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Exmark 4500-528 Lawn Mower User Manual

1. Part No 4500 528 Rev For Serial Nos 850 000 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 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 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 Canadian ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme a la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such ch
2. RELEASE Mgt 103 2432 103 2432 ONLY USE EXMARK HYDRO OIL FILL TO TOP OF BAFFLE HOT i SURFACE 116 0404 116 0404 CALIFORNIA SPARK ARRESTER WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrester may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements 17 718 117 2718 Specifications Specifications Model Numbers Serial Nos 850 000 and Higher 20 TT24KAE TT24KAECA Systems Engine Engine Specifications See your Engine Owner s Manual e RPM Full Speed 3600 No Load Fuel System e Capacity 5 0 gal 18 9 L Type of Fuel Regular unleaded gasoline 87 octane or higher containing no more than 10 methanol or ethanol e Fuel Filter Replaceable In line Fuel Shut Off Valve 1 4 turn increments Electrical System e Charging System Flywheel Alternator e Charging Capacity 15 amps Battery Type BCI Group U1 235 amps 0 F e Battery Voltage 12 Volt Polarity Negative Ground e Fuses Two blade type 20 amp to charging circuit 20 amp to electric clutch Safety Interlock System e Operator must have OPC Operator Presence Control levers held in contact with handle grips speed control lever in neutral and PTO disengaged to start engine
3. 1 wea STWNINYAL Iwo TE ava X TWNIWYSL 8 ag 8 Ju et HOLMS Old JILIN TWNIWYSL 1 9 TWNIWYSL La 002090 Gee meg 4 Y HOLIMS HOLIMS eee yaa 5 iY 17 SNOILOINNOI boo 18 18 HOLIMS NOILINDI 37 Schematics Electrical Logic Schematic NI 1 6012028 09199 02 LON 9 0 2 5381 03193NN09 5381 HOLIMS NOILINOI ATWNINYSL X TWNIWHSL TWNIWY3L 9 TWNIWYAL 5 Old NMOHS HOLIMS 014 WHLNAN 9 ae T aa 355 02 YNOH WED 3504 02 e 099 1 TH Tavis 340 1 gt
4. N3309 5 5 6 TH Fe IWO DETENTE 1 59158 1915 Y 330 LINDE NOILISOd 211 ar 1 1 5 F FOR HOLIMS HOLIMS 5 1 eye HOLVHAdO 1915 GaDVONASIC 036019 SI HO LIMS S434771 290 NAHM 036019 SI 5 38 Schematics Hydraulic Diagram HIGH PRESSURE a FORWARD 2 REVERSE HYDRAULIC TANK HIGH PRESSURE HIGH PRESSURE L FORWARD 1 FILTER 12 gt gt gt 1 1 1 55 5 VALVE VALVE cheers ee a oa ol SES Ss Sas an Se ey EN ee See HIGH PRESSURE CHARGE PUMP INLET FRONT OF UNIT G006197 o e e e CASE DRAIN 39 Exmark Commercial Turf Equipment 2 Year Limited Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein
5. i 14 Operat E E EER E 15 15 PEPE SLADE 16 Operating 8 17 20 22 Recommended Maintenance Schedule s 22 Periodic Maintenance 23 Check Engine Oil 23 Cheek Battery 23 Check Mower Blades 24 Check Safety Interlock System 25 Check for Loose 26 Service Air Cleaner 26 Change 26 Check Hydraulic Oil Level 26 Check Tire Pressures 26 Check 27 Lubricate Grease 27 Lubricate Caster Wheel Hubs 27 Remove Engine Shrouds and Clean Cooling FIN a 28 Check Spark 28 Change Hydraulic System Filtet 29 Thread Locking 30 Mobil HTS Grease Or Food Grade ia 31 Copper Based Anti seize 31 31 31 Dicks Wey elie 31 Pump Drive Belt 31 Deck Tension 31 Blade Drive Belt Tensi
6. 27 Maintenance 6006115 2 Figure 13 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 or damage and replace if necessary 6 Pack the bearings with 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 nuts 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
7. mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval Monthly A WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Maximum Charger Settings 16 volts 7 amps Voltage
8. Park Brake Adjustment 1 Shut off engine and wait for all moving parts to stop 2 Disengage the park brake 3 Remove the hairpin in the park brake linkage Turn the linkage in the yoke until there is 3 16 inch 4 8 mm to 1 4 inch 6 4 mm clearance between the park brake tire bars and the tires with the park brake disengaged Re install the hairpin Hydro Drive Linkage Adjustment Adjust Speed Control Linkage and Neutral Safety Switch 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s Move the speed control lever located on the console to the full forward position and check the orientation of the tabs on the ends of the speed control crank see Figure 15 These tabs should be pointing straight down at the 6 o clock position or slightly forward Adjust the threaded yoke at the bottom of the 31 Maintenance speed control linkage see Figure 15 until the tabs are positioned correctly 1 Neutral Safety Switch 3 we 2 9 a 2 5 1 2 006193 Figure 15 Viewed from Left Side of Unit 3 5 16 inch 7 9 mm 2 Actuating Tab in neutral position 3 Pull the speed control lever back to neutral Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is about 5 16 inch 7 9 mm between the tab and the switch see Figure
9. Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 8 Remove the key to prevent children or other unauthorized persons from starting engine 9 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building 17 Driving the Machine Drive Lever Neutral Lock Latch Operation To lock the drive levers in neutral lock squeeze the drive levers to the neutral position Do Not squeeze the drive levers all the way back as this will cause the drive wheels to go into full reverse direction See Figure 5 position 1 Place thumbs on the inner lobe of the neutral lock latches and rotate them under the drive levers into the neutral lock position See Figure 5 position 2 Release the drive levers A CAUTION If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage Be sure the drive levers are past the roller and securely seated at the bottom of the neutral lock latches To place the drive levers in the forward position slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches or the index finger on th
10. Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries Note The following instructions are adapted from the SAE J1494 Rev Dec 2001 Battery Booster Cables Surface Vehicle Recommended Practice SAE Society of Automotive Engineers A WARNING Batteries contain acid and produce explosive gases Shield the eyes and face from the batteries at all times Do Not lean over the batteries Note Be sure the vent caps 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 10 9012785 Figure 10 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block NOaRWN gt 4 Connect the other end of the positive cable to the positive terminal of the booster battery 5 Connect the black negative cable to the other terminal negative of the booster battery 6 MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEG
11. Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged e Park brake must be disengaged to move speed control out of neutral or engine will kill Operator Controls Steering Control Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward reverse stopping and power turning Transmission Two Gear variable displacement piston pumps independently coupled to two high efficiency Parker wheel drive motors e Hydraulic Oil Use Exmark Premium Hydro Oil e Hydraulic Oil Capacity 2 4 qt 2 2 L e 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 6 75 mph 10 9 km hr forward 0 2 25 mph 3 6 km hr reverse Drive wheel 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 12 Specifications Tires amp Wheels _ Pneumatic Pneumatic Semi Air Filled Air Filled Pneumatic All Serial SN 599 999 SN 600 000 Nos amp Lower amp Higher 18 x 8 50 8 11 x4 00 5 11 x 4 00 5 Pressure 14 psi 96 16 psi 110 kPa kPa Cutting Deck e Mode
12. cables or ropes Do Not rely solely on the parking brake to hold the machine on the trailer Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain 21 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position WARNING While maintenance or adjustments are being made someone could start the engine Accidental starting of the engine could seriously injure you or other bystanders Remove the key from the ignition switch engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s WARNING The engine can become very hot Touching a hot engine can cause severe burns Allow the engine to cool completely before service making repairs around the engine area Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval Change the engine oil After the first 5 hours After the first 250 hours Change the hydraulic filter the engine oil level k the mower blades Kt nec nec Before each use or daily Every 40 hours Kt Kt Kt nec nec nec he tire pressures he hydraulic oil level he safety interlock system k for loose hardware ean the grass build up from under the deck he condition of the
13. etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwards Be aware that operating on wet grass across steep slopes or downhill may cause the mower to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counter weights to improve stability Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from 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 fue
14. 15 If necessary move the switch fore and aft Adjust Neutral Control Linkages 1 Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground Start the engine and move the throttle ahead to the full throttle position Place the neutral lock latches in the forward position as shown in Figure 4 Release the park brake and move the speed control lever to the mid speed position Note The OPC levers must be held down and the park brake must be disengaged whenever the speed control lever is moved out of neutral or the engine will kill Squeeze the respective drive lever until an increased resistance is felt this is where neutral should be If the wheel turns while holding the drive lever in neutral the neutral control linkages need to be adjusted If the wheel stops then go to step 7 Neutral Control Linkage 5 Hydro Control Linkage 6 2 8 Figure 16 Viewed from Left Side of Unit G011361 Speed Control Linkage Adjust here rotate at approximately 1 4 turn increments and re check Drive Lever Linkage 7 Loosen nut Speed Control Crank 8 Yoke 4 Loosen the nut against the neutral control 6 T linkage yoke as shown in Figure 16 Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring neutral positi
15. Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed 1 Stop the machine and move the drive levers to the neutral lock position Disengage the PTO Engage the park brake Stop the engine remove the key and wait for all moving parts to stop 5 After adjusting the height of cut adjust the anti scalp rollers by removing the spring disc washer and bolt see step 7 6 Adjust anti scalp rollers for Normal Operating Conditions Place rollers in one of the positions shown in Figure 8 Rollers will maintain 3 4 inches 19 mm clearance to the ground to minimize gouging and roller wear or damage Note For Maximum Deck Flotation place rollers one hole position lower Rollers should 19 maintain 1 4 inch 6 35 mm clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts are installed with the spring disc washer between head of the bolt and mounting bracket 2 1 2 2 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm Figure 8 For cutting heights above 3 5 inches 38 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller mounting bracket 2 Cutting height 7 Four types of anti scalp roller assemblies are available See Figure 9 to determine which assembly has been installed on the unit Torque hardware as specified or loss
16. 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 2010 Exmark Mfg Co Inc Part No 4500 528 Rev B Industrial Park Box 808 402 223 6300 Cle Beatrice NE 68310 Fax 402 223 5489 Rights Reserved Printed in the USA www exmark com
17. Reading 12 6 100 greater 124 12 6 75 100 16 volts 7 30 Minutes amps 122 12 4 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 50 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours More Recommended Jump Starting Procedure Service Interval As required 1 Check the weak battery for terminal corrosion white green or blue snow it must be cleaned off prior to jump starting Clean and tighten connections as necessary CAUTION Corrosion loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur A DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist 23 Maintenance 2 Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system
18. for both pumps Note Hydraulic reservoir can be pressurized up to 5 psi to speed this process 6 If either drive wheel still does not rotate stop and repeat steps 4 and 5 above for the respective pump If wheels rotate slowly the system may prime after additional running Check oil level as stated in Check the Hydraulic Oil Level section 7 Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position Check oil level as stated in Check the Hydraulic Oil Level section 8 Check hydro drive linkage adjustment as stated in Hydro Drive Linkage Adjustment section in Adjustments Fuel Tank Mounting Hardware Specifications Service Interval As required When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners e Pump drive sheave set screws e Square head setscrews on Hydro pump control arms Shoulder bolts in ends of speed control crank OPC lever setscrews Electric clutch retaining bolt e Pump drive idler pivot bolt e Thumb latch screw threads on handles e Caster wheel spacer nuts e Fuel tank bulkhead fitting nuts Adhesives such as Locti
19. fuel tank Open the fuel shutoff valve Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate Engine load is excessive Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Tracking needs adjustment Tire pressure in drive tires not correct Bypass valve is not closed tight Drive or pump belt is worn loose broken Drive pump belt is off a pulley Blade s not sharp Cutting blade s is are bent
20. long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 589_B Service Record Date Description of Work Done Service Done By 41 PREMIUM HYDRO OIL BENEFITS Designed amp manufactured with superior anti wear protection Superior thermal stability Consistent hydro performance Superior shear resistance under heavy loads Field tested amp proven performance Twice the shear stability of SPECIALLY FORMULATED amp competing oils MANUFACTURED FOR SUPERIOR REORMANEE IN ALL EXMARK Enhanced control performance DRAULIC DRIVE SYSTEMS Specially formulated for any 1 US Quart 946 ML 32 FL oz Exmark hydraulic system NOW AVAILABLE FOR PURCHASE Part No 109 9828 42 6011841 Figure 20 This page may be copied for personal use 1 The maximum slope you can safely operate the machine on is 20 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 20 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 43 SEE EXMARK S COMPLETE
21. 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 the product Write the numbers in the space provided 1 Model and serial number location G006179 Figure 1 Model No Serial No Contents Pr Tre eer erent 3 SALLY 5 Safety 5 Safe Operating 5 Safety and Instructional Decals 10 Specifica ONS 12 12 Sy Ste 12 Dimensions 13 Torque Requirements 14 Product Overview
22. operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing 25 Maintenance Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Visually inspect machine for any loose hardware ot any other possible problem Tighten hardware or 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 2 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 2 Drain oil while engine is warm from operation 3 The oil drain hose is located on right hand side of engine for Kohler or left hand side
23. when starting the engine Refer to Neutral Lock Latches section in Controls Engaging the PTO A DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged 4 DANGER An uncovered discharge opening will allow objects to be thrown in operatot s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO switch engages the cutting blades Be sure that all persons are clear of mower deck and discharge area before engaging the PTO 1 Set throttle to MIDWAY position 2 Pull the PTO switch outward to the ROTATE position to engage the blades 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle to the MIDWAY position 2 Push the PTO switch in to the STOP position to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Lock drive levers in neutral 3 Disengage the PTO 4 Move speed control lever to neutral 5 Engage the parking brake 6 Place the throttle midway between the SLOW and FAST positions 7
24. 81 cm to 11 4 cm in 1 2 inch increments 1 Stop the machine and move the drive levers to the neutral locked position 2 Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 Install hairpin clips in the holes for the desired cutting height See Figure 6 Important To maintain correct cutting height and rake check the following for proper adjustment A The front and rear hairpins are in the same holes with the proper spacers under the hair pins See Figure 6 2 1 5 inch 38mm 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm 4 0 inch 102mm 4 5 inch 114mm G006182 Figure 6 1 Deck support pin 2 Cutting Height B The tire pressures are set as directed in Check Tire Pressures in the Maintenance section C The length of the rear deck support link assemblies average 6 89 inches approximately 6 7 8 inches 175 01 mm from the center of the balljoint to the center of the farthest hole See Figure 7 Note All four pins must equally support the weight of the deck Adjustment in the length of the rear deck support assemblies may be necessary If one side is longer than 6 89 inches approximately 6 7 8 inches 175 01 mm than the opposite side must be shorter by the same amount 3 8 inch 9 53 mm 6 7 8 inches 175 01 mm Figure 7 Left Hand Side Shown Adjusting the
25. ATIVE POST AWAY FROM THE BATTERY STAND BACK 7 Start the vehicle and remove the cables in the reverse order of connection the engine block black connection is the first to disconnect Check Mower Blades Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck procedure Inspect blades and sharpen or replace as required 4 Reinstall blades if they were removed in the following order A Install bushing through blade with bushing flange on bottom grass side of blade 24 Maintenance 03006111 1 Figure 11 1 Install bushing in blade prior to installing bushing in spindle B Install bushing blade combo into spindle G006112 Figure 12 2 1 Use wrench here for blade installation This nut has been torqued to 90 110 ft lb 122 149 N m Torque to 55 60 ft lb 75 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 55 60 ft lb 75 81 N m WARNING Incorrect installation of the blade or com
26. 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 Blade mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Belt is damaged Drive belt is worn loose or broken Drive belt is off pulley Deck belt is worn loose or broken Deck belt is off pulley Broken or missing idler spring PTO clutch does not engage 36 Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust the tracking by turning knob on the right hydro control linkage in the direction that the mower needs to be adjusted to Turn the knob in 1 4 turn increments until the mower tracks correctly Adjust tire pressure in the drive tires Tighten the bypass valve Change the belt Change the belt Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to tear 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
27. Tighten the blade mounting bolt Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Contact an Authorized Service Dealer Install new belt Check the belt tension Check belt for damage replace if necessary Install drive belt and check adjusting shafts and belt guides for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Replace the spring Contact an Authorized Service Dealer Schematics Schematics Electrical Diagram z 6012027 HOLIMS 014 La 6 ANSNOdWO9 084 031131 SYOLOANNOD 13100 Seo 0 12 12141491 LZ EH asna T 1 E dV 02 ax 1 INE 4 INON 34011 504 N T asna UE 1 02 _________ m NOILIN I ____ 484 9
28. age Make sure flat part of linkage is perpendicular to pin part of swivel see Figure 17 6006195 17 to neutral Recheck the drive wheel rotation to see if further adjustment is necessary The spring that keeps tension on the knob should normally not need adjustment However if adjustment is needed adjust to where length of spring is about 1 inch 2 5 cm between the washers Adjust spring length by turning nut at front of spring Drive Lever Linkage Adjustment 1 With rear of machine still on jack stands and engine running at full throttle disengage the park brake and move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches Figure 18 If the tire rotates in either direction the length of the drive lever link will need to be adjusted Left Hydro Control Link 4 Linkage is perpendicular left side shown to pin correct position Front nut 5 Linkage in incorrect position Rear nut 6 End view of swivel After adjusting the left hydro control linkage move the speed control lever to the mid speed position and then back to the neutral position Recheck the left drive wheel rotation to see if further adjustment is necessary be sure the speed control lever is in the neutral position Important If inconsistent neutral occurs check to be sure both spri
29. ake Push the lever forward and down to disengage the brake When parking on a steep slope the wheels must be chocked or blocked in addition to the brake being engaged The unit must be tied down and brake engaged when transporting Park brake must be disengaged to move speed control out of neutral or engine will kill Ignition Switch Located on the left side of the control console The ignition switch is used to start and stop the engine The ignition switch has three positions Off On and Start Insert key into switch and rotate clockwise to the position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Operator must have speed control lever in neutral OPC levers depressed and PTO disengaged to start engine When engine starts release key Hour Meter Located on the front left hand side of console just above the PTO switch The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If ignition switch is left on without engine running hour meter will not run Note This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve Located in the fuel line midway between the tank and engine The fuel shut off valve is used to shut off the flow of fuel when parking inside a building during
30. ample 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 fall only to the COLD level Check Tire Pressures Service Interval Every 40 hours T Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tire pressure in drive tires Inflate drive tires to 12 14 psi 83 97 kPa Inflate tires to pressures stated above Measure the circumference of each drive tire Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible For Serial Nos 599 999 and Lower Check the tire pressure in the pneumatic front caster tires Adjust the tire pressure to 16 psi 110 kPa Maintenance Note Front caster tires have permanent tire sealant installed For Serial Nos 600 000 and Higher Semi pneumatic caster tires do not need to be inflated Note Do Not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove the three mower deck belt shields to check mower primary and secondary belt condition 3 Look under
31. anges 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 2010 Exmark Mfg 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 mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor Exmark parts manuals are available online at http www exmark com
32. atible 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 40 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 whether performed by a dealer or by you is at you
33. aution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed e Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Slope Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes Safety A 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 or 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
34. belts Grease the hydro control arm support bushings Every 80 hours Remove engine shrouds and clean cooling fins Every 100 hours Change the engine oil May need more often under severe conditions Every 160 hours Check the spark plugs Replace t Every 250 hours information Replace t Every 500 hours he primary air cleaner element check secondary air cleaner element replace if dirty need more often under severe conditions See the Engine manual for additional he secondary air cleaner element May need more often under severe conditions See the Engine manual for additional information Change the hydraulic filter Every 250 hours yearly if using Mobil 1 15W50 e Grease the front caster wheel hubs Grease front caster pivots Grease the idler pivots Mower Deck Grease the idler pivot Pump Drive e Lubricate the caster wheel hubs 22 Maintenance Periodic Maintenance Check Engine Oil Level Service Interval 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 fill to the FULL
35. d 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 if equipped Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps 16 Operation Operating Instructions Open the Fuel Shut Off Valve Rotate the valve 1 4 turn counterclockwise to turn fuel on Starting the Engine 1 Ona cold engine place the throttle midway between the Slow and Fast positions and place the choke in the On position On a warm engine place the throttle lever midway between Slow and Fast positions and leave the choke in the Off position 2 Turn ignition switch to Start position Release the switch as soon as the engine starts 3 Ona cold engine gradually return choke to the Off position after engine starts and warms up Important Do not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second starter cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor Note It is helpful to have the left and right neutral lock latches locked in neutral
36. e WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Safety Operation A WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching e 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 or in a small confined area where dangerous carbon monoxide fumes can collect e Operate only in daylight or good artificial light keeping away from holes and hidden hazards e Be sure all drives are in neutral and parking brake is engaged before starting engine e Never raise deck wit
37. e 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 14 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 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 eac
38. e front lobe and rotate them from under the drive levers Slowly and carefully release the drive levers See Figure 5 position 3 To place the drive levers in the reverse position squeeze the drive levers past the neutral position See Figure 5 position 4 G006190 Figure 5 1 Drive Lever in neutral 3 Drive Lever in forward position position 2 Drive Lever locked in 4 Drive Lever in reverse neutral position position Driving Forward 1 Release the parking brake 2 With drive levers locked in neutral shift speed control lever to desired forward speed Slowly squeeze and hold both drive levers in the neutral position and rotate both neutral lock latches from the neutral lock position to the forward position Note Do Not squeeze both drive levers all the way back This will cause the drive wheels to engage in the reverse direction To move forward in a straight line smoothly release both drive levers to engage drive wheels To turn left or right squeeze the right hand drive lever to turn right and the left hand drive lever to turn left To make a zero turn squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed Note For smooth operation of this machine avoid quick jerky movements of the drive levers Move the drive levers smoothly and delibera
39. e in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible 7 OPEN BELT DRIVE STOP ENGINE BEFORE REACHING UNDERNEATH 1 303517 1 303517 Use Only Riding Attachments Use of Other Riding Attachments May Create a Hazardous Condition Resulting in Injury 4403143 1 403143 TRACKING 238 gt 1 413214 10 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 o
40. engine deck to check the pump drive belt condition 4 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 one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval Caster Wheel Hubs 3 Idler Pivots Mower Deck Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval 4 Idler Yearly Pivot Pump Drive 5 Hydro 40 Hours Control Arm Support Bushings See step 3 for special lubrication instructions on the front caster pivots and the Lubricate Caster Wheel Hubs section for special lubrication instructions on the front casters wheel hubs 2 1 G011945 Number 4 Idler Pivot Pump Drive Located Under Engine Deck 3 Lubricate front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thread plug back in Place cap back on Lubricate Caster Wheel Hubs Service Interval Yearly 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake
41. f Drive Tire 60 inch Deck 43 3 inches 110 0 cm 52 inch Deck 43 3 inches 110 0 cm Curb Weight 52 inch Deck 720 lb 327 60 inch Deck 760 lb 345 Product Overview Torque Requirements Product Overview Cutter Housing Spindle 140 145 ft lb 190 197 Nut N m Blade Mounting Bolt 55 60 ft lb 75 81 N m lubricate with anti seize Engine Deck Mower 30 35 ft lb 41 47 N m Deck Support Mount Bolts Type 1 Hardware 40 45 ft lb 64 61 N m Anti Scalp Roller Whizlock Nut See Figure 9 Type 2 30 35 ft lb 41 47 N m Hardware Anti Scalp Roller Nyloc Nut See Figure 9 Type 2 amp 3 Hardware 50 55 ft lb 68 75 N m Figure 3 Anti Scalp Roller Hex 1 Controls 3 Park Brake Lever Capscrew See Figure 9 2 Fuel Cap 4 Height of Cut Pins Type 3 30 35 ft lb 41 47 N m Hardware Anti Scalp Roller Flanged Nyloc Nut See Figure 9 Type 4 30 35 ft lb 41 47 N m Hardware Anti Scalp Roller Whizlock Nut See Figure 9 Type 4 30 35 ft lb 41 47 N m Hardware Anti Scalp Roller Nyloc Nut See Figure 9 Engine Mounting Bolts 15 20 ft lb 20 27 N m Kohler Engine Mounting Bolts 17 25 ft lb 23 31 N m Kawasaki Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Hub Slotted Nuts minimum 100 ft lb 136 N m Clutch Retaining Bolt 55 60 ft lb 75 81 N m secured with threadlocker Wheel Motor Mounting 30 35 ft lb 41 47 N m Bolts Operati
42. for Kawasaki Place pan under machine to catch oil Remove plug from end of drain hose Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft lb 4 Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove 26 Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks Stop engine and recheck oil level Check Hydraulic Oil Level Service Interval Every 40 hours 1 Stop engine and wait for all moving parts to stop and remove key Engage parking brake Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use Exmark Premium Hydro oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Note The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For ex
43. ge in the reverse direction regardless of the position of the neutral lock latches and the speed control lever Neutral Lock Latches Located on the upper handle assembly on the ends of the handle grips These latches allow the operator to lock the drive levers in a neutral position where the drive wheels are not engaged in either a forward or reverse direction Choke Control Located on the control console front right hand side Choke is used to aid in starting a cold engine The choke control is pulled out to be in the ON position and pushed in to be in the OFF position Do Not run a warm engine with choke in the position Throttle Control Located on the control console s right side The throttle is used to control engine speed Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed Moving the throttle forward into the detent is full position Speed Control Lever Located in middle of control console The speed control lever controls the maximum forward speed and is infinitely variable from neutral 0 6 75 mph 10 9 km hr Park brake must be disengaged to move speed control out of neutral or engine will kill Brake Lever Located on the left side of the unit above the hydraulic tank 15 The brake lever engages the park brake on the drive wheels Pull the lever up and rearward to engage the br
44. h 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 e Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting overspeed the engine Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mower 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 e Stop engine wait for all moving parts to stop and engage parking 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 c
45. h variable displacement pump Figure 14 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed 29 Maintenance 1 G006192 Figure 14 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 the speed control lever to the middle speed position and place the drive levers in the drive position If either drive wheel does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position Note It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature If the cap is too hot to touch turn off engine The pumps may be damaged if the pump becomes too hot If either drive wheel still does not rotate continue with step 4 Thoroughly clean the area around each of the charge pump housings To prime charge pump loosen two hex socket head capscrews shown in Figure 14 11 2 turns only Make sure engine is not running Lift the charge pump housing upward and wait for 30 a steady flow of oil to flow out from under the housing Retighten the capscrews Do this
46. l Numbers FMD524 FMD604 e Cutting Width 52 inch 132 1 cm 60 inch 152 4 cm e Discharge Side Blade Size 3 ea 52 inch Deck 18 00 inches 45 7 cm 60 inch Deck 20 50 inches 52 1 cm e Blade Spindles Solid steel spindles with 1 3 4 inch 4 45 cm LD bearings e Deck Drive Electric clutch mounted on engine shaft Blades driven by two belts w self tensioning idlers e Deck floating deck is attached to out front support frame removable for service Anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge Deck Depth 52 inch Deck 5 5 inches 14 0 cm 60 inch Deck 5 5 inches 14 0 cm e Cutting Height Adjustment Adjusts from 1 1 2 inches 3 8 cm to 4 1 2 inches 11 4 cm in 1 2 inch 1 3 cm increments e Mulching Kit Optional e Bagger Optional Dimensions Overall Width inch Deck 60 inch Deck Deflector Up 53 4 inches 61 4 inches 135 6 cm 156 0 cm Deflector Down 64 8 inches 73 0 inches 164 6 cm 185 4 cm Overall Length 52 inch Deck 83 4 inches 211 8 cm 60 inch Deck 83 4 inches 211 8 cm Overall Height 52 inch Deck 45 inches 114 3 cm 60 inch Deck 45 inches 114 3 cm Tread Width Outside to Outside of Tires Widthwise 52 inch Deck 45 8 inches 116 3 cm 60 inch Deck 45 8 inches 116 3 cm Wheel Base Center of Caster Tire to Center o
47. l near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s or wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Charging 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 e 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
48. ment Filters Kawasaki Kawasaki P N 49019 7001 Maintenance Change Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 Note Use only Exmark Part No 109 4180 for Summer use above 32 F 0 C or P N 1 523541 for Winter use below 32 F 0 C Refer to Transmission section in Specifications for filter specifications 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 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 rubber 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 clockwis
49. ngs are properly tightened on the speed control lever under the console especially the rear pivot spring Repeat above adjustments if necessary Place the speed control lever in neutral Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward Begin to retighten the knob clockwise about 1 4 turn at a time stopping to move the speed control forward and back 6006196 S Figure 18 Adjust the linkage length by loosening the jam nuts at both ends of the linkage and rotating the linkage in the ball joints Lengthen the linkage if the tire is turning in reverse and shorten the linkage if the tire is creeping forward Tighten the jam nuts at both ends Release and re engage the neutral lock latch checking that the tire stops Continue this process until the tire is at a dead stop Make this adjustment for both sides Stop engine and wait for all moving parts to stop Raise rear of machine remove jack stands and carefully lower machine to the ground Tracking Adjustment 1 Stop engine and wait for all moving parts to stop 33 Maintenance 2 Check the drive tire pressures and tire circumferences as stated in Check the Tire Pressures section in Maintenance 3 Run the unit and observe the tracking on a level smooth hard surface such as concrete or asphalt 4 Ifthe unit tracks to one side or the other turn the quick track knob T
50. nly to a clean dry surface Smooth to remove any ait bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower 103 1541 PTO Engage at 1 2 throttle Disengage at idle LIET E 6 5 4 3 2 1 Read operator s manual before operating Do NOT operate unless trained to safely operate this machine Do NOT operate without shields guards and safety devices in place and working A Do NOT carry passengers Glear area of debris before mowing Thrown objects or blade contact can lt Before leaving operator s position cause serious injury or death 2 Lock drive levers neutral lock position Keep all people and pets out of 2222 lt area when mowing Shift speed control lever to neutral Engage park brake Avoid blades unless blades and lt Shut off engine and remove key before engine are stopped adjusting servicing or cleaning Use extreme caution when operating on slopes Do NOT operate on slopes greater than 20 A Mow across slope NOT up and down AUTI N Do NOT mow wet slopes R Hearing protection recommended 103 1541 Safety ENHANCED CONTROL SYSTEM 103 2242 Use 5 8 wrench One turn counterclockwise to release Do not over tighten 103 4935 J 103 4935
51. nnectors Starter does not crank Engine will not start starts hard or fails to keep running Engine loses power PTO is engaged Speed control lever is are not in neutral lock position OPC levers are released Battery does not have a full charge Electrical connections are corroded loose faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed The throttle and choke ate not in the correct position Dirt in fuel filter Dirt water or stale fuel is in the fuel system Air cleaner is dirty Electrical connections corroded loose faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Engine load is excessive Air cleaner is dirty Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt water or stale fuel is in the fuel system 35 Disengage the PTO Ensure the speed control lever is in the neutral lock position Depress OPC levers Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Fill the
52. of roller may result See Figure 9 9 10 6010007 Figure 9 Front left anti scalp bracket shown Type 1 hardware Type 2 hardware Type 3 hardware Type 4 hardware Type 1 3 8 16 x 4 hex screw Type 2 amp 3 3 8 24 2 hex screw Torque to 50 55 ft lb 68 75 N m 7 4 3 8 whizlock nut Torque to 30 35 ft lb 41 47 N m 8 Spring disc washer cone towards bolt head 9 Type 1 3 8 whizlock nut and heavy flat washer Torque to 40 45 ft lb 54 61 N m 10 Type 2 3 8 nyloc nut and heavy flat washer Torque to 30 35 ft lb 41 47 N m 11 Type 3 3 8 flanged nyloc nut without washer Torque to 30 35 ft lb 41 47 N m 12 4 3 8 nyloc nut Torque to 30 35 ft lb 41 47 N m OT OO Transporting Transporting a Unit WARNING Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous The ramps could collapse causing the unit to fall which could cause injury Use proper ramps that are secured to the truck or trailer Keep feet and legs out from under the unit when loading and unloading Ifnecessary use assistance when loading Be sure the fuel shut off valve is closed Use a heavy duty trailer to transport the machine Engage neutral lock latches and park brake then block wheels Operation Securely fasten the machine to the trailer with straps chains
53. on 31 Park Brake A Hydro Drive Linkage 31 Tracking Adjustment 33 Hydro Pump Spring Tension Setting 34 Electric Clutch 34 a ad cri wenn acide cn 34 Clean Grass Build Up Under Deck 34 34 PROUD ESO ORIG 35 37 Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 Safety alert symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING 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 use
54. on Operation Note Determine the left and right sides of the machine from the normal operating position Controls Operator Presence Control OPC Levers Located on the upper handle assembly directly above the handle grips When these levers are depressed the OPC system senses that the operator is in the normal operator s position When the levers are released the OPC system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the PTO is engaged see Figure 4 Figure 4 1 Lever 3 Neutral Lock Latch Rotate neutral lock latch 4 Drive Lever in neutral downward for neutral position lock position Drive Levers Located on each side of the upper handle assembly ahead of and below the handle grips These levers individually control the speed and direction of each drive wheel When the speed control lever is moved out of the neutral position and the neutral lock latches are moved into the drive position as shown in Figure 4 and the drive levers are released the drive wheels are engaged in the forward direction Squeezing the left hand and or right hand lever causes the left hand and or right hand drive wheel respectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to enga
55. on Turn the adjusting bolt approximately 1 4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1 4 turn counterclockwise if the wheel is turning forward Release the drive lever to the forward drive position and squeeze back into the neutral position Check to see if the wheel stops If not repeat the above adjustment procedure Make this adjustment on both sides After adjustments made and the wheels stop when the drive levers are in the neutral position tighten the nuts against the yokes e Adjust Hydro Control Linkages 1 32 Place the speed control lever in the neutral position This adjustment is again made with reat of machine on jack stands and engine running at full throttle OPC levers will have to be held down and the park brake must be disengaged whenever speed control levers are moved out of the neutral position Maintenance Note The neutral lock latches should be unlocked and in the forward position Loosen the front nut on left hydro control linkage as shown in Figure 16 Turn the rear control linkage adjusting nut counterclockwise until wheel rotates forward Turn the rear nut of left control linkage clockwise 1 4 of a turn at a time stopping to move the speed control forward and back to neutral until left wheel stops rotating forward Turn the rear nut an additional 1 2 turn and tighten the front nut making sure not to put a bind on the link
56. onto the axle with the wrench flats facing outward 13 Torque the nut to 75 80 1 8 9 N m loosen then re torque to 20 25 in lb 2 3 N m Make sute 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 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 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 Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Ownet 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 Replace
57. opriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire or explosion from gasoline can burn you others and cause property damage e 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 if equipped e Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark e St
58. ore gasoline in an approved container and keep it out of the reach of children fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot 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 A DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage e Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground 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 complet
59. ponents 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 1 Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and PTO disengaged Try to start the engine with OPC levers disengaged speed control lever in neutral and PTO disengaged starter must not crank Try to start with OPC levers depressed speed control lever in any speed but neutral and PTO disengaged starter must not crank Try to start with OPC levers depressed speed control lever in neutral and PTO engaged starter must not crank Check OPC circuits Clear the area Run engine at one third throttle then with drive levers and neutral lock latches in neutral lock position move the speed control lever out of neutral and release OPC levers engine must stop Again run engine at one third throttle move the speed control lever to neutral engage PTO and release OPC levers engine must stop Note Park brake must be disengaged before the speed control lever is moved out of neutral or engine will kill Note If machine does not pass any of these tests do not
60. r 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 consequential damages or limitations on how
61. s two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training e Read the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them e Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate 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 N 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 The owner user can prevent and is responsible for accidents 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 Wear appr
62. 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 e Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard WARNING Removing standard original equipment parts or using non Exmark replacement parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury or death Replace all parts including but not limited to tires belts and blades 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 ar
63. sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the 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 34 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 co
64. te RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining II are used on the following Maintenance OPC lever hubs and cross shaft Note Care must be used not to bond the bearing next to each OPC hub to the cross shaft which could cause binding of the OPC levers and erratic operation Fuel tank studs where studs are inserted into tank Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations e Between the cutter housing spindle and bearings e Between the cutter housing spindle and sheave Under top cutter housing bearing guard Copper Based Anti seize Copper based anti seize is used in the following locations On threads of Blade Bolts Serial Nos 540 000 and Higher See Check Mower Blades section for instructions 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 Deck Leveling See Adjusting the Cutting Height section in Operation Pump Drive Belt Tension Self tensioning No adjustment necessary Deck Belt Tension Self tensioning No adjustment necessary Blade Drive Belt Tension Self tensioning No adjustment necessary
65. tely To stop squeeze drive levers back to the neutral position Move the neutral lock latches into the neutral lock position and release drive levers Move the speed control lever to the neutral position Driving in Reverse To move rearward in a straight line squeeze drive levers into the reverse position To turn left or right squeeze the right hand drive lever to turn left and the left hand drive lever to turn right To make a zero turn squeeze either the left hand ot the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed Note For smooth operation of this machine avoid quick jerky movements of the drive levers Move the drive levers smoothly and deliberately stop squeeze drive levers back to the neutral position Move the neutral lock latches into the neutral lock position and release drive levers Move the speed control lever to the neutral position 18 Operation Adjusting the Cutting Height A WARNING When the two front support rod hairpins are removed from the mower deck the weight of the tractor section may cause the front frame of the unit to rise suddenly If the unit rises suddenly injury may occur Securely hold down the front of the unit when the front support rod hairpins are removed The cutting height of the mower deck is adjusted from 1 1 2 to 4 1 2 inches 3
66. that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark commercial turf equipment sold in the U S or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine 2 years The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following Pickup and delivery charges to and from any authorized Exmark Service Dealer Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments 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 supplies including gasoline oil or lubricants incomp
67. transportation to and from the job sites and when the machine will not be used for a few days Rotate valve 1 4 turn clockwise to shut fuel off Rotate valve 1 4 turn counterclockwise to turn fuel on Drive Wheel Release Valves Located on the left rear corner of the hydrostatic pumps Drive wheel release valves ate used to release the hydro static drive system to allow the machine to be moved by hand without the engine running With a 5 8 wrench turn both valves one turn counterclockwise to release the drive system Turn clockwise to reset the drive system Do Not overtighten Tracking Adjustment Knob Located on the right hand side of the rear of the fuel tank support The knob can be adjusted so that machine will track straight ahead with the drive levers released PTO Engagement Switch Switch is located on left side of control console The switch must be pulled out to the Rotate position to engage the blades The switch is pushed in to the Stop position to stop the blades Operator must have operator presence control levers depressed when PTO is engaged or engine will stop 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 damage
68. urn the knob right to steer right turn the knob left to steer left Hydro Pump Spring Tension Setting 1 For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling For a heavier drive setting relocate the spring anchor link as shown in Figure 13 The spring anchor links are located under the engine deck on the left and right hand sides Note In medium or heavy duty positions the drive lever forces at the upper handle will also be increased a ae 2 5 Figure 19 1 Heavy duty 3 Standard 2 Medium duty 4 Retaining bolt Electric Clutch Adjustment No adjustment necessary Cleaning Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise deck to the transport maximum cutting height position Lift the front of unit and support unit using jack stands or equivalent support 3 Clean out any grass build up from underside of deck and in discharge chute Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations Battery Disposal 4 DANGER Battery electrolyte contains

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