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Exmark 103-0656 Lawn Mower User Manual

1. 5 5 IMS lt C5 51 Schematics Hydraulic Diagram eoo hv p asoy ssed g Jeeupioous ssed g 2 19115 f t 1 1 i 1 2 6008623 y BuwelA uonejog 1ndu MOO 52 Lazer Z E Series Turf Equipment 2 Year Limited Commercial Warranty 4Year or 500 Hours Limited Consumer Warranty General Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Commercial Warranty Conditions This warranty applies to Exmark Lazer Z E Series turf equipment sold in the U S or Canada for a period of two years for commercial usage This warranty includes the cost of parts and labor for a period of two years This warr
2. 5 8 4 N O A r7 Ax 62 Yi Qs lt For Serial Nos 920 000 amp Higher Lazer Z LZE Units Part No 4500 872 Rev A 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 impr
3. i nre rts 39 Deck Belt Ienstoti 39 Adjusting the Parking Brake 39 Electric Clutch Adjustment need 41 Motion Control Linkage Adjustment 42 Motion Control Damper Adjustment 43 Motion Control Neutral Lock Pivot TOI PHPECN o 44 Motion Control Handle Adjustment 44 Motion Control Full Forward Tracking 44 Caster Pivot Bearings Pre Load Adj stment 45 run 45 Clean Engine and Exhaust System EA dote goce esso gs ERR UII Ma cR ME 45 Remove Engine Shrouds and Clean Cooling P MN NU TER NUT 45 Clean Hydro Cooling FInS oe toss 45 Clean Debris From 46 Clean Grass Build Up Under Deck 46 Waste Disposal 46 Troubl shooting 47 Schematics 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 Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which
4. 5 Dirt in fuel filter 6 Dirt watet or stale fuel is in the fuel system 1 Drive release handle not in operating position 2 Drive or pump belt is worn loose or broken 3 Drive or pump belt is off a pulley 4 Broken or missing idler spring 5 Hydraulic fluid level is low or too hot 1 Blade s not sharp 2 Cutting blade s is are bent 3 Mowet deck is not level 4 Underside of mower is dirty 5 Tire pressure in drive tires not correct 6 Blade spindle bent 7 Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness 1 Cutting blade s is are bent or unbalanced 2 Blade mounting bolt is loose 3 Engine mounting bolts are loose 4 Loose engine pulley idler pulley or blade pulley 5 Engine pulley is damaged 6 Blade spindle is bent 1 Deck belt is worn loose ot broken 2 Deck belt is off pulley 3 Broken or missing idler spring 4 Drive belt not routed correctly 48 1 Reduce the ground speed 2 Clean or teplace the air cleaner element 3 Add oil to the crankcase 4 Remove the obstructions from the cooling fins and air passages 5 Replace the fuel filter 6 Contact an Authorized Service Dealer 1 Tire pressure in drive tires not correct 1 Adjust tire pressure in the drive tires 1 Position handle in operating position see Drive Wheel Release Valves se
5. Moving motion control levers outwatd in slots locks the drive system in neutral PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades Parking Brake Lever Engages parking brake Parking Brake Release Button Releases parking brake Deck Height Adjustment Lever Sets cutting height to desired position Specifications Deck Lift Pedal Foot pedal that lifts deck Transport Lock Latching position Automatically latches at the transport position Unlatching position Deck does not latch at the transport position Seat Type Standard seat with foam padded seat cushion with armrests and integral safety switch Optional seat Seat with high back extra wide foam padded seat cushion with internal suspension thick bolstering two tone cover armrests integral safety switch and seat vibration isolation system Optional seat accessories for units with standard seats Custom ride suspension system to enhance Standard Seat Adds approximately 3 inches 7 6 cm to seat height Deluxe suspension seat with high back dampened adjustable spring suspension armrests and integral safety switch Adds approximately 1 2 inch 1 3 cm to seat height Seat Isolation System for reduced vibration to enhance ride of standard seat standard seat with Custom Ride Seat Suspension or Deluxe Suspension Seat Adds approximately 1 inch 2 5 cm to seat height Mounting
6. 1 PTO disengage 2 116 3303 WARNING DANGER WARNING To avoid serious injury or death To avoid serious injury To avoid serious injury or death Read and understand the operator s Do NOT operate without shields guards or death Pick up objects that could be Before leaving the cg ns engine tro tens 5 Di PTO use this machine presence controls OPC safety system and blades stopped Me eS Do NOT operate under the influence of daily Do NOT defeat the OPC system Nr k p alcohol or drugs Stop engine and remove key before Do NOT carry passengers neutral lock position Look behind and to the side Engage park brake Hearing protection is recommended adjusting servicing or cleaning machine and to the and attachments 109 7069 before changing directions Stop engine 109 7069 14 Specifications Specifications Model Numbers Serial Nos 920 000 and Higher Systems Engine Engine Specifications See your Engine Owner s Manual Engine Oil Exmark 4 Cycle Premium Engine Oil RPM Full Speed 3750 50 RPM PTO not engaged Idle 1500 100 RPM Fuel System Capacity 8 0 gal 30 3 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 Kohler P N 24 050 1
7. A Install the blade onto the spindle shaft 6011878 Figure 21 Spindle Blade Blade drive washer Blade bolt washer assembly 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 B Apply lubricant to the threads of the blade bolt as needed to prevent seizing Copper based anti seize is preferable Grease is an acceptable substitute C Install the blade drive washer and blade bolt washer assembly into the spindle Make sure the hex in the washer is engaged on the spindle before tightening the bolt Install blade bolt finger tight D Place wrench on the top spindle nut then torque the blade bolts to 50 60 ft lb 68 81 N m 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 Note To prevent engine cut outs on rough terrain the seat kill switch has a 1 2 second delay 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the
8. SS 2 0 1010015 Figure 39 RH Motion Control Shown 1 Screw 3 Motion control lever 2 Cover plate 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 40 ae Figure 40 6006131 1 Spring disc washers 45 Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all 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 100 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from externa
9. 84 8 inches Down 205 5 cm 205 5cm 215 4 cm Overall Height Roll Bar Up Roll Bar Down 69 5 inches 176 5 cm 45 8 inches 116 3 cm 17 Specifications Accessory Weight Table Worksheet Use the table below to determine if extra weight is required for the unit Identify the accessories and correct deck size and place the corresponding values in the Accessory Score column If the Total Accessory Score meets the following add the recommended weight kit See Deck Deck Deck Score CO a poo omm mex 3 Sunshade 2 Kit Total Accessory Score Total Accessory Score Required Weight Kit s 10 19 116 1173 Under toe board mount weight kit 20 and Higher Two 116 1173 Under toe board mount weight kits ot one 116 1173 Under toe board mount weight kit and one 116 1238 Front toe board mount weight kit 48 inch units that come with an under toe board weight as standard can add an additional toe board weight for primary accessory weighting scores 10 19 and front toe board weight kit for secondary accessory weighting scores 20 and higher Other units should install a first under toe board kit for primary accessory weighting scores 10 19 and second under toe board kit for secondary accessory weighting scores 20 and higher Torque Requirements Blade Drive Sheave 130 160 ft Ib 176 217 Mounti
10. Adjustable fore and aft on seat tracks Armrests Molded flip up armrests Seat Safety Switch Integrated seat switch Time delay seat switch eliminates rough ground cut outs Hydrostatic Ground Drive System e Two unitized hydrostatic transmissions 12cc Parker axial piston pump 240cc Parker geroler motor Hydraulic Oil Type Exmark Premium Hydro Oil Hydraulic Oil Capacity 52 oz 1 5 L per side Hydraulic Filter P N 116 0164 Speeds 0 8 mph 12 9 km hr forward 0 4 5 mph 7 2 km hr reverse Drive wheel telease valves allow machine to be moved when engine is not running Tires amp Wheels cs 2 p mee Hie Panne Cutting Deck Cutting Width 48 inch Deck 121 9 cm 52inch Deck 132 1 cm 60 inch Deck 152 4 cm Discharge Side Blade Size 3 ea 48 inch Deck 16 25 inches 41 3 cm 52 inch Deck 18 00 inches 45 7 cm 60 inch Deck 20 50 inches 52 1 cm Blade Spindles Solid steel spindles with 1 00 inch 25 mm I D bearings Deck Drive Section belt with self tensioning idler e Electric clutch 200 ft lb Mag Stop Deck Full floating deck is attached to out front support frame Anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge 16 Specifications 48 inch Deck 3 anti scalp rollers Tread Width Center to Center of 52 inch De
11. are installed with the spring disc washer between the head of the nut and the mounting bracket Note The foot operated deck lift lever can be used to momentarily lift the deck to clear objects Be sure that PTO is disengaged Torque the 3 8 16 whizlock nut to 30 35 ft lb 41 47 N m Figure 19 Torque the 3 8 nyloc nut to 30 35 ft lb 41 47 N m 6006758 Figure 19 1 Spring disc washer 3 3 8 nyloc torque to 30 35 cone towards nut ft lb 41 47 N m 2 Front right anti scalp 4 3 8 16 whizlock nut bracket shown torque to 30 35 ft lb 41 47 N m Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain 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 ot roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not drive a unit on a public street or roadway Operation WARNING Loading a unit on a trailer or truck increases the p
12. as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes Safety DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Do Not mow slopes when grass is wet Do Not mow near drop offs near water Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution slopes Avoid sudden turns or rapid speed changes Keep the roll bar in the raised and locked position and use seat belt See inside the back cover to determine the approximate slope angle of the area to be mowed e Usea walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figure 3 G000963 Figure 3 1 Safe Zone Use the mower here on slopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water Remove matk obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Avoid sudden starts when mowing uphill because the mower may tip backwards Be aware that operating on wet grass across
13. bar necessary Do not wear seat belt when the roll 25 10 25 CHARGE bar is down ACC 109 7330 Drive slowly and carefully 109 7330 Raise the roll bar as soon as clearance permits Read follow Slope operation instructions and warnings 107 2102 107 2102 Lubricate Blade Bolt threads with copper based antiseize or grease A o MN o 109 7929 and torque to 55 60 ft lbs 75 81 N m 109 3148 109 3148 Safety Engage and disengage at 1 2 throttle SERVICE AID n Every 50 hours 1 Check hydraulic oil Only use recommended hydro oil 2 Check tire pressure in pneumatic tires 13 psi Yearly 3 Grease belt idlers 4 Grease front caster pivots 4 LL See operator s manual for additional details 116 0211 109 8483 1 Throttle fast 3 Choke on 2 Throttle slow 4 Choke off 116 0157 1 See Operator s Manual FILL ON LEVEL GROUND FILL TO BOTTOM OF FILLER NECK _ MAX DO NOT OVERFILL 116 1654 116 1654 ROTATING BELT DRIVE Can cause serious injury Stop engine and wait until all moving parts have stopped before reaching underneath 116 0205 116 0205 116 1965 48 116 1966 52 116 2630 116 2630 13 Torque Wheel Lug Nuts to 90 95 ft Ibs 122 129 N m Check after first Torque Wheel Hub Slotted Nut to 211 260 ft Ibs 100 hrs th
14. be pushed forward or pulled rearward to get both knobs fully engaged see Figure 13 Figure 13 1 Engaged 2 Partially engaged Do Not operate with ROPS in this condition Important Always use the seat belt with the roll bar in the operate raised position Ensure that the rear part of the seat is secured with the seat latch Open the Fuel Shut Off Valve Rotate the valve and align with the fuel line to open Starting the Engine 1 Move the motion control levers out to the neutral lock position Pull up and back on the parking brake lever to engage the parking brake Push down on the PTO switch to the disengage position Note It is not necessary for the operator to be in the seat to start the engine Place the throttle midway between the SLOW and FAST positions On a cold engine push the choke lever forward into the ON position On a warm engine leave the choke in the OFF position Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the ON position gradually return choke to the OFF position as the engine warms u
15. less resistance loosen the flanged nut 3 Tighten jam nut Motion Control Handle Adjustment Adjusting the height The motion control levers can be adjusted higher or lower for maximum operator comfort 1 Remove the two bolts holding the control lever to the control arm shaft Figure 38 6008631 Figure 38 1 Bolts 2 Control lever 3 Control arm shaft 4 Nuts 5 Slotted holes 2 Move the control lever to the next set of holes Secure the lever with the two bolts 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort 1 Loosen the upper bolt holding the control lever to the control arm shaft 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 38 Tighten both bolts to secure the control in the new position 3 Repeat the adjustment for the opposite control lever Motion Control Full Forward Tracking Adjustment If the machine travels or pulls to one side when the motion control levers are in the full forward position adjust the cover plates 1 Loosen the screws cover plate see Figure 39 2 Slide the cover plate backward or forward to adjust the travel of the lever and tighten the screws 3 Drive the machine and check the full forward tracking 4 Repeat steps 1 through 3 until desired tracking is obtained 44 Maintenance
16. 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 Remove the rear tites from the machine Remove any debris from the brake area Rotate the drive wheel release handle to the released position Refer to the Drive Wheel Release Valves section in Operation Disengage the park brake Hold the threaded rod end with a tool and loosen the lock nut away from the standard nut see Figure 29 Do Not allow the cable to turn when the nuts are being loosened 6011060 Figure 29 Left Hand Brake Shown Cable anchor 7 Pull cable threaded rod this direction Threaded rod 8 Hold threaded rod here Push lever this direction 9 Swivel pivot head Caliper lever arm 10 Caliper Standard nut shown 11 Hub against swivel Lock nut 10 11 12 13 14 15 16 IZ 40 Remove all slack from cable by pulling on the caliper lever arm with a medium amount of force Using hands and fingers only push the caliper lever arm to engage the brake pads on the rotor until the lever stops While holding the lever at the stopped position use the other hand or fingers to pull the slack out of the cable threaded end through the swivel Spin the standard nut against the swivel see Figure 29 Note the order of the standard nut and lock nut no nut on the cable anchor side of the s
17. may result in fuel leakage or damage to the engine or emission system Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Raise the Rollover Protection System ROPS Important The roll bar is an integral and effective safety device Keep the roll bar in the raised and locked position when operating the mower Lower the roll bar temporarily only when absolutely necessary 1 The knob must be completely latched with the tabs interlocking as shown in Figure 12 to lock the roll bar in the raised operate position 22 Operation 2 Apply forward pressure to the upper hoop of the roll bar Pull the knob and rotate 90 to hold in the unlatched position to lower the roll bar To return to the operate position raise the roll bar and then rotate knobs 90 so that the tabs interlock partially Apply forward pressure to the roll bar upper hoop and observe that the knobs return to the completely latched position 5 Figure 12 6008592 Roll bar upper hoop Knob in latched position Pull knob to unlatch Rotate 90 to hold unlatched Knob unlatched position 5 Make sure the knobs are fully engaged with the roll bar in the raised position The upper hoop of the roll bar may need to
18. warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Replace all parts including but not limited to tires belts and blades with original Exmark parts Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system 10 Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease New safety signs may be obtained from dirt and debris from safety signs and instructional your authorized Exmark equipment dealer or labels distributor or from Exmark Mfg Co Inc Replace all worn damaged or missing safety Safety signs may be affixed by peeling off the signs backing to expose the adhesive surfac
19. 3 1 Feeler gauge 42 Maintenance WARNING Engine must be running and drive wheels must be turning so adjustments can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces 1 Prior to starting the engine push the deck lift pedal and remove the height of cut pin Lower deck to the ground 2 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 3 Remove the electrical connection from the seat safety switch located under the bottom cushion of the seat The switch is a part of the seat assembly 4 Temporarily install a jumper wire across the terminals in the connector of the main wiring harness 5 Start engine Brake must be engaged and motion control levers out to start engine Operator does not have to be in the seat because of the jumper wire being used Run engine at full throttle and release brake 6 Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature Note The motion control lever needs to be in neutral while making any necessary adjustments 7 Bring the motion control levers into the neutral position Adjust pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly c
20. 3 Figure 30 2 inch height of cut location 18 E Start the mower while in the operator position WARNING Engine must be running and drive wheels must be turning so adjustments can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces Release the park brake so the handle rests on the 1 2 x 6 inch rod or bolt Move the throttle to high idle Move both motion control levers to the full forward position and hold for 15 seconds I Move both motion control levers to the full reverse position and hold for 15 seconds Turn off the engine and completely release the park brake by removing the 1 2 x 6 inch rod or bolt K Allow the hubs to cool until they are cool enough to safely touch Rotate the drive wheel release handle to the released position Refer to the Drive Wheel Release Valves section in Operation M Readjust both brakes following the procedure in steps 10 through 14 Rotate the drive wheel release handle to the operating position Refer to the Drive Wheel Release Valves section in Operation 19 Install the rear tires and torque lug nuts to 90 95 ft lb 122 129 N m 20 Remove jack stands Electric Clutch Adjustment No adjustment necessary However on units with 60 inch decks when the clutch brake has worn to the point where the clutch no longer engages
21. 3 Fuel Shut Off Valve All Units 1 4 turn increments VON OFF Fuel level eight segment display right hand control panel Low fuel indicator light Electrical System Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type BCI Group U1 Recommended Minimum Battery CCA 260 CCA Battery Voltage 12 Volt Low Voltage Light RH control panel Polarity Negative Ground Fuses All units 25 amp main fuse 25 amp charging system fuse 10 amp PTO fuse 15 amp accessory fuse Safety Interlock System LCD indicators appear for the PTO park brake drive levers and operator presence in the message display on the RH control panel PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levers are adjustable to two heights Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the position of the levers relative to each other
22. L NOILINSI TVNIWH3L AgaLiva 8 TVNINH3L AHOSS392V TVNINH3L SNOILO3NNOO WNIWH3L HOLIMS NOLLINOI 50 Schematics Electrical Logic Schematic M 1310lA7 A 5198009 NVL L n v HO 3 LH91 89 A3HD AD c it Jf ND gt 5 8 r ams 5 8 NMOHG8 E 3 5 y yovig 2 PEE 202 L v Na 8 0 2 5 5 vse 8 TX Md 3141 ANa Sv Tanan sjej ofa 1HVLS na b MS 9v na ame HO LIMS 014 a ov LHVLS cx za 1 SS bo sas e ana E NOLLINDI b SMS A 9 Jona 1 vsz 4 2 LYVLS A VIE NO sauossa0ov suonoouuoo 440 Wat 1 NY suoneoo jeujuue uoniuBI
23. anty does not cover pickup and delivery charges to and from any authorized Exmark Service Dealer Consumer Warranty Conditions This warranty applies to Exmark Lazer Z E Series turf equipment sold in the U S or Canada for a period of four years or 500 hours whichever occurs first for residential usage Residential usage means use of the product on the same lot as your home Use at more than one location is considered commercial use and the commercial use warranty detailed above would apply This warranty only includes the cost of parts and labor For the first warrantable service repair Exmark will cover up to 45 for associated pick up and delivery charges to and from any authorized Exmark Service Dealer Additional transportation charges may apply contact your Dealer for details Warranty Exceptions Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet Items and Conditions Not Covered This warranty does not cover the following Any damage or deterioration due to normal use wear and tear or exposure Costof 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 d
24. ck 3 anti scalp rollers Tires Widthwise 60 inch Deck 4 anti scalp rollers 48 inch 52 inch 60 inch Deck Deck Deck Deck Depth Drive 36 2 inches 36 2 inches 41 6 inches 48 inch Deck 5 5 inches 14 cm Wheels 91 9 cm 91 9 cm 105 7 cm 52 inch Deck 5 5 inches 14 cm Caster 32 8 inches 32 8 inches 39 5 inches Wheels 83 3 83 3 100 3 60 inch Deck 5 5 inches 14 cm Cutting Height Adjustment Wheel Base Center of Caster Tire to Foot activated lever is used to adjust the cutting Center of Drive Tire height from 1 1 2 inch 3 8 cm to 4 1 2 inches 11 4 cm in 1 4 inch 6 4 mm increments e Mulching Kit Optional 48 0 inches 48 0 inches 51 6 inches 121 9 cm 121 9 cm 131 1 cm Dimensions Curb Weight 48 inch 52 inch 60 inch Deck Deck Deck Kawasaki 1081 Ib 1115 Ib Units 490 kg 506 kg Overall Width 48 inch 52 inch 60 inch Deck Deck Deck Without 45 7 inches 45 7 inches 50 0 inches 116 1 1161 cm 127 0 cm Kohler Unit 1098 Ib 498 Deflector 51 8 inches 56 3 inches 62 5 inches Up 131 6 143 0 158 8 cm Deflector 59 6 inches 64 8 inches 72 8 inches Down 151 4 164 6 184 9 cm Overall Length 48 inch 52 inch 60 inch Deck Deck Deck Roll Bar 79 2 inches 79 2 inches 83 1 inches Up 201 2 cm 201 2 211 1 cm Roll Bar 80 9 inches 80 9 inches
25. ck the wheel hub slotted nut torque specifications Check the wheel lug nuts Check the park brake adjustment Seld Grease the deck and pump idler pivots y i Grease the front caster pivots Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving patts to stop Make sure unit is on a level surface Check with engine cold 3 Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick according to the engine manufacturer s recommendations Remove the dipstick and read the oil level 4 Ifthe oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick 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 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 30 Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To pres
26. consistently the shim can be removed to extend the clutch life 6011732 2 1 Figure 31 1 Armature 5 Brake spacer 2 Field shell 6 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 Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers Check the condition of the wire harness leads connectors and terminals Clean or repair as necessary Verify that 12V is present at the clutch connector when the PTO switch is engaged 5 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 both brake mounting bolts one half to one full turn see Figure 32 Note Do Not remove the brake pole from the field shell armature The brake pole has worn to match the armature and needs to 41 Maintenance continue to match after the shim is removed 1 to ensure proper brake torque EL 6011735 Figure 34 1 Feeler gauge Fi 32 SUIS If the gap is less than 0 010 inch then 1 Brake mounting bolt 2 Shim reinstall the shim and reference the Troublesho
27. console when the park brake is engaged see Figure 9 Pull the lever up and rearward to engage the brake Depress the release button and push downward to disengage the brake m 8 G008607 Figure 7 1 Release button 2 Park brake The unit must be tied down and brake engaged when transporting Ignition Switch Located on right console see Figure 6 The ignition switch 1s used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Allow the key to return to the on position immediately after the engine starts 1 5 Ours G008610 3 Figure 8 3 Start Note Brake must be engaged motion control levers out neutral lock position and PTO switch disengaged to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right console in the message display see Figure 6 and Figure 9 20 Operation The hour meter records the number of hours that the engine has run 6008612 Figure 9 LCD Indicators Low fuel indicator light Fuel level bar display Low voltage indicator light Hour Voltage display o9 RON The hour meter is recording
28. ct the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping the grass catcher WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts NEVER carry passengers DO NOT operate the mower when people especially children or pets are in the area Be alert slow down and use caution when making tutns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed e Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck 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
29. ction in Operation 2 Change the belt 3 Change the belt 4 Replace the spring 5 Add hydraulic fluid to reservoir or let it cool down 1 Sharpen the blade s 2 Install new cutting blade s 3 Level mower deck from side to side and front to reat 4 Clean the underside of the mower 5 Adjust tire pressure in the drive tires 6 Contact an Authorized Service Dealer 7 Replace blades spindles and or check for damage to mower deck 1 Install new cutting blade s 2 Tighten the blade mounting bolt 3 Tighten the engine mounting bolts 4 Tighten the appropriate pulley 5 Contact an Authorized Service Dealer 6 Contact an Authorized Service Dealer 1 Install new deck belt 2 Install belt on clutch and deck pulleys idlers and tensioning idler per routing decal on deck 3 Replace the spring 4 Refer to belt routing decal on deck Troubleshooting Clutch will not engage 1 Fuse is blown Low voltage supply at the clutch Damaged coil Inadequate current supply Rotor armature 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 Sch
30. cts the filter adapter then tighten filter an additional 1 2 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in the Check Engine Oil Level section Do Not overfill Start the engine and check for leaks Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Every 50 hours 1 Stop engine and wait for all moving parts to stop Engage parking brake 2 Wait until the unit cools before checking the hydraulic oil 3 Slide the seat all the forward to access the caps on the LH and RH hydro drives 4 Clean the area around hydraulic reservoir cap and remove cap 5 Wipe the dipstick clean and re insert the cap back into the hydro Lightly tighten the cap 6 Remove the cap again and check the level of the oil on the dipstick See Figure 23 for oil levels 6008606 Figure 23 1 Full 2 Add Note The oil level on the dipstick will be incorrect if the oil is checked when the unit is hot 7 If the dipstick oil level is at the mark add Exmark Premium Hydro Oil 8 Replace hydraulic reservoir cap and tighten until snug Do Not overtighten 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 tire pressure in drive tires Inflate drive tires to 13 psi 90 kPa Semi pneumat
31. djusted 1 4 inch 6 4 mm higher than the front 6009997 Figure 26 1 3 1 4 inches 8 3 cm 2 Back blade tip 3 Front blade tip 4 inches 7 6 5 Level surface 10 Fine tune the front deck lift assembly by turning the adjuster screw until it reaches the 3 inch 7 6 mm height see Figure 27 To increase the height turn the adjuster screw clockwise to decrease turn counterclockwise Maintenance 6012075 Figure 27 1 Adjuster screw 2 Jam nut 11 The back tips of the side blades should measure 3 1 4 inches 8 3 cm Fine tune rear adjusters as required The single point adjustment can be utilized to gain more adjustment 12 Re measure until all four sides are the correct height Tighten all the nuts on the deck lift arm assemblies 13 14 Lower discharge deflector If the four deck links do not have enough adjustment to achieve accurate cut height with the desired rake the single point adjustment can be utilized to gain more adjustment see Figure 28 Figure 28 1 Single point height adjustment bolt 2 Front height of cut plate mounting bolt 3 Rear height of cut plate mounting bolt 39 15 To adjust the single point system first loosen the front and rear height of cut plate mounting bolts 16 If the deck is too low tighten the single point adjustment bolt by rotating it clockwise If the deck is too high loosen the single point adjustment bolt by r
32. dware 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 Owner s Manual for additional information Every 500 hours Replace the secondary air cleaner element May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 See the Engine Owner s Manual for maintenance instructions Change Engine Oil Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Drain oil while engine is warm from operation Maintenance The oil drain hose is located on right hand side of engine at the rear Place pan under machine to catch oil Remove plug from end of drain hose Allow oil to drain and replace oil drain plug Torque plug to 20 24 ft lb Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of Exmark 4 Cycle Premium Engine Oil on the surface of the rubber seal Turn filter clockwise until rubber seal conta
33. e wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward 35 Maintenance 13 Torque the nut to 75 80 in Ib 8 9 N m loosen then re torque to 20 25 in lb 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 Lubricate Brake Handle Pivot Service Interval Every 200 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lubricate brake handle pivot with a spray type lubricant or light oil Lubricate Deck Lift Pivot Service Interval Every 100 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lubricate deck lift pivot with a spray type lubricant or light oil Check Spark Plugs Service Interval Every 200 hours Remove spark plugs check condition and reset gaps replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filtet is installed be
34. e Apply When replacement components are installed be only to a clean dry surface Smooth to remove sure that current safety signs are affixed to the any air bubbles replaced components Familiarize yourself with the following safety signs fan attachment or accessory has been installed and instruction labels They are critical to the safe make sure current safety signs are visible operation of your Exmark commercial mower ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm GROUND CLEARANCE WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 CUTTING HEIGHT INCHES mm 1 1 FOR MAXIMUM FLOTATION ROLLERS MAY POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS TO SUPPORT THE MOWER DECK 1 633922 KEEP HANDS and FEET AWAY 1 633922 1 403005 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 CAUTION HOT Kf LA SURFACE 103 2076 103 2076 11 Safety en A WARNING TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked position and use seat belt 109 7232 1 Fast 3 Neutral 2 Slow 4 Reverse BAR IS DOWN Lower the roll
35. e stop engine and remove key or disconnect Safety 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 neat flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoots Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s ot wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Char
36. e pedal closer to the operator Nuts 5 Hole set that moves the pedal away from the operator Adjustment holes 6 Adjusts the pedal higher or lower 8 Position the deck lift pedal for operator comfort and reinstall the nuts Tighten hardware Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed 1 Stop the machine move motion control levers outward to the neutral locked position Disengage the PTO Engage the park brake Stop the engine remove the key and wait for all moving parts to stop After adjusting the height of cut adjust the anti scalp rollers by removing the nyloc nut bushing spring disc washer and whizlock nut Place the rollers in one of the positions shown Figure 18 Rollers will maintain 3 4 inch 19 mm clearance to the ground to minimize gouging and roller wear or damage Operation E 2 0 inch 51mm 2 5 inch 64mm 3 0 inch 76mm 3 5 inch 90mm G006184 Figure 18 For cutting heights above 3 5 inches 90 mm use the bottom hole The rollers will still be effective against 1 scalping Anti scalp roller 2 Cutting height mounting bracket For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 4 mm clearance to the ground Do Not adjust the rollers to support the deck Be sure the whizlock nuts
37. e 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 55 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 2010 Exmark Mfg Co Inc Part No 4500 872 Rev A Industrial Park Box 808 402 223 6300 Cle Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
38. ematics Schematics Electrical Diagram 1858009 9 3NI9N3 Av 138 1915 L 0123 02 G3AM3IASHOL93NNOO 4 B 1 e HOLNTO Old v gt 30010 SAL z t e ha e 1 t 1 y 659810626 8v av 81 L REET Pree rere NMOHE IWE INTE XOVTE L Tana HEJ 9 Lor ar XOVTE TONVEO FONVET INTE avo 84969061 21696 Lz 8 9 8 6 S v4 8 9 v 2 26 ZL ral 2 coc oP HOLIMS 1 35 e 81 v 1 HOLIMS NOLLINSI HOLIMS Old aSa ILON HOLIMS 3 vug HOLIMS HI HOLIMS WHLNAN HH AdOSS320V stitute Luvas t 3NON 407i av NOLLISOd 1 TVNIWYAL WNINWHSL WNIWH3L VTVNIWH3L lavis VNIWH3
39. en every 286 352 N m See Operator s Manual for more details 500 hrs thereafter 116 2643 Safety 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 117 748 117 2718 Message Display 116 2927 Fuel 6 Hour meter Empty 7 PTO Half 8 Parking brake Full 9 Neutral Battery 10 Operator presence A WARNING Switch Operating on wet grass or steep slopes can cause sliding and loss of control 1 Latch 2 Unlatch Wheels dropping over edges can cause rollovers Going up or backing down steep slopes or ramps can result in backward rollovers To avoid loss of control and possibility of rollover resulting in serious injury or death Do not operate near drop offs or water Do not operate on slopes or ramps greater than 15 Do use split ramps use full width ramps to load a unit for transport Reduce speed and use extreme caution on slopes or ramps Avoid sudden turns and rapid speed changes There is no rollover protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warnings PTO Switch Symbols E HERD
40. er or distributor 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 Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 6011896 Figure 1 Model and serial number location Model No Serial No Contents ERR Lan 3 Mov dp E 5 Safety Alert 5 Sate Operating Practices 5 Safety and Instructional Decals 11 EN desto 15 Model as crate oe ot 15 caput ial A 15 17 Torque Requirements 18 Product Overview 19 O
41. erve 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 Percent Charge 12 6 100 greater Maximum Charging Charger Settings 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 30 Minutes amps 12 2 12 4 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 50 14 4 volts 4 2 Hours amps Maintenance Maximum Charging Charger Interval Settings 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours or amps 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 or loose connect
42. fore 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 ON position Deck Lift Pedal Located at the right front corner of the floor pan Push the pedal forward with your foot to raise the cutting deck Allow the pedal to move rearward to lower the cutting deck to the cut height that has been set Transport Lock Located on the height of cut adjustment plates to the right of the parking brake Position in the transport latching position to automatically latch the cutting deck when raised to the transport position see item 1 in Figure 11 In the non latching position the deck will automatically return to the cutting height when the pedal is lowered see item 3 in Figure 11 Figure 11 1 Latching position 2 Transport lock control 3 Non latching position 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
43. ging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery e Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid e Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately A CAUTION If the ignition is in the ON position there is potential for sparks and engagement of components Sparks could cause an explosion ot moving parts could accidentally engage causing personal injury Be sure ignition switch is in the OFF position before charging the battery Keep all guards shields and all safety devices 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
44. ic 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 50 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt 3 Check under machine to inspect the pump drive belt 34 Maintenance Note No adjustments are required for belt tension Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval cond See step 3 for special lubrication instructions on the front caster pivots Pump Idler G008599 Lubticate 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 H
45. ine is stopped Hot particles exhausted during engine operation may ignite flammable materials Fire may result in personal injury or property damage Do Not refuel or run engine unless spark arrester is installed 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Wait for muffler to cool 3 If any breaks in the screen or welds are observed replace arrester 4 If plugging of the screen is observed remove arrester and shake loose particles out of the arrester and clean screen with a wire brush soak in solvent if necessary Reinstall arrester on exhaust outlet Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners e ROPS spring pin housing Hydro pump control arm linkage bolt and attachment bolt Hydro park brake cable anchor mounting bolt Sheave and clutch retaining bolt in the end of engine crankshaft Thread locking adhesives are required for some hardware on engines see the Engine manual Copper Based Anti seize Copper based anti seize is used in the following location On threads of Blade Bolts See Check Mower Blades section Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 37 Maintenance Adjustments Note Disengage PTO shut off engine wait for all mov
46. ing parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit CAUTION Raising the mower deck for service or maintenance relying solely on mechanical ot hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support 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 1 Position the mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check the tire pressure in the drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary 4 Position the transport lock in the latching position 5 Push the foot pedal all the way forward and the deck will latch at the 4 1 2 inch 11 4 cm transport position Figure 25 G011890 Figure 25 1 Foot lever 3 Transport lock 2 Height of cut pin 6 Insert the height adjustment pin into the 3 inch 7 6 cm cutting height location 38 7 Release the transport lock and allow the deck to lower to the cutting height 8 Raise the discharge deflector 9 Measure from the level surface to the front tip of the center blade The measurement should read 3 inches 7 6 mm Note In most conditions the back tips on the side blades should be a
47. ions 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 4 DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries gt 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 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
48. ium Hydro Oil on the surface of the two rubber seals Install the new filters and torque to 14 ft lb 19 N m Fill the hydraulic system as stated in Check Hydraulic Oil Level section Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative 36 Maintenance Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours 10 Remove the catch pan and properly dispose of hydro oil and filter according to local codes 11 Re install the pump drive belt 12 Start engine and move throttle control ahead to full throttle position Move the speed control levers to the full speed and run for one minute Shut down the machine allow the hydros to cool and recheck oil level 13 Remove the jack stands Note Do Not change the hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated ot been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminants into the system Wheel Hub Slotted Nut Torque Specification Service Interval After the first 100 hours Every 500 hours thereafter Torque the slotted nut to 211 260 ft lb 286 352 N m Note Do Not use anti seize on wheel hub Check Spark Arrester if equipped Service Interval Every 50 hours WARNING Hot exhaust system components may ignite gasoline vapors even after the eng
49. l surfaces of engine which can cause inadequate cooling 3 Make sure cooling shrouds are reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating Clean Hydro Cooling Fins Service Interval Before each use or daily Removing debris from the hydro cooling fins will allow the hydro system to run cooler and improve the life of the hydro system 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Maintenance 2 Slide seat all the way forward 3 Remove accumulated debris from the hydro cooling fins Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Clean off any oil debris or grass build up on the machine and cutting deck especially under deck belt shields around the fuel tank around engine and exhaust area Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Raise deck to the transport 4 1 2 inch 11 4 cm cutting height position Lift the front of unit and support unit using jack stands or equivalent support CAUTION Raising the mower deck for service maintenance relying solely on mechanical ot hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough suppo
50. limited to the duration of the express warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 734 B 53 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 rated with wet clutch compatibility for other machines EXMARK MAINTENANCE D Gari Available from your local Exmark dealer Find your closest dealer at exmark com 54 G011841 Figure 41 This page may be copied for personal use 1 The maximum slope you can safely operate the machine on is 15 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match th
51. llow the engine and hydraulic drive units to cool completely before accessing the drive wheel release valves Located on the back of the unitized hydraulic drive units below the engine deck During normal operating conditions the drive wheel release valves are positioned horizontally If the machine has to be pushed by hand the valves must be in the released position see Figure 10 9011876 Figure 10 1 Handle in released position 2 Handle in operating position To release the drive system see item 1 in Figure 10 rotate the handle 1 4 turn to the vertical position until it hits against the stop To reset the drive system see item 2 in Figure 10 rotate the handle 1 4 turn to the horizontal position until it hits against the stop Note The handle must be horizontal and against the stop for operation Do Not tow machine Operation PTO Engagement Switch Located on right console see Figure 6 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 disengaged see Figure 9 Low Voltage Indicator Located on the right console in the message display see Figure 6 and Figure 9 A low voltage condition less than 12 3 volts exists when the LCD indicator appears on the message display while the engine is running If the ignition key is turned to the ON position for a few seconds be
52. ly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a 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
53. ment 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 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 Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine e Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or b
54. must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED 2 1 Safety alert symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous 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 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 Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users e Never let children or untrained people operate ot service the equip
55. n Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Replace module Fill the fuel tank Open the fuel shutoff valve Add oil to the crankcase Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the seat switch indicator Replace seat if needed Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Replace module Troubleshooting Engine loses power Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate 1 Engine load is excessive 2 cleaner is dirty 3 Oil level in the crankcase is low 4 Cooling fins and air passages for the engine are plugged
56. n proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running PTO is engaged Parking brake is not engaged Drive levers are not in neutral lock position Battery does not have a full charge Electrical connections are corroded loose faulty Fuse is blown Relay or switch is defective Faulty module Fuel tank is empty Fuel shutoff valve is closed Oil level in the crankcase is low The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Air cleaner is dirty Seat switch is not functioning properly Electrical connections are corroded loose faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Faulty module 47 Disengage the PTO Set the parking brake Ensure the drive levers are in the neutral lock positio
57. n the latching position 4 Raise and lock the deck to the 4 1 2 inch 11 4 cm transport position Figure 16 The deck is raised by pushing the foot operated deck lift pedal forward The pedal is located at the front right corner of the floor pan Note When changing the cutting height positions always come to a complete stop and disengage the PTO 25 Operation 1 2 6011888 Figure 16 Deck lift foot pedal Height adjustment pin 3 Height of cut decal 4 Transport lock control 5 Insert the height adjustment pin into the hole 6 corresponding to the desired cutting height See the decal on the side of the deck lift plate for cut heights Push the deck lift pedal release the transport lock and allow the deck to lower to the cutting height Adjusting the Deck Lift Foot Pedal 48 amp 52 inch Decks Only The deck lift foot pedal can be adjusted for operator comfort 1 Stop the machine and move the motion control levers outward 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 Position the transport lock in the latching position 6 Raise and lock the deck to the 4 1 2 inch 11 4 cm transport position Figure 16 7 Remove the two nuts from the deck lift foot pedal see Figure 17 26 6011889 Figure 17 Deck lift foot pedal 4 Hole set that moves th
58. n you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer 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 WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debri
59. neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown after one second has elapsed if the handles are in The delay will be 1 2 second if the handles are out Maintenance Run engine at one third throttle with brake disengaged move levers in and raise off seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever in engine must ini
60. ng Nut N m Blade Mounting Bolt 50 60 ft lb 68 81 N m lubricate with anti seize Anti Scalp Roller Nyloc 30 35 ft lb 41 47 N m Nut See Figure 19 Anti Scalp Roller Whizlock 30 35 ft lb 41 47 N m Nut See Figure 19 Engine Mounting Bolts Kawasaki Kohler 17 23 ft lb 23 31 N m 27 33 ft lb 37 45 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Hydro Mounting Bolts 72 77 ft lb 98 104 N m Wheel Hub Slotted Nut 211 260 ft lb 286 352 N m Rollover Protection 75 80 ft lb 102 108 N m System Roll Bar 1 2 inch Mounting Bolts Clutch Retaining Bolt 55 60 ft lb 75 81 N m secured with threadlocker Hydro Park Brake Cable Anchor 1 2 inch Mounting Bolt secured with threadlocker 67 89 ft lb 91 121 N m 18 Operation Product Overview Figure 4 Rollover Protection 5 Fuel cap System ROPS Engine Controls right 6 Height of cut adjustment console Seat belt 7 Parking brake Motion control levers Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of the machine Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position int
61. nt of Unit 6 Reverse Driving Forward 1 Release the parking brake 2 Move the motion control levers inward to the center to the neutral position To move forward in a straight line move both levers forward with equal pressure 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 0008595 Figure 15 1 Front of Unit 3 Neutral 2 Forward 4 Reverse Driving in Reverse 1 Move the motion control levers inward to the neutral operate position To move rearward in a straight line move both levers rearward with equal pressure To turn right release pressure on the RH motion control lever and the rear of the machine will move towards the rear and to the right To turn left release pressure on the LH motion control lever and the rear of the machine will move towards the rear and to the left To stop position both motion control levers in the neutral operate position Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 1 2 to 4 1 2 inches 3 8 cm to 11 4 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position 2 Disengage the PTO Position the transport lock i
62. o cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A WARNING While maintenance or adjustments are being made someone could start the engine 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 or 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 he wheel hub slotted nut torque specifications he wheel lug nuts he park b
63. o the T slot locks them in the neutral position Figure 5 When the motion control levers are in the neutral position the LCD indicator appears in the message display on the RH console see Figure 9 q G008593 Figure 5 1 Neutral lock position 4 Forward handles out 2 Neutral operate position 5 Neutral operate handles in 3 Front of Unit 6 Reverse 19 Operation Choke Control Located on right console black lever see Figure 6 The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the ON position G009389 Figure 6 Right Console 1 Fuses 4 PTO engagement switch 2 Message display 5 Throttle 3 Ignition switch 6 Choke Throttle Control Located on right console red lever see Figure 6 The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle Brake Lever Located on right side of unit just to the front of the RH motion control lever The brake lever engages a parking brake on the drive wheels Note The LCD indicator appears in the message display on the RH
64. ons 5 Disengage the PTO 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine CAUTION Machine spin very rapidly by positioning lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop When the motion control levers are positioned fully outward apart in the T slot the drive system is in the neutral lock position Figure 14 Note The N LCD indicator appears when both levers are in the neutral lock position When the motion control levers are moved directly inward together the drive system is in the neutral operate position 24 Operation Figure 14 1 Neutral lock position 4 Forward handles out 2 Neutral operate position 5 Neutral operate handles in 3 Fro
65. ossibility 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 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit The lower teat section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward Having a full width ramp provides a sutface for the frame members to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck Do Not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may als
66. otating it counterclockwise Note Loosen or tighten the single point adjustment bolt enough to move the height of cut plate mounting bolts at least 1 3 the length of the available travel in their slots This will regain some up and down adjustment on each of the four deck links 17 Re tighten front and rear height of cut plate mounting bolts Important Torque the front and rear height of cut plate mounting bolts to 27 33 ft lb 37 45 N m 18 Repeat steps 9 through 13 Pump Drive Belt Tension Self tensioning No adjustment necessary Deck Belt Tension Self tensioning No adjustment necessary Adjusting the Parking Brake Service Interval After the first 100 hours Every 500 hours thereafter Check to make sure brake is adjusted properly This procedure must be followed after the first 100 hours ot when a brake component has been removed or replaced 1 Drive the machine onto a level surface 2 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine wait for all moving parts to stop and remove the key 4 Raise the back of the machine up and support the machine with jack stands Maintenance ak CAUTION Raising the mower deck for service or maintenance relying solely on mechanical ot hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support
67. oting section B Using needle nose pliers or by hand take If the gap is sufficient proceed to the hold of the tab and remove the shim Do Not safety check in step discard the shim until proper clutch function has been confirmed Perform the following safety check C Using a pneumatic line blow out any debris Sit on the seat and start the engine from under the brake pole and around the b Make sure the blades Do Not engage brake spacers with the PTO switch off and the clutch D Re torque each bolt M6 x 1 to 10 ft lb 13 disengaged N m 0 5 ft lb 0 7 N m If the clutch does not disengage E Using a 0 010 inch thick feeler gauge verify oe and ihe that a gap is present between the rotor and TEGUDIESDODODO senan armature face on both sides of the brake pole c Engage and disengage the PTO switch as shown Due to the way the rotor and ten consecutive times to ensure the clutch armature faces wear peaks and valleys it is is functioning propetly If the clutch sometimes difficult to measure the true gap does not engage propetly reference the Troubleshooting section Motion Control Linkage Adjustment Located on either side of the fuel tank below the seat 1 are the pump control linkages Rotating the pump linkage with a 1 2 inch wrench allows fine tuning adjustments so that the machine does not move in neutral Any adjustments should be made for neutral positioning only G011733 Figure 3
68. ovements 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 2010 Exmark Mfg Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact yout authorized Exmark equipment deal
69. p Engaging the PTO 4 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 23 Operation DANGER An uncovered discharge opening will allow objects to be thrown in an operator s 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 push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle midway between the SLOW and FAST positions 2 Pull the PTO switch outward to engage the blades 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle midway between the SLOW and FAST positions 2 Push the PTO switch in to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Move the motion control levers out to the neutral lock position 3 Engage the parking brake 4 Place the throttle midway between the SLOW and FAST positi
70. perat EEE EEA 19 goin 19 PES Sali 22 Operating Instr retloris v 22 23 MM 29 Recommended Maintenance Schedule s 29 Periodic Maintenance 30 Check Engine Oiblevel autores 30 Cheek Battery Chatoes niodo ee do madi eens 30 Check Mower Blades 32 Check Safety Interlock System 32 Check Rollover Protections Systems Roll Bat 33 CHECK Seat 33 Check for Loose s ence 33 Service Alr C Ieafie Puis ipe ras 33 Chance Enotne 33 Check Hydraulic Oil Level a oe tese tot 34 Check Tire Presstites 34 Check Condition Of Belts uite desde 34 Lubricate Grease 35 Lubricate Brake Handle Pivot 36 Lubricate Deck Lift o eren 36 Check Spark Plugs coo tas uidit Hh 36 Change Hydraulic System Filter and PRO Sh boh fbit 36 Wheel Hub Slotted Nut Torque 5 o vestib e e Seite 37 Check Spark Arrester if equipped 37 Thread Locking Adhesives eerte 37 Copper Based Anti seize 37 37 PRLS TICES se iT ERO EPA a OR 38 Deck B veling diee topo AREA In Enid 38 Pump Drive Belt
71. rake adjustment After the first 100 hours heck the engine oil level heck the mower blades heck the safety interlock system heck the rollover protections systems roll bar knobs heck the seat belt heck for loose hardware ean the engine and exhaust system area ean the hydro cooling fins ean the grass and debtis build up from the machine and cutting deck ean the grass build up from under the cutting deck Before each use or daily heck the hydraulic oil level heck the tire pressures heck the condition of the belts heck spark arrester if equipped Every 50 hours C C C C C C C C C C C C C C C C C Change the engine oil May need more often under severe conditions Lubricate the deck lift pivots Remove the engine shrouds and clean the cooling fins Lubricate the brake handle pivot Every 200 hours Check the spark plugs Replace the primary air cleaner element check secondary air cleaner element replace if dirty May need more often under severe conditions See the Engine Owner s Manual for additional information Every 100 hours Every 250 hours 29 Maintenance Maintenance Service Maintenance Procedure Interval Replace the secondary air cleaner element May need more often under severe conditions See the Engine Owner s Manual for additional information Every 500 hours Change the hydraulic filter and fluid Che
72. reep in reverse Figure 35 Move the motion control levers to the reverse position and while applying slight pressure to the lever allow the reverse indicator springs to bring the levers back to neutral The wheels must stop turning or slightly creep in reverse G008621 Figure 35 1 Double nuts 8 Shut off unit Remove jumper wire from wire harness and plug connector into seat switch 9 Remove the jack stands 10 Raise the deck and re install the height of cut pin 11 Check that the machine does not creep in neutral with the park brakes disengaged Motion Control Damper Adjustment The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance See Figure 36 for mounting options U G008620 Figure 36 RH Motion Control Shown 1 Torque nyloc nut to 200 in Ib 16 7 ft Ib Bolt must protrude past end of nyloc nut after torque A T 40 Torx bit will be necessary to hold the stud from turning Most resistance firmest feel Damper Medium resistance medium feel Least resistance softest feel o BON 43 Maintenance Motion Control Neutral Lock Pivot Adjustment The flanged nut can be adjusted to obtain a more desired motion control lever resistance Figure 37 6008621 Figure 37 1 Flanged nut 2 Jam nut 1 Loosen the jam nut 2 Tighten or loosen the flanged nut to the desired feel For more resistance tighten the flanged nut For
73. rt 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 DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state ot local laws If a battery 1s 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 i
74. s such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING Engine exhaust contains carbon monoxide which is an 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 Be sure all drives are in neutral and parking brake is engaged before starting engine Use seat belts with the roll bar in the raised and locked position Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working propetly Do Not change the engine governor setting or overspeed the engine e Park machine on level ground Stop engine wait for all moving parts to stop remove key and engage patking brake Before checking cleaning ot working on the mowet After striking a foreign object or abnormal vibration occurs inspe
75. 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 ot 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 Using the Rollover Protection System ROPS A Rollover Protection System roll bar is installed on the unit WARNING There is no rollover protection when the roll bar is down Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Keep roll bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely necessary Do Not wear seat belt when the roll bar is down Drive slowly and carefully e Raise the roll bar as soon as clearance permits e Check carefully for overhead clearances i e branches doorways and electrical wires before driving under any objects and Do Not contact them In the event of a rollover take the unit to an Authorized Service Dealer to have the ROPS inspected Maintenance and Storage Disengage drives lower implement set parking brak
76. tiate shutdown after 1 2 second has elapsed Repeat again moving the right lever in then moving both levers in engine must initiate shutdown after 1 2 second has elapsed whether operator is on seat or not Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check Rollover Protections Systems Roll Bar Knobs Service Interval Before each use or daily Check that both the mounting hardware and the knobs are in good working condition Make sure the knobs are fully engaged with the ROPS in the raised position The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged 6008619 Figure 22 1 Engaged 2 Partially engaged Do Not operate with ROPS in this condition Check Seat Belt Service Interval Before each use or daily 33 Visually inspect seat belt for wear cuts and proper operation of retractor and buckle Replace before operating if damaged Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Visually inspect machine for any loose hardware or any other possible problem Tighten har
77. tween the fuel tank and the engine Replace when necessaty Replacement Filters Kawasaki Kawasaki P N 49019 7005 Kohler Kohler P N 24 050 13 Note It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage Change Hydraulic System Filter and Fluid Service Interval Every 500 hours Note Only use Exmark Hydro Filter Part No 116 0164 for summer or winter 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Raise the reat of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely CAUTION Raising the mower deck for service or maintenance relying solely on mechanical ot 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 Remove the pump drive belt Place a catch pan under the hydro Carefully clean area around the filters It is important that no dirt or contamination enter the hydraulic system Using a socket unscrew filters to remove and allow oil to drain Before installing the new filters apply a thin coat of Exmark Prem
78. ubs Service Interval As required 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 6006115 2 Figure 24 1 Seal guard 2 Spacer nut with wrench flats Remove caster wheel from caster forks Remove seal guards from the wheel hub 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 Pry out seals and inspect bearings for wear or damage and replace if necessary Pack the bearings with a NGLI grade 1 multi purpose grease Insert one bearing one new seal into the wheel Note Seals Exmark P N 103 0063 must be replaced 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 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 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 th
79. ue to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 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 proper
80. 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 20 3 G012785 2 5 Figure 20 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 31 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 Maintenance 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 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 Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck section Inspect blades and sharpen or replace as required Reinstall the blades if they were removed in the following order
81. 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 e g the indicator turns on when the operator is in the seat Fuel Shut Off Valve Located behind and below the seat 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 Fuel Gauge Located on the right console in the message display see Figure 6 and Figure 9 The fuel level is shown on a bar display The indicator light appears when the fuel level is low approximately one gallon remaining in the tank Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck which could result in serious injury or death Stop engine remove key allow all the moving parts to stop before accessing the drive wheel release valves WARNING The engine and hydraulic drive units can become vety hot Touching a hot engine or hydraulic drive units can cause severe burns A
82. wivel Release the caliper lever and cable Turn the wheel hub by hand in both directions relative to the caliper slight drag of the caliper pad on the wheel hub is desired If there is no movement between the hub and the caliper then back off the standard nut one turn from the swivel and repeat step 11 drive release valves must be in the released position on the hydros If the hub moves very freely relative to the caliper then tighten the standard nut one turn against the swivel and repeat step 11 Once step 11 is achieved hold the threaded rod end with a tool and tighten the lock nut against the standard nut Do Not allow the cable to turn when the nuts are tightened After adjusting the brakes on both sides of the mower cycle the brake handle a minimum of six times to allow the cable to seat into the sheath and mounting tabs Readjust both brakes following the procedure in steps 10 through 14 If a brake component has been removed or replaced see the steps below otherwise proceed to step 18 Burnishing the Brake Procedure Clear the area of any flammable material before starting the burnishing process B Rotate the drive wheel release handle to the operating position Refer to the Drive Wheel Release Valves section in Operation Apply the park brake Install a 1 2 x 6 inch approx rod or bolt through the 2 inch height of cut hole see Figure 30 Maintenance 1 601189
83. ystanders Safety DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire or explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors 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 fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Iffuelis spilled Do Not attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do Not operate without entire exhaust system in place and in proper working condition DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can bur

Exmark 103-0656 Lawn Mower User Manual

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