system and touching a hot radiator may Cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system 19 A CAUTION POTENTIAL HAZARD Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets With machine on level surface and with cool engine remove radiator cap under hood and add a 50 50 mix of wate
83. ubject of this warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state NOTES 541 NOTES 59 SERVICE RECORD Description of Work Done Service Done By 53 FOLD ALONG APPROPRIATE LINE hee ll O LELLA UR LES LLE gy Et if ntti EXAMPLE COMPARE ee a eg AY SLOPE WITH FOLDED SE o ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC SEE EXMARK S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z HP LAZER Z XP LAZER Z CT TURF RANGER VIKING HYDRO TURF TRACER TURF TRACER HP METRO METRO HP ULTRA VAC ULTRA VAC QDS SELF STEERING SULKY GRASS CATCHER MICRO MULCH ACCESSORY 4A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1997 2003 PART NO 103 5505 Rev A EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 All ALL RIGHTS RESERVED PRINTED IN U S A 8 MFG CO INC
84. ure 12 Place a 3 4 19 mm thick block of wood under each of the two 2 rear anti scalp roller brackets and place one under one of the front center anti scalp roller brackets Loosen the two 2 top chain bolts in slots in the rear deck lift arms Loosen jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose Turn the socket head adjusting screws in until slack is taken out of each chain Tighten the jam nuts Tighten the chain bolts in the deck lift arms making sure they don t move while tightening Loosen the four 4 nuts which secure the front swivels two per side until the front chains are loose and front of deck is supported by the 3 4 19 mm block Do not loosen the front chain hardware On left side adjust front swivel using the locking nut behind the swivel until the front chain is tight and all slack is removed from linkage Do not lift front of deck off 3 4 19 mm block Secure front swivel using locking nut in front of swivel Repeat for right side Recheck that the 3 4 19 mm blocks fit just snugly under the brackets and that the tension on all the chains are approximately equal Make sure all chain attachment bolts are tight Reposition anti scalp rollers and tighten securely For 72 Deck Place locking pliers here to hold spring 10 1 2 26 7 cm For 60 Deck lt 11 1 2 29 2 cm For 72 Deck Remove torce on de
85. use e Peerless 5 speed transmission extended beyond manufacturer s warranty of 90 days e Frame Hydrostatic Traction System Electric Clutch and Exmark supplied Mufflers e Blade Spindle Assy and Deck Jackshaft Assy 3 years 1 year parts and labor with additional 2 years parts only e Belts and Tires 90 days e Battery Refer to the battery manufacturer s warranty in the literature packet e Engine Warranty is covered by engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are not authorized to handle warranty adjustments on engines This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance e 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 All warra
86. ve all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide can kill you HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect 4 DANGER POTENTIAL HAZARD 4 In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD 4 DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do not operate without entire exhaust system in plac
87. vice is available only in the 48 contiguous United States UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exmark by 3 00 p m central time Orders must be six 6 line items or less Exclusions from the Exmark Parts Plus Program are Any wholegood or accessory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions Due to UPS restrictions aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air Exmark Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation OPERATOR S MANUAL This manual contains assembly
88. wait for all moving parts to stop Remove spark plug wire s or remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Y Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 002 Ce syst me d allumage par tincelle de vehicule est conforme a 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 syst
89. yloc nut and spring disk washer to bolt protruding from the wheel motor channel as shown NOTE Be sure the spring disk washer cone is installed towards the nyloc nuts 2 Install one 3 8 16 x 1 hex capscrew spring disk washer and 3 8 16 whizlock nut to the top front hole as shown 3 Install one 3 8 16 x 1 hex capscrew spring disk washer and 3 8 16 whizlock nut to the top rear hole as shown 4 Install one 3 8 16 x 4 1 2 hex capscrew spring disk washer and 3 8 16 whizlock nut through the top tube as shown NOTE Be sure the spring disk washer cone is installed towards the head of all capscrews 45 3 2 5 BAR TUBES O WHEELNUTS RAISE REAR OF UNIT HERE AND FIGURE 2 SUPPORT WITH JACK STANDS LOWER ROLL BAR INSTALLATION Install the upper u shaped section of the roll bar Reference Figure 3 for alignment and installation instructions below a b b Locate the latch pin assemblies pin and hairpin connected with a lanyard Install a 1 2 13 x 3 1 4 capscrew in the washer on the lanyard of each pin assembly Note Make sure the bent tab in the washer points toward the head of the capscrew Lightly oil the inside surfaces of the ear shaped plates at the upper end of the lower roll bar tubes Locate the upper u shaped section of the roll bar Install the upper roll bar section using one 1 2 13 x 3 1 4 capscrew from step b and one 1 2 13 hex flange lock nut on each side Do not

Husqvarna 115 13 81-96 Chainsaw User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents