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Exmark 4500-759 Rev A Lawn Mower User Manual

1. safely use this machine And working Stop engine and remove key before Do NOT carry pa Move drive levers out to neutral lock position NOT operate on slopes greater than 20 Do NOT operate under the Influence servicing or cleaning machine Look behind and to the side before changing Engage park brake across slope NOT up and down of alcohol or drugs and attachments directions Stop engine mow on wet slopes 116 4647 SPEED CONTROL ADJUSTMENT UNLOCK Every 50 hours 1 Check hydraulic oil level Only use recommended hydro oil 2 Check tire pressure 13 psi 3 Grease lift linkage pivots 7 Yearly 4 Grease front caster pivots 5 Grease front caster wheel bearings 6 Grease belt idler See operator s manual for additional details CALIFORNIA SPARK ARRESTER WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrester may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements 116 5040 1 Forward position faster 2 Backward position slower 5 RELEASE 1 ENGAGE T H R T T L E I o 116 4648 116 4648 All Units Except 1 PTO on 4 Slow 2 PTO off 5 Choke on 3 Fast 6 Choke off 12 Safety 5 RELEASE 1 ENGAGE
2. 9 9 25 2 o 5 gt e 2 zi N N 69 Part No 4500 759 Rev A For Serial Nos 920 000 amp Higher A WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Important The engine in this product is not equipped with a spark arrester muffler It is a violation of California Public Resource Code CPRC Section 4442 to use or operate this engine on any forest covered brush covered or grass covered land as defined in CPRC 4126 Other states or federal areas may have similar laws To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with the Canadian standard ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements
3. 8 5 L v v 8 Lz 9 gt gt 28 i t HOLIMS Old 9 9 O13NOVM GION310S 1303 10 Wolvino3s 0 3105 5 t MOTTA 5 1 NYL 8 13701A 6 0 2181818 3 32 m m z ROS RR 5 4 e HOLIMS 30 WOVE S187 1uVIS 18 NO 8 v 819 21 Spe Zt zt NOILOANNNOD ON 440 s ava xX 1 HOLIMS HOLIMS 9078 3514 HOLIMS A33 HOLMS 50 Schematics Electrical Diagram Kohler EFI 031 YOLVOIGNI HOLIMS 18418 39N3S3td 8179109 30010 SAL HOLNTO 014 av 1 bye LZ 8 BE gt gt 28 a HOLIMS Old 9 1 8 2 OI3NOVW 3NION3 n 87193 yovig 2 8 daos
4. R T T L E Engage and disengage PTO at 1 2 throttle 116 5026 EFI Only 1 PTO on 3 Fast 2 PTO off 4 Slow 13 Specifications Specifications Model Numbers Serial Nos 920 000 and Higher Systems Engine Engine Specifications See your Engine Owner s Manual Engine Oil Type Exmark 4 Cycle Premium Engine Oil RPM Full Speed 3600 100 RPM No Load Fuel System e Capacity 8 0 gal 30 2 L Type of Fuel Regular unleaded gasoline 87 octane or higher containing no more than 10 methanol or ethanol Fuel Filter Kawasaki Kawasaki P N 49019 7005 Kohler EFI Kohler P N 25 050 42 Fuel Shut Off Valve 1 4 turn increments Electrical System Electric Start Charging System Flywheel Alternator Charging Capacity Kawasaki 15 amps Kohler EFI 20 amps Battery Type BCI Group U1 Battery Voltage 12 Volt Polarity Negative Ground e Fuses 30 amp main fuse 25 amp charging system fuse 10 amp PTO fuse 15 amp accessory fuse Safety Interlock System LCD indicators appear for the park brake drive levers and operator presence in the message display on the front control panel Note Because the PTO must be disengaged to statt the engine the LCD indicator will not illuminate at this time e PTO must be disengaged and motion control levers in neutral to start engine It is not necessary for the operator to be o
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6. Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard WARNING Removing standard original equipment parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Making unauthorized changes to the engine fuel or venting system may violate EPA and CARB regulations Replace all parts including but not limited to tires belts blades and fuel system components with original Exmark parts WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the
7. Check the weak battery for terminal corrosion white green or blue snow it must be cleaned off prior to jump starting Clean and tighten connections as necessary CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine or EFI may occur DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity NOaARWN gt CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the EFI system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries Note The following instructions are adapted from the SAE J1494 Rev Dec 2001 Battery Booster Cables Surface Vehicle Recommended Practice SAE Society of Automotive Engineers WARNING Batteries contain acid and produce explosive gases Shield the eyes an
8. Fuel Gauge Located on the top left side of the tank see Figure 5 18 Operation The fuel gauge monitors the amount of fuel in the tank Drive Wheel Release Valves Located on the right front corner of the hydrostatic pumps Drive wheel release valves ate used to release the hydrostatic drive system to allow the machine to be moved by hand without the engine running With a 5 8 wrench turn both valves one turn counterclockwise to release the drive system Turn clockwise to reset the drive system Do Not overtighten Do Not tow machine PTO Engagement Switch Located on front control panel see Figure 5 Switch must be pulled out up to engage the blades Switch is pushed in to disengage the blades The LCD indicator will appear when the PTO switch is engaged see Figure 7 Low Voltage Indicator Located on the front control panel in the message display see Figure 5 and Figure 7 A low voltage condition less than 12 3 volts exists when the low voltage indicator light appears on the message display while the engine is running If the ignition key is turned to the ON position for a few seconds before cranking the engine the battery voltage will display in the area where the hours are normally displayed Note The indicator normally appears when the engine is off and the key switch is turned to the position Deck Lift Handle Located on the RH of the front control panel Pul
9. 6015584 1 15 SAL Old Xx Na 9 voL Hr asna s umous HOLIMS Old ZMS 52 Schematics Electrical Schematic Kohler EFI 6209109 3719 2 1815 5 5 MOTISA A AD 13701A OIA NVL 1 ang 3002 310102 LYVLS 2328 Eli 1 A yt s 21 1 3NIONA 8 O vot 2 V v 5 A x 5 v NOLLO3NNOO HOLIMS IMS Md LYVLS A9 D MS Saud z 9MS MS A39 quo 3NION3 SAL z 3 c 5 3 oa 5 a 3 8 8 3 gt v AD 1 1 D H21IMS MS nivd 4 DS i YMS umoys HOLIMS Old ZMS HOLIMS 40 Q3M3IA SI8 1uVIS NO ON 440 ya v Old 9 voL 2018 3513 5 53 Schematics Hydrau
10. Before each use or daily 1 Stop engine and wait for all moving parts to stop Make sure unit is on a level surface Check with engine cold Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Do Not screw into place Remove the dipstick and read the oil level If the oil level is low wipe off the area around the oil fill cap remove cap and add oil to the FULL mark on the dipstick Exmark 4 Cycle Premium Engine Oil is recommended refer to the Engine Owner s manual for an acceptable alternative Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval As required A WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage o
11. The blades should stop rotating 10 11 With the engine running pull up the blade control switch PTO and release without holding right side motion control lever to the center operating position The blades should not rotate Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Visually inspect machine for any loose hardware ot any other possible problem Tighten hardware ot correct the problem before operating Service Air Cleaner Service Interval Every 250 hours Replace the primary air cleaner element check secondary air cleaner element replace if dirty May need more often under severe conditions See the Engine manual for additional information Every 500 hours Replace the secondary air cleaner element May need more often under severe conditions See the Engine manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake See the Engine Owner s Manual for maintenance instructions Change Engine Oil Service Interval After the first 5 hours Every 100 hours May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Drain oil while engine is warm from operation The oil drain hose assembly is located on the left side of the engine Pl
12. This nut has been torqued to 130 160 1 0 176 217 N m Torque to 50 60 ft lb 68 81 N m Apply lubricant to threads as needed to prevent seizing Copper based anti seize preferable Grease acceptable substitute C Apply lubricant to threads of blade bolt as needed to prevent seizing Copper based anti seize preferable Grease acceptable substitute Install blade bolt finger tight Place wrench on the top spindle nut then torque the blade bolts to 50 60 ft lb 68 81 N m WARNING Incorrect installation of the blade or components used to retain the blade can be dangerous Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death Always install the original Exmark blades blade bushings and blade bolts as shown Check Safety Interlock System Service Interval Before each use or daily CAUTION If safety intetlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury Do not tamper with the interlock switches Check the operation of the interlock switches daily and replace any damaged switches before operating the machine Understanding the Safety Interlock System The safety interlock system is designed to prevent the mower blades from rotating unless The right side motion control lever is moved to the center operating po
13. in neutral position Battery does not have a full charge Electrical connections are corroded loose faulty Fuse is blown Neutral LCD indicator does not illuminate Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Ait cleaner is dirty Electrical connections are corroded loose ot faulty Disengage the PTO Ensure the speed control lever is in the neutral position Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Check reed switch Contact an Authorized Service Dealer Fill the fuel tank Open the fuel shutoff valve Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect 8 Relay or s
14. Engage parking brake 2 Push the right motion control lever down out of locked neutral position 3 Check if it aligns horizontally with the left motion control levet Figure 40 1 LH Motion control lever 2 RH Motion control lever 3 RH Motion control lever in PTO disengaged position 4 Check the horizontal alignment here 4 To adjust the right motion control lever horizontally the cam needs to be adjusted 5 Release the cushion from the rear of the machine 6 Loosen the nut and bolt holding the cam 7 Adjust the cam until it aligns with the left motion control lever and tighten the nut and bolt for the cam Maintenance Bom G012745 Figure 41 Switch screws Nut and bolt Cam Front reference speed control handle After the cam is adjusted the lever switch needs to be checked Check the gap between the control lever and switch as shown in Figure 42 The gap needs to be an 1 8 inch 3mm with the right motion control lever in the neutral operate position 1 Caster Pivot Bearings Pre Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1 4 of a turn to properly set the pre load on the bearings If disassembled make sure the spring disc washers are reinstalled as shown in Figure 43 G006131 Figure 43 Spring disc washers G012746 47 Figure 42 1 Switch 2 3 Right mot
15. allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO switch engages the cutting blades Be sure all persons are clear of mower deck and discharge area before engaging the PTO 1 Set throttle to MIDWAY position 2 Release the parking brake 3 Move the right side motion control lever to the center operate position 4 Continue holding the right side motion control lever in the center operate position and pull up on the blade control switch PTO and release The clutch should engage and the mower blades begin rotating 5 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle midway between the SLOW and FAST positions Push down on the PTO switch to disengage the blades Note The PTO will be disengaged by releasing the right side motion control lever and allowing it to spring outward to the PTO disengage position The PTO will not re engage when the RH motion control lever is moved out of the PTO disengage position without pulling up on the PTO switch To fully disengage the PTO continue to push the switch downward Stopping the Engine 1 Bring the
16. desired maximum forward speed 1 Stop the machine and move the motion control levers to the neutral position Disengage the PTO 3 Unlock the handles on both sides of the control tower by pulling outward see Figure 11 22 Figure 11 1 Front of the machine 4 Forward position faster 2 Control tower 5 Backward position slower 3 Unlock 6 Lock 4 Move the bar forward to obtain the fastest speed Move the bar backward to obtain the slowest speed 5 On both sides rotate and push the handles inward to lock the handles against the control tower Important Make sure the handles are locked in place so the front reference speed control bar does not move during operation Operating the Platform The machine can be used with the platform in the up or down position It is the operator s preference on which position to use Operation WARNING The operator platform is heavy and may cause injury when lowering and raising the operator platform The platform may suddenly drop if not supported when the latch pin is pulled out Do Not put your hands or fingers in the platform pivot area when lowering or raising the operator platform Make sure the platform is supported when the latch pin is pulled out Make sure the latch secures the platform when folding it in the up position Push it tight against the cushion for the latch pin to lock into place Operating the Machine with
17. directly inward together the drive system is in the neutral operate position 1 2 3 NS 54 9011899 Figure 8 1 LH Motion control lever 6 Neutral 2 RH Motion control lever 7 Forward 3 RH Motion control 8 Front reference Speed lever in PTO disengage control bar position 4 Reverse 9 Front of unit 5 Rearreference bar Driving Forward 1 Make sure the motion control levers are in the neutral position Release the parking brake 3 To move forwatd in a straight line move both levers forward with equal pressure Figure 9 To turn left or right pull the motion control lever back toward neutral in the desired turn direction The machine will move faster the farther the motion control levers are moved from the neutral position To stop position both motion control levers in the neutral operate position Driving in Reverse 1 Move the motion control levers to the neutral operate position To move rearward in a straight line slowly move both levers rearward with equal pressure 21 Operation G009474 Figure 10 Adjusting the Front Reference Speed To turn left or right release pressure on the motion conttol levet towatd the desired turn direction To stop position both motion control levers in the neutral operate position Control Bar Adjust the front reference speed control bar for
18. disengage reinstall the shim and reference the Troubleshooting section c Engage and disengage the PTO switch ten consecutive times to ensure the clutch is functioning properly If the clutch does not engage properly reference the Troubleshooting section Motion Control Neutral Adjustment Check to see if an adjustment is required 1 With the engine off turn the ignition switch to the position 2 Locate the LCD indicator in the message display 9012864 Figure 36 1 Neutral LCD indicator 3 With the motion control levers in the neutral position see Figure 4 with no force on the lever either forward or back the neutral LCD indicator should appear 4 If the indicator illuminates move the RH lever first forward then backward noting the position of the control lever when the indicator disappears The amount of movement both forward and back should be approximately the same if not go to step 6 5 If the indicator does not illuminate move both motion control levers forward and then backward Continue to watch the message display and note the position of the controls when it appears 6 Loosen the lock nuts on the RH motion control linkage as viewed from the rear of the machine see Figure 37 With the right motion control in the PTO disengage position hold the LH motion control in the position determined in step 4 or 5 Rotate the adjustment rod until t
19. hydraulic system WARNING Fuel system components are under high pressure The use of improper components can result in system failure gasoline leakage and possible explosion Use only approved fuel lines and fuel filters for high pressure systems Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 KEEP HANDS and FEET AWAY 1 403005 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 1 106 5517 Warning do not touch the hot surface New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any ait bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of yo
20. lever switch needs to be checked Check the gap between the brake lever and the switch as shown in Figure 29 The gap needs to be an 1 8 inch 3mm with the brake engaged Maintenance 9012741 Figure 31 Switch 3 Brake lever 2 1 8 inch 3mm gap needed between switch and brake lever 9 If needed loosen the screws holding the switch and adjust the switch Electric Clutch Adjustment No adjustment necessary However when the clutch brake has worn to the point where the clutch no longer engages consistently the shim can be removed to extend the clutch life G011732 2 1 Figure 32 1 Armature 5 Brake spacer 2 Field shell 6 Re gap shim 3 Rotor 7 Brake pole 4 Brake mounting bolt Removing the Shim 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Allow the machine to cool completely before starting these instructions 2 Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers 3 Check the condition of the wite harness leads connectors and terminals Clean or repair as necessary 40 Verify that 12V is present at the clutch connector when the PTO switch is engaged Measure the gap between the rotor and armature If the gap is greater than 04 inch 1 mm proceed with the following steps A Loosen bo
21. moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 25 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position WARNING While maintenance or adjustments are being made someone could start the engine WARNING The engine can become very hot Touching a hot engine can cause severe burns Accidental starting of the engine could seriously injure you or other bystanders Allow the engine to cool completely before service making repairs around the engine area Remove the key from the ignition switch engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil After t
22. pump temperature If the cap is too hot to touch turn off engine The pumps may be damaged if the pump becomes too hot If either drive wheel still does not rotate continue with step 4 Thoroughly clean the area around each of the charge pump housings To prime charge pump loosen two hex socket head capscrews shown in Figure 21 1 1 2 turns only Make sure engine is not running Lift the charge pump housing upward and wait for a steady flow of oil to flow out from under the housing Retighten the capscrews Do this for both pumps Note Hydraulic reservoir can be pressurized up to 5 psi to speed this process If either drive wheel still does not rotate stop and repeat steps 4 and 5 above for the respective pump If wheels rotate slowly the system may prime after additional running Check oil level as stated in Check the Hydraulic Oil Level section 7 Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position Check oil level as stated in Check the Hydraulic Oil Level section 8 Check hydro drive linkage adjustment as stated in Hydro Drive Linkage Adjustment section in Adjustments Wheel Hub Nut Torque Specification Service Interval After the first 100 hours Every 500 hours thereafter Torque the nut on the wheel motor tapered shaft to 175 225 ft Ib 237 305 N m Note Do Not use anti seize compound on the wheel hub Check Spark
23. the Platform Up Operating the machine with the platform up is tecommended when e Mowing near drop off s e Mowing small areas where the machine is too long Areas with low over hanging branches or obstacles Loading the machine for transport Unloading the machine after transport Driving up or backing down slopes or ramps Turning in tight areas where platform may contact obstacles To raise the platform pull the bottom upward and push it tight against the cushion The latch pin knob will snap inward to lock the platform into place see Figure 12 G011158 Figure 12 1 Platform 2 Raise upward 3 Latch pin knob snaps inward Operating the Machine with the Platform Down Operating the machine with the platform down is tecommended when Mowing most areas Driving down slopes To lower the platform push the platform forward against the cushion to release pressure on the latch pin pull the knob outward and lower the platform see Figure 13 G011159 Figure 13 1 Pull latch pin knob outward 2 Platform 3 Lower Operation Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 to 5 inches 2 5 cm to 12 7 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers to the neutral position Disengage the PTO 3 Raise and lock the deck to the 5 inch 12 7 cm transport position The deck is raised by pu
24. unit to a full stop 2 Move the motion control levers to the neutral position move the RH control lever out to the PTO disengage position 3 Place the throttle midway between the SLOW and FAST positions 4 Push down on the PTO switch to disengage the blades 5 Engage the parking brake 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building 20 Operation Driving the Machine CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the brake lever must be disengaged pushed forward before the motion control levers can be moved or the engine will stop When the RH motion control lever is positioned fully outward apart the drive system is in the PTO disengage position Figure 8 Note The N LCD indicator appears when the RH lever is in the PTO disengage position When the RH motion control levet is moved
25. 3 Figure 6 3 Start Note To start the engine place the LH motion control lever in neutral the RH motion control in PTO disengage position and the PTO switch disengaged It is not necessary for the operator to be on the platform Hour Meter Located on the LH side of the front control console in the message display see Figure 5 and Figure 7 The hour meter records the number of hours that the engine has run G009467 Figure 7 1 LCD Indicators 2 Low voltage indicator light 3 Hour Voltage display The hour meter is recording when the decimal point is flashing in Hour Voltage display Hours are displayed when the key is off or when the machine is running Note If the ignition key is turned to the ON position for a few seconds before cranking the engine the battery voltage will display in the area where the hours are normally displayed Note The LCD indicators appear when each control meets the safe to start mode Because the PTO must be disengaged to start the engine the LCD indicator will not illuminate at this time Fuel Shut Off Valve Located on the RH side of the control tower behind the knee cushion The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Align valve handle with the fuel line to open Rotate 90 to close
26. 52 00 inches 132 1 cm Discharge Side Blade Size 3 ea 48 inch Deck 16 25 inches 41 3 52 inch Deck 18 00 inches 45 7 cm Blade Spindles Solid steel spindles with 1 00 inch 25 4 mm I D bearings Deck Drive Electric clutch mounted on engine shaft Blades driven by one belt w self tensioning idlers Deck Full floating deck is attached to support frame removable for service Deck design allows for bagging mulching or side discharge Deck Depth 48 inch Deck 5 5 inches 14 0 cm 52 inch Deck 5 5 inches 14 0 cm Cutting Height Adjustment Adjusts from 1 inch 2 5 cm to 5 inches 12 7 cm in 1 4 inch 6 4 mm increments Mulching Kit Optional e Bagger Optional Dimensions Overall Width 48 inch Deck 52 inch Deck Deflector Up 51 8 inches 56 3 inches 131 6 cm 143 0 cm 64 8 inches 164 6 cm Deflector Down 59 6 inches 151 4 cm Overall Length 48 inch Deck 52 inch Deck Platform Up 59 0 inches 59 0 inches 150 0 cm 150 0 cm Platform Down 74 0 inches 74 0 inches 188 0 cm 188 0 cm Overall Height 48 inch Deck 52 inch Deck 50 0 inches 127 0 cm 50 0 inches 127 0 cm Tread Width Outside to Outside of Tires Widthwise 48 inch Deck 52 inch Deck 46 5 inches 118 1 cm 46 5 inches 118 1 cm Curb Weight 48 inch Deck 52 inch Deck 855 b 388 kg 875 lb 397 kg Note Weights will vary slightly depe
27. Arrester if equipped Service Interval Every 50 hours WARNING Hot exhaust system components may ignite gasoline vapors even after the engine is stopped Hot particles exhausted during engine operation may ignite flammable materials Fire may result in personal injury or property damage Do Not refuel or run engine unless spark arrester is installed 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Wait for muffler to cool 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 Reinstall arrester on exhaust outlet 35 Maintenance Thread Locking Adhesives Thread locking adhesives such as Loctite 242 Fel Pro Pro Lock Nut Type are used on the following fasteners Pump sheave setscrews Sheave retaining bolt in end of engine crankshaft e Caster wheel spacer nuts Platform spring pin Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations Between splines of the cutter housing spindle and sheave Copper Based Anti seize Copper based anti seize is used in the following locations On threads of Blade Bolts See Check Mower Blades section Between engine crankshaft pump
28. Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Charging jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery e Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid Always shield eyes and face from battery Safety 4 DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately CAUTION If the ignition is in the ON position there is potential for sparks and engagement of components Sparks could cause an explosion ot moving parts could accidentally engage causing personal injury Be sure ignition switch is in the OFF position before charging the battery
29. Remove the hairpins on each side of the cushion 3 Push the plastic slides to the inside 4 Remove the cushion and lower it to the platform 5 Perform any maintenance or adjustment on the machine Raise the cushion and slide it onto the pins on both sides of the machine Figure 17 Push the plastic slides into the cushion bracket and secure them with a hairpin X WN SS pw Us S Bas SS e WS 55 Ce X 1 SS NS jus n odd 8 preci NOS SS 7 G009475 Figure 17 1 Plastic slide 2 Cushion bracket with key hole 3 Hairpin Check Mower Blades Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck section 3 Inspect blades and sharpen or replace as required 4 Reinstall the blades if they were removed in the following order A Install bushing through blade with bushing flange on bottom grass side of blade 29 Maintenance 6006780 Figure 18 1 Install bushing in blade prior to installing bushing in spindle B Install bushing blade assembly into spindle 1 Mem 1 2 9014914 Figure 19 1 Use wrench here for 2 blade installation
30. 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 Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level Check Tire Pressures Service Interval Every 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tite pressure in drive tires 3 Inflate drive tires to 12 16 psi 83 110 kPa Semi pneumatic caster tires do not need to inflated Check Condition Of Belts Service Interval Every 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Look on the top side of the cutting deck to check the mower blade drive belt condition Look under the engine deck to check the pump drive belt condition Check all idler arms to be sure they pivot freely Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Serv
31. ace pan under machine to catch oil Remove oil drain plug Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft Ib 27 33 N m Replace the oil filter per the Engine Owner s Manual Clean around the oil filter and carefully remove the filter by unscrewing it Make sure no oll drains onto the belt drive or clutch through the holes in the engine deck Before the new filter is installed apply a thin coating of Exmark 4 Cycle Premium Engine Oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in the Check Engine Oil Level section Do Not overfill Start the engine and check for leaks Stop engine and recheck oil level Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Every 50 hours 31 Maintenance 1 Stop engine and wait for all moving parts to stop and remove key Engage parking brake Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use Exmark Premium Hydro Oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Note The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil
32. be subject to traffic tickets and or fines Do Not drive a unit on a public street or roadway 24 Operation WARNING Loading a unit on a trailer or truck increases the possibility of backward tip over Backward tip over could cause serious injury or death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit Ifindividual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit Do Not exceed a 20 degree 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 e Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit With the platform up a full width ramp provides a surface to walk on behind the unit 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 20 degrees A steeper angle may cause mower deck components to get caught as the unit
33. ber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn Fill reservoir as stated in Check Hydraulic Oil Level Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours 5 Loosen filter 1 2 turn and allow a small amount of oil to leak from the oil filter this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir Turn filter clockwise until rubber seal contacts the filter adapter Then tighten the filter an additional 2 3 to 3 4 turn Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely A CAUTION Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support If either drive wheel does not rotate one or both of the charge pumps located on the top of the main pump as shown in Figure 21 may have lost their prime Refer to Hydraulic System Air Purge section Note Do Not change hydraulic system oil except for what can be drained when
34. bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders 4 DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors on level ground in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer Do Not fill the fuel tank completely full Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot If fuel is spilled Do Not attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do Not operate without entire exhaust system in place and in proper working condition DANGER In certain conditions during fueling static electricity can be
35. changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Hydraulic System Air Purge Service Interval As required Air must be purged from the hydraulic system when any hydraulic components including oil filter are removed or any of the hydraulic lines are disconnected The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump Figure 21 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed 34 Maintenance 1 9012582 Figure 21 Charge pump cap 2 Loosen 1 1 2 turns only Stop engine and wait for all moving parts to stop Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground Check oil level as stated in Check Hydraulic Oil Level section Start engine and move throttle control ahead to full throttle position Move RH motion control lever inward together and move both levers forward with equal pressure If either drive wheel does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position Note It is necessary to lightly touch the charge pump cap with your hand to check the
36. d face from the batteries at all times Do Not lean over the batteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 16 3 9012785 Figure 16 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block Maintenance Connect the other end of the positive cable to the positive terminal of the booster battery Connect the black negative cable to the other terminal negative of the booster battery MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK Start the vehicle and remove the cables in the reverse order of connection the engine block black connection is the first to disconnect Release the Cushion for Rear Access Service Interval As required The cushion can be released for teat access to the machine for maintenance or adjustment 1 Lower the platform 2
37. drive sheave and clutch Between pump shafts and sheaves Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit CAUTION Raising the mower for service maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Deck Leveling Note Side to side deck leveling should be done by an Authorized Service Dealer Small adjustments can be accomplished by increasing the tire pressure in the tire on the low side 1 Park the machine on a level surface and disengage the blade control switch 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check the air pressure in the drive tires If needed adjust to the recommended inflation refer to Checking the Tire Pressure in Drive System Maintenance section 4 Set the height of cut lever to the 3 inch 7 6 cm position 5 Raise the discharge deflector 6 Carefully rotate the blades front to rear Measure f
38. e necessary inspection and maintenance steps Operating Instructions Open the Fuel Shut Off Valve Rotate the valve and align with the fuel line to open Starting the Engine 1 Leave the LH motion control lever in neutral and the RH lever in the PTO disengage position see Figure 4 Pull the parking brake rearward and over to the right to engage the parking brake 19 Operation 3 Push in down on the PTO switch to the disengage position 4 Place the throttle midway between the SLOW and FAST positions 5 Ona cold engine push the choke lever forward into the ON position except Kohler EFI units On warm engine leave the choke in the OFF position Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the ON position gradually return choke to the OFF position as the engine warms up PTO Engagement DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged DANGER An uncovered discharge opening will
39. e mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Belt is damaged Drive belt is off pulley Deck belt is worn loose or broken Deck belt is off pulley Broken or missing idler spring Damaged electric clutch 48 Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust tire pressure in the drive tires Adjust the tracking by turning the LH adjustment rod in the direction that the mower needs to be adjusted to Rotate the adjustment rod in 1 4 turn increments until the mower tracks correctly Tighten the bypass valve Change the belt Change the belt Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to rear Clean the underside of the mower Adjust tire pressure in the drive tires Contact an Authorized Service Dealer Replace blades spindles and or check for damage to mower deck Install new cutting blade s Tighten the blade mounting bolt Tighten the engine mounting bolts Tighten the appropriate pulley Con
40. ence speed control bar controls the maximum forward speed and is infinitely variable from approximately 4 8 mph 6 13 km hr Park Brake Lever Located on left side of unit just to the front of the LH motion control lever see Figure 5 Operation The brake lever engages a parking brake on the drive wheels Note The LCD indicator appears in the message display on the front console when the park brake is engaged see Figure 5 and Figure 7 To engage the brake pull the lever rearward and to the right to position into the engaged position To release pull the brake lever back and over to the left position into the slot and push the lever forward When parking on a steep slope the wheels must be chocked or blocked in addition to the brake being engaged The unit must be tied down and brake engaged when transporting Park brake must be disengaged before moving motion control out of neutral or engine will kill Ignition Switch Located on the LH side of the front control console see Figure 5 The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Allow the key to return to the ON position immediately after the engine starts a 5 0008610 2
41. ential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 733 B 55 Notes 56 Service Record Date Description of Work Done Service Done By 57 MAXIMIZE THE PERFORMANCE OF YOUR EXMARK 4 CYCLE PREMIUM ENGINE OIL PREMIUM HYDRO OIL Part No 116 3373 Part No 109 9828 Both SAE 30 and SAE 10W 30 in one Commercial quality for tough high bottle heat conditions Contains increased levels of zinc and Designed specifically for zero turn phosphorus for better lubricity mower hydraulic systems No Viscosity Index Improvers that tend Superior shear resistance under to shear down in high heat heavy loads Synthetic formulation Gas amp Diesel compatible Anti corrosion additives SL and JASO rated with wet clutch compatibility for other machines EXMARK MAINTENANCE Available from your local Exmark dealer Find your closest dealer at exmark com 58 G011841 Figure 44 This page may be copied for personal use 1 The maximum slope you can safely operate the machine on is 20 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 20 degrees Fold along the appropriate line to match the rec
42. ents edt ttes 16 Product Overview ape eae 16 uis Dude hus a P TN OP TEUER 17 E 17 PEC Salt 19 Operating InswucOns s 19 MANS POPU tai uu tion 24 MM 26 Recommended Maintenance Schedule s 26 Periodic Maintenance eoo dee 27 Check Engine Oil Level 21 Check Mower Blades 29 Check Safety Interlock System 30 Check for Loose Hardware 31 Service Air Cleaner Ph 31 Change neh Ens 31 Check Hydraulic Oil Level 31 Check Hire citas 32 Check Condition Of sao ede 32 Lubricate Grease PICUngs uu ect rtp 32 Lubricate Caster Wheel Hubs 32 Check Spark Deas 33 Change Hydraulic System Filter and ct tefie 33 Wheel Hub Nut Torque Specification 35 Check Spark Arrester if equipped 35 Thread Locking Adhesives 36 Mobil HTS Grease Or Food Grade Jette Fon eeu 36 Copper Based Anti seize 36 Dielectri 36 36 Deck Ieveling 36 Adjus
43. es and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately 45 Maintenance 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 46 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do Not attempt to service or replace major items or any items that call for special timing of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors Do Not pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running PTO is engaged One of the speed control levers are not
44. f the battery with a digital voltmeter or with the message display If the ignition key is turned to the position for a few seconds the battery voltage will be displayed in the area where the hours are normally displayed Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cable is disconnected and the battery charger used for charging the battery should have an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings This is especially important on Kohler EFI Electronic Fuel Injection units Failure to do so may damage the ECU Electronic Control Unit Voltage Reading Maximum Charging Charger Settings 16 volts 7 amps 12 4 12 6 75 100 16 volts 7 30 Minutes amps 12 2 124 50 75 16 volts 7 1 Hour amps 12 6 greater 100 27 Maintenance Voltage Reading Percent Charge Maximum Charging Charger Interval Settings 12 0 12 2 25 50 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 less 0 14 4 volts 2 6 Hours amps More Important For Kohler EFI units Unplug the harness from the ECU before performing any welding on the equipment Recommended Jump Starting Procedure Service Interval As required 1
45. he LCD indicator comes on 41 Maintenance 1 Figure 37 3 Lock nut LH thread Lock nut 2 Adjustment rod 1 Continue to rotate the adjustment rod counting the turns until the LCD indicator turns off Rotate the adjustment rod in the opposite direction half the number of turns counted Release the LH motion control lever and tighten the lock nuts on the right side Turn the adjustment rod on the LH side as viewed from the rear of the machine see Figure 38 until the left control has approximately the same natural neutral position as the right If more adjustment is needed contact an Authorized Service Dealer Final adjustment of the left side is done in the tracking adjustment section If no adjustment is required see Check the Neutral Switch Alignment section G012744 Figure 38 Rotate to increase speed 2 Adjustment rod 3 Rotate to decrease speed 9 Reinstall the rear cushion Motion Control Tracking Adjustment If the machine travels or pulls to one side when the motion control levers are in the full forward position adjust the tracking 1 Push both control levers forward the same distance Check if the machine pulls to one side If it does stop the machine and set the parking brake Release the tear cushion from the rear of the machine Place the front reference speed control bar in the maximum forward position See Adjusting the Front Reference Speed Con
46. he ftst 100 hours Check the wheel hub torque specification Check the wheel lug nuts After the first 250 hours Change the hydraulic filter and fluid heck the engine oil level heck the mower blades heck the safety interlock system heck for loose hardware ean the engine and exhaust system area ean the grass and debris build up from the machine and cutting deck ean the grass build up from under the deck Before each use or daily heck the hydraulic oil level heck the tire pressures heck the condition of the belts rease the lift linkage pivots Every 50 hours heck spark arrester if equipped Replace the primary air cleaner element check secondary air cleaner element replace if dirty May need more often under severe conditions See the Engine manual for additional information C C C C C C C C C C G C Every 250 hours 26 Maintenance Maintenance Service Maintenance Procedure Interval Replace the secondary air cleaner element May need more often under severe conditions See the Engine manual for additional information Every 500 hours Change the hydraulic filter and fluid Every 250 hours yearly if using Mobil 1 15W50 Check the wheel hub torque specification Check the wheel lug nuts Grease the front caster pivots Grease the deck belt idler pivot Lubricate the caster wheel hubs Periodic Maintenance Check Engine Oil Level Service Interval
47. ibutor Exmark parts manuals are available online at http www exmark com manuals htm All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and ate equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 G011934 Figure 1 Model and serial number location Model No Serial No Contents teg E ERR 3 Mov dp 5 Safety Alert eii dis cR 5 Safe Operating e 5 Safety and Instructional Decals 10 Specifica ONS aatan 14 Model Sati Dees 14 14 15 Torque Requirem
48. ice Locations Pumps Places Interval 1 Lift Linkage 1 2 7 Every 50 Pivots hours 2 Deck Belt Idler 1 1 Yearly Pivot 3 Front Caster 2 Yearly Wheel Hubs 4 Front Caster 2 Yearly Pivots 1 1 1 manne G014316 See step 3 for special lubrication instructions on the front caster pivots 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 beating Remove grease zerk and thread plug back in Place cap back on Lubricate Caster Wheel Hubs Service Interval Yearly Stop engine wait for all moving parts to stop and remove key Engage parking brake Maintenance G006115 2 Figure 20 1 Seal guard 2 Spacer nut with wrench flats 2 Remove caster wheel from caster forks 3 Remove seal guards from the wheel hub 4 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 axle Remove the axle with the other spacer nut still assembled to it from the wheel assembly 5 Pry out seals and inspect bearings for wear damage and replace if necessaty 6 Pack the bearings with a NGLI grade 1 multi purpose grease 7 Insert one bearing one new seal into the wheel Note Seals Exmark P N 103 0063 must be replaced 8 If the axle assembly has had both spacer n
49. ion control lever in the neutral operate position 4 1 8 inch 3mm 10 If needed loosen the screws holding the switch and adjust the switch 11 Tighten the switch screws 44 Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions A CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen around engine shrouding and exhaust system area 3 Wipe up any excessive grease or oil around the engine and exhaust system area Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 80 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling 3 Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wai
50. k the neutral switch alignment again as the deck is moved through the highest and lowest cut height setting adjust the lower neutral switch surface if necessary Figure 39 4 Lower neutral switch surface 5 Hardware Alignment reference Upper neutral switch surface Switch mounting plate 7 Adjust the upper neutral switch surface left ot tight if side to side alignment is needed The upper and lower switches should be as close together as possible without touching approximately 06 inch 1 5 mm gap is desirable The switch mounting plate can be moved up or down to adjust the position of the lower neutral switch Check the function of the neutral switches by temporarily replacing the key With the engine off turn the ignition switch to the position Locate the LCD indicator in the message display Raise and lower the deck If the indicator displays while moving the deck up and down the neutral switches have been adjusted properly and no further adjustment is necessaty 43 B If the indicator does not stay lit while moving the deck up and down contact an Authorized Service Dealer Remove the key Adjust RH Motion Control Handle Position If the motion control levers do not align horizontally adjust the right side motion control levet Note Adjust the horizontal alignment before the front to back alignment 1 Stop engine wait for all moving parts to stop and remove key
51. l the handle rearward to raise the cutting deck Allow the handle to move forward to lower the cutting deck to the cut height that has been set Pull the handle rearward and to the right to latch the cutting deck into the raised transport position Figure 6 Electronic Control Unit Malfunction Indicator Kohler EFI Units Only The electronic control unit ECU continuously monitors operation of the EFI system If a problem or fault within the system is detected the malfunction indicator light MIL is illuminated The MIL is the light located in the console panel to the left of the PTO switch Follow the troubleshooting steps outlined in the Kohler engine operator s manual if the MIL is illuminated Pre Start Fill fuel tank on level ground For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Important Never use methanol gasoline containing methanol gasohol containing more than 10 ethanol premium gasoline or white gas because the fuel system could be damaged Do Not add oil to gasoline Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all th
52. lert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 Safety Alert Symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or 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 This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them e Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is
53. lic Diagram LEFT PUMP CASE_DRAIN CASE DRAIN io 9 uU INLET lt gt M 280 22 HYDRAULIC TANK G009494 54 Exmark Lazer Z X Series Lazer Z S Series and Vantage Turf Equipment 3 Year Limited Commercial Warranty 5 Year or 750 Hours Limited Consumer Warranty General Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Commercial Warranty Conditions This warranty applies to Exmark Lazer Z X Series Lazer Z S Series and Vantage turf equipment sold in the U S or Canada for a period of three years for commercial usage This warranty includes the cost of parts and labor for a period of two years and the cost of parts for one additional year This warranty does not cover pickup and delivery charges to and from any authorized Exmark Service Dealer Consumer Warranty Conditions This warranty applies to Exmark Laze
54. lling the deck lift handle rearward and to the right to place it into the transport lock position G011903 Figure 14 3 Front reference speed control bar 4 Deck lift handle Transport lock position N RH Motion control lever Note When changing the cutting height positions always come to a complete stop and disengage the PTO Insert the height adjustment pin into the hole corresponding to the desired cutting height See the decal on the side of the deck lift plate for cut heights reference Figure 15 5 Pull the deck lift handle rearward and to the left and slowly allow the deck to lower to the cutting height 6011907 Figure 15 1 Height adjustment pin 3 Deck lift handle 2 Height of cut holes Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain CAUTION This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street roadway without such equipment may also be a violation of State laws and the operator may
55. n disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counter weights to improve stability Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excessive grease ot oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and do not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s or wear gloves and use caution when servicing them Only replace damaged blades
56. n the platform to start the engine Mowet blades will stop if the right side motion control lever is moved or released into the PTO disengage position Engine will stop if the motion control levers are moved from the neutral position with the park brake engaged Operator Controls Steering Control Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning Transmission Two Hydro Gear variable displacement high efficiency pumps independently coupled to two high efficiency Parker Ross wheel drive motors Hydraulic Oil Use Exmark Premium Hydro Oil Hydraulic Oil Capacity 2 4 qt 2 2 L Hydraulic Filter is replaceable cartridge type P N 109 4180 25 microns 10 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C Speeds 0 8 0 mph 13 km hr forward 14 Specifications 0 4 0 mph 6 km hr reverse Drive wheels release valves allow machine to be moved when engine is not running Wheel Drive System Drive wheels are direct coupled to Parker wheel drive motors with 1 inch 25 4 mm tapered shaft Tires amp Wheels Pneumatic Semi Air Filled Pneumatic 20 x 10 00 8 11 x 4 00 5 Pressure 14 psi 97 kPa Cutting Deck Cutting Width 48 inch Deck 48 inches 121 9 cm 52 inch Deck
57. nch 19 mm gap between the park brake handle and the slot in the control panel see Figure 28 AN 6015588 Figure 28 1 Brake bar 4 3 4 inch 19 mm 2 Push down 5 Park brake handle 3 Slot 6 There are two methods to adjust the park brake one ot both methods may be used A Adjusting the lower brake lever a Remove the hairpin washer and clevis pin from the lower brake lever and yoke as shown in Figure 29 9014329 Figure 29 1 Jam nut 4 Lower brake lever 2 Yoke 5 Washer 3 Clevis pin 6 Hairpin b Loosen the jam nut c Rotate the yoke To tighten the brake rotate the yoke up To loosen the brake rotate the yoke down d Secure the yoke to lower brake levet with the hairpin washer and clevis pin e Tighten the jam nut f Check the brake operation again B Adjusting the upper brake linkage a Loosen the top jam nut b To tighten the brake turn the bottom jam nut clockwise as viewed from the top then turn the top jam nut Move the linkage upward to achieve the desired setting c To loosen the brake turn the top jam nut countetclockwise as viewed from the top then turn the bottom nut counterclockwise Move the linkage downwatd to achieve the desired setting Figure 30 Move down to loosen 4 Bottom jam nut brake Move up to tighten brake 5 Linkage Top jam nut d Tighten the jam nuts e Check the brake operation again After the brake is adjusted the
58. nding on engine 15 Product Overview Torque Requirements Product Overview Cutter Housing Spindle 130 160 ft lb Nut 176 217 N m Blade Mounting Bolt 50 60 ft lb 68 81 N m lubricate with anti seize Engine Deck Mower 30 35 ft lb 41 47 N m Deck Support Mount Bolts Engine Mounting Bolts Kawasaki 17 23 ft lb 23 31 N m Kohler 27 33 ft lb 37 45 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Hub Nuts 175 225 ft lb 237 305 N m Wheel Motor Mounting 67 83 ft lb 91 113 N m Figure 3 Bolts 1 Platform 4 Motion control levers 2 Fuel Cap 5 Engine Controls 3 Height of Cut 6 Park Brake Lever Adjustment 16 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the top console control the forward and reverse motion of the machine Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively Wheel speed is proportional to the amount the lever is moved 1 2 3 NN 34 Figure 4 1 LH Motion control lever 6 Neutral 2 RH Motion control lever 7 Forward 3 RH Motion control 8 Front reference Speed lever in PTO disengage control bar position 4 Reverse 9 Front of unit 5 Rearreference bar When the motion control levers are in the neutral position
59. nt rods Figure 25 2 H 5 1i 2 T Pe D x 37 Ki TTAN 3 Figure 25 1 Adjustment rod 3 Front lock nut 2 Rear lock nut 37 Note Make sure the engine deck brackets are resting firmly on the rear lift points see Figure 26 If it is lifting off tighten the front locknut of the adjusting rod on the opposite side Maintenance G011945 Figure 26 1 Rear lift points 2 Engine deck brackets To raise the front of the mowing deck tighten the front locking nuts by the same amount on both front adjusting rods Tighten both rear locking nuts Check the side to side level of the mower again refer to Deck Leveling Note Rake adjustments may affect the motion control neutral position See the Motion Control Neutral Adjustment and Motion Control Tracking Adjustment sections in Maintenance Adjusting the Rear of the Deck 1 Park the machine on a level surface and disengage the blade control switch Stop engine wait for all moving parts to stop and remove key Engage parking brake Check the air pressure in the drive tires If needed adjust to the recommended inflation refer to Checking the Tire Pressure in Drive System Maintenance section Set the height of cut to the 3 inch 7 6 cm position Carefully rotate the blades front to rear Measure from the tip of the front blade to the level surface The blades should measure 3 inche
60. ommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 59 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Engine Serial No E No Serial No 2011 Exmark Mfg Co Inc Part No 4500 759 Rev A Industrial Park Box 808 402 223 6300 Beatrice 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
61. r Z X Series Lazer Z S Series and Vantage turf equipment sold in the U S or Canada for a period of five years or 750 hours whichever occurs first for residential usage Residential usage means use of the product on the same lot as your home Use at more than one location is considered commercial use and the commercial use warranty detailed above would apply This warranty only includes the cost of parts and labor For the first warrantable service repair Exmark will cover up to 45 for associated pick up and delivery charges to and from any authorized Exmark Service Dealer Additional transportation charges may apply contact your Dealer for details Warranty Exceptions Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet Items and Conditions Not Covered This warranty does not cover the following Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or s
62. r objects that may obscure vision Slope Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes Safety DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Loss of control and or loss of operator s footing could result in a fall with an arm or leg getting under the mower ot engine deck which may result in serious injury death or drowning Mow across slopes never up and down Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 20 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes See inside the back cover to determine the approximate slope angle of the area to be mowed Remove ot mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwards Be aware that operating on wet grass across steep slopes or downhill may cause the mower to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose tractio
63. r performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are limited to the duration of the express warranty Some states do not allow exclusions of incidental or consequ
64. r replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary For Kohler EFI Units WARNING Fuel system components are under high pressure The use of improper components can result in system failure gasoline leakage and possible explosion Use only approved fuel lines and fuel filters for high pressure systems Replacement Filters Kawasaki Kawasaki P N 49019 7005 Kohler EFI Kohler P N 24 050 03 Change Hydraulic System Filter and Fluid Service Interval After the first 250 hours Maintenance Every 500 hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 Note Use only Exmark Part No 109 4180 for Summer use above 32 F 0 C or P N 1 523541 for Winter use below 32 F 0 C Refer to Transmission section in Specifications for filter specifications 1 Stop engine wait for all moving parts to stop and remove key or spark plug wire s Engage parking brake Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system Unscrew filter to remove and allow oil to drain from reservoir Important Before reinstalling new filter fill it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rub
65. rating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered brush covered unimproved land WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors in a small confined area where dangerous carbon monoxide fumes can collect e Operate only in daylight or good artificial light keeping away from holes and hidden hazards e Be sure all drives are in neutral and parking brake is engaged before starting engine Never raise deck with blades running Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting overspeed the engine e Park machine on level ground Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or wo
66. released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container 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 e If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Safety Operation A WARNING Ope
67. responsible for training the users e Never let children or untrained people operate ot service the equipment Local regulations may restrict the age of the operator Only adults and mature teenagers should operate a mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Manual and recognizes the risks involved 2 is sufficiently mature to use caution and 3 is of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks e The owner user can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark e Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Safety Inspect the area where the equipment is to be used and remove all rocks toys sticks wires
68. rking on the mowet After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage patking brake Before refueling Before dumping the grass catcher Before making height adjustments WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts DO NOT operate the mower when people especially children or pets are in the area Be alert slow down and use caution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed e Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or othe
69. rom the tip of the front blade to the level surface Figure 22 The blades should measure 3 inches 7 6 cm 36 Maintenance 1 G012795 Figure 22 Blades front to rear 2 Measure here 1 Measure between the outside cutting edges and the flat surface Figure 23 If both measurements are not within 3 16 inch 5 mm an adjustment is required contact an Authorized Service Dealer G012715 FEES Figure 23 Blades side to side 2 Measure here 8 Lower the discharge deflector Adjusting the Cutting Deck Rake 1 Park the machine a level surface and disengage the blade control switch Stop engine wait for all moving parts to stop and remove key Engage parking brake Check the air pressure in the drive tires If needed adjust to the recommended inflation refer to Checking the Tire Pressure in Drive System Maintenance section 4 Check and adjust the side to side blade level if you have not checked the setting refer to Deck Leveling 5 Carefully rotate the blades front to rear Figure 24 Measure from the tip of the front blade to the level surface and the tip of the rear blade to the level surface on all blades The blades should be 1 4 inch 6 4 mm lower in the front than in the rear 25 N N N Figure 24 1 Blades front to rear 2 Measure here 6 Loosen the rear lock nuts on both adjustme
70. s 7 6 cm If it does not measure correctly locate the height of cut rod on the right side of the machine see Figure 27 38 9012953 Figure 27 1 Adjustment screw 7 Turn the adjustment screw until the blade tips match 3 inches 7 6 cm Pump Drive Belt Tension Self tensioning No adjustment necessary Mower Deck Drive Belt Tension Self tensioning No adjustment necessary Check the Park Brake 1 Park the machine on a level surface 2 Shut off engine and wait for all moving parts to stop 3 When the park brake is released the brake bars should lift off the tires and the hand lever should travel forward to the end of the slot in the control panel When engaging the brake the hand lever should travel 3 4 inch 19 mm at the control panel slot when the brake bars first contact the tire Measure the gap from the front of the lever to the end of the slot in the control panel when the brake bar contacts the tire Park Brake Adjustment If the parking brake does not hold securely an adjustment is required 1 Park the machine on a level surface 2 Shut off engine and wait for all moving parts to stop 3 Check the air pressure in the drive tires If needed adjust to the recommended inflation refer to Maintenance Checking the Tire Pressure in Drive System Maintenance 4 Disengage the park brake 5 Push down on the brake bar until it touches the tires There will be a 3 4 i
71. sition The blade control switch PTO is pulled on The safety interlock system is designed to stop the mower blades if you move or release the right side motion control lever into the PTO disengage position The right side motion control lever is moved to the center operating position the parking brake is engaged and the blade control switch PTO is pulled on Checking the Safety Interlock System 1 Start the engine 2 Set the parking brake 3 Move the motion control levers forward The engine should initiate shutdown after momentaty pause 4 Start the engine and release the parking brake Maintenance Move the right side motion control lever to the center operating position Continue holding the right side motion control lever in the center operating position and pull up on the blade control switch PTO and release The clutch should engage and the mower blades begin rotating Move or release the right side motion control lever into the neutral position The blades should stop rotating and the engine should continue running Push the blade control switch down and move the right side motion control lever to the center operating position Continue holding the right side motion control lever in the center operating position and pull up on the blade control switch PTO and release The clutch should engage and the mower blades begin rotating Push the blade control switch PTO down to the off position
72. t for all moving parts to stop and remove key Engage parking brake Clean off any oil debris or grass build up on the machine and cutting deck especially under deck belt shields around the fuel tank around engine and exhaust area Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Raise deck to the transport maximum cutting height position Lift the front of unit and support unit using jack stands or equivalent support CAUTION Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Clean out any grass build up from underside of deck and in discharge deflector Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations Battery Disposal 4 DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield ey
73. tact an Authorized Service Dealer Contact an Authorized Service Dealer Install new belt Check belt for damage replace if necessary Install drive belt and check adjusting shafts and belt guides for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Replace the spring Contact an Authorized Service Dealer Troubleshooting Clutch will not engage 15 Fuse is blown Low voltage supply at the clutch Damaged coil Inadequate current supply Rotor armatute airgap is too large 49 Replace fuse Check coil resistance battery charge charging system and witing connections and replace if necessary Check coil resistance battery charge charging system and wiring connections and replace if necessary Replace clutch Repair or replace clutch lead wire or electrical system Clean connector contacts Remove shim or replace clutch Schematics Schematics 0 xod Electrical Diagram All Units Except Kohler EFI MS 1N3S3ud 2 3NION3 30010 SAL HOLNT9 014
74. th brake mounting bolts one half to one full turn see Figure 33 Note Do Not remove the brake pole from the field shell armature The brake pole has wotn to match the armature and needs to continue to match after the shim is removed to ensure proper brake torque _ 6011734 Figure 33 Brake mounting bolt 2 Shim B Using needle nose pliers or by hand take hold of the tab and remove the shim Do Not discard the shim until proper clutch function has been confirmed C Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers D Re torque each bolt M6 x 1 to 10 ft lb 13 N m 0 5 ft lb 0 7 N m E Using a 0 010 inch thick feeler gauge verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown Due to the way the rotor and armature faces wear peaks and valleys it is sometimes difficult to measure the true gap Maintenance G011733 Figure 34 1 Feeler gauge Figure 35 1 Feeler gauge e If the gap is less than 0 010 inch then reinstall the shim and reference the Troubleshooting section e If the gap is sufficient proceed to the safety check in step Perform the following safety check a Sit on the seat and start the engine b Make sure the blades Do Not engage with the PTO switch off and the clutch disengaged If the clutch does not
75. the LCD indicator appears in the message display on the front control console see Figure 5 and Figure 7 When the motion control levers in the neutral position and the RH motion control lever is moved into the PTO disengage position the mower blades will disengage Choke Control All Units Except Kohler EFI Located on the front control console right of the PTO engagement switch The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the position and moving the choke lever to the reat to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the position Figure 5 1 Throttle 8 Fuel gauge 2 RH Motion control lever 9 engagement switch 3 LH Motion control lever 10 Choke 4 Front Reference Speed 11 Deck lift handle Control Bar 5 Message display 12 Fuel cap 6 Park brake lever 13 Height of cut pin 7 Ignition switch 14 Platform latch Throttle Control Located on the RH side of the front control console red lever see Figure 5 The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle Front Reference Speed Control Bar Located in front of the motion control levers see Figure 5 The front refer
76. ting the Cutting Deck Rake 37 Adjusting the Rear of the Deck 38 Pomp Drive 38 Mower Deck Drive Belt Tension 38 Check the Park 38 Park Brake 38 Electric Clutch Adjustment eres 40 Motion Control Neutral Adjustment 41 Motion Control Tracking Adjustment 42 Check the Neutral Switch Alignment diae erts ra ee 42 Adjust RH Motion Control Handle POSH ODS sx user br RR OUT 43 Caster Pivot Bearings Pre Load vel s eio 44 45 Clean Engine and Exhaust System is siete cette inde 45 Remove Engine Shrouds and Clean Cooling jl EE 45 Clean Debris From Machine 45 Clean Grass Build Up Under Deck 45 Waste Disposals uiv e ees 45 45 01 11 16 47 50 Safety Safety Safety Alert Symbol This lawn mower meets or exceeds the B71 4 specifications of the American National Standards Institute in effect at the time of production Exmark designed and tested this lawn mower to offer reasonably safe service however failure to comply with the following instructions may result in personal injury This Safety A
77. 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 2011 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT If your Exmark dealer does not have the Exmark part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact yout authorized Exmark equipment dealer or distr
78. trol Bar in Operation Rotate the adjustment rod on the LH side of the machine as viewed from the rear of the machine see Figure 38 Looking down towards the adjustment rod rotate it counterclockwise in 1 4 turn increments to increase speed or clockwise to decrease speed Drive the machine and check the full forward tracking Repeat steps 5 through 7 until desired tracking is obtained With the motion control levers in the neutral position see Figure 4 with no force on the lever either forward or back the neutral LCD indicator should If it does not appear refer to the Troubleshooting section 10 Reinstall the rear cushion Check the Neutral Switch Alignment 1 Park the machine on a level surface and disengage the blade control switch 2 Stop engine wait for all moving parts to stop and remove the key or spark plug wire s 3 Set the height of cut to the 3 inch 7 6 cm position 4 Perform the Motion Control Neutral Adjustment and Motion Control Tracking Adjustment as stated in the Maintenance section 5 Release the rear cushion from the rear of the 42 machine and lower to the platform Maintenance 6 Check the alignment on the LH and RH neutral switches upper and lower surfaces reference Figure 39 If they are not in alignment loosen the hardware on the lower neutral switch and adjust it forward or rearward as necessary Once aligned tighten the hardware Chec
79. upplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whethe
80. ur Exmark commercial mower Lubricate Blade Bolt threads with copper based antiseize or grease and torque to 55 60 ft lbs 75 81 N m 109 3148 109 3148 Or 00 NR 115 4186 115 4186 Interval Power Take off PTO Parking brake Neutral Operator presence switch Battery Safety ONLY USE EXMARK HYDRO OIL FILL TO TOP OF BAFFLE 4 CAUTION 116 0404 OT SURFACE 116 0404 116 3267 116 2040 99 4627 48 116 3283 116 3111 52 116 3283 MOTION CONTROL FILL ON LEVEL GROUND FILL TO BOTTOM OF FILLER NECK E MAX DO NOT OVERFILL 116 3290 DISENGAGE MOTION CONTROL 3 Neutral 4 Reverse Safety Torque Wheel Lug Nuts to 90 95 ft Ibs 122 129 N m Check after first Torque Wheel Hub Nut to 175 225 ft lbs 100 hrs then every 237 305 N m See Operator s Manual for more details 500 hrs thereafter 116 4181 WARNING WARNING To avold serious injury or death To avold serious injury or death Rise eed prorseti n la 128 Check he function of operate presence ss Pick up objects that could be thrown by the blades Before leaving the operator s position Use extreme caution when NOT operate unless trained to guards and safely devices in place defeat the OPC system z Do mew wt ie Sn pete 17
81. uts removed or broken loose apply a thread locking adhesive to one 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 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 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 11 Insert the second bearing and new seal into the wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward 13 Torque the nut to 75 80 in Ib 8 9 N m loosen then re torque to 20 25 in Ib 2 3 N m Make sure axle does not extend beyond either nut 14 Reinstall the seal guards over the wheel hub and insert wheel into caster fork Reinstall 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 Reapply thread locking adhesive Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps o
82. witch is defective 8 Contact an Authorized Service Dealer 9 Faulty spark plug 9 Clean adjust or replace spark plug 10 Spark plug wire is not connected 11 MIL illuminates and blinks 10 Check the spatk plug wire connection 11 Contact an Authorized Service Dealer 47 Troubleshooting Engine loses power Engine overheats Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate Engine load is excessive Air cleaner is dirty Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt water or stale fuel is in the fuel system Engine load is excessive Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Tire pressure in drive tires not correct Tracking needs adjustment Bypass valve is not closed tight Drive or pump belt is worn loose or broken Drive or pump belt is off a pulley Blade s not sharp Cutting blade s is are bent Mower deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Cutting blade s is are bent or unbalanced Blad

Exmark 4500-759 Rev A Lawn Mower User Manual

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