Exmark 0 Lawn Mower User Manual

PIONEER S-SERIES
For Serial Nos.
312,000,000 & Higher
Part No. 4501-000 Rev. 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 système d’allumage
par ètincelle de vèhicule est conforme à la norme
NMB-002 du Canada.
The enclosed Engine Owner’s Manual is
supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
©2011 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
CONGRATULATIONS on the purchase of your
Exmark Mower. This product has been carefully
designed and manufactured to give you a maximum
amount of dependability and years of trouble-free
operation.
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
Figure 1
1. Model and serial number location
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Model No.
If additional information is needed, or should
you require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Exmark parts manuals are available online at
http://www.exmark.com
Serial No.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Adjusting the Seat Ride Suspension.................40
Electric Clutch Adjustment.............................40
Cleaning ............................................................42
Clean Engine and Exhaust System
Area ...........................................................42
Remove Engine Shrouds and Clean
Cooling Fins...............................................42
Clean Hydro Fan Cooling Fins ........................42
Clean Debris From Machine ...........................42
Clean Grass Build-Up Under Deck .................42
Waste Disposal ...............................................42
Troubleshooting ....................................................44
Schematics ............................................................46
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ......................11
Specifications ........................................................15
Model Numbers .............................................15
Systems ..........................................................15
Dimensions....................................................17
Torque Requirements .....................................18
Product Overview .................................................18
Operation ..............................................................19
Controls .........................................................19
Pre-Start.........................................................21
Operating Instructions ...................................22
Transporting ..................................................26
Maintenance ..........................................................27
Recommended Maintenance Schedule(s) ............27
Periodic Maintenance ........................................28
Check Engine Oil Level ..................................28
Check Battery Charge .....................................28
Check Mower Blades ......................................29
Check Safety Interlock System ........................30
Check Rollover Protections Systems (Roll
Bar) Knobs.................................................31
Check Seat Belt...............................................31
Check for Loose Hardware .............................31
Service Air Cleaner .........................................31
Change Engine Oil .........................................31
Check Hydraulic Oil Level ..............................32
Check Tire Pressures ......................................32
Check Condition Of Belts...............................32
Lubricate Grease Fittings................................32
Check Spark Plugs ..........................................33
Change Hydraulic System Filter and
Fluid ..........................................................33
Check Spark Arrester (if equipped)..................34
Thread Locking Adhesives..............................35
Copper-Based Anti-seize ...............................35
Dielectric Grease............................................35
Adjustments ......................................................35
Deck Leveling ................................................35
Adjusting the Blade Slope ...............................36
Pump Drive Belt Tension................................37
Deck Belt Tension ..........................................37
Adjusting the Parking Brake............................37
Motion Control Handle Adjustment ...............38
Full Forward Tracking Adjustment..................38
Motion Control Linkage Adjustment ..............39
4
Safety
Safety
Safe Operating Practices
Safety Alert Symbol
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.
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
1. has read and understands the Operator's
Manual and recognizes the risks involved;
2. is sufficiently mature to use caution; and
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
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 must be followed to avoid
accidents.
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
Figure 2
Safety Alert Symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
Preparation
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
• 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.
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.
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.
5
Safety
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
DANGER
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite gasoline vapors. A fire or
explosion from gasoline can burn you and
others and cause property damage.
DANGER
• Always place gasoline containers on the
ground away from your vehicle before
filling.
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.
• 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.
• Fill the fuel tank outdoors on level ground,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Do Not fill the fuel tank completely full.
Fill the fuel tank to the bottom of the filler
neck. The empty space in the tank allows
gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine
or emission system.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• 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.
WARNING
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add
fuel when engine is running or when the
engine is hot.
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.
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• 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.
6
Safety
Operation
damage and make repairs before restarting
and operating the mower).
WARNING
– Before clearing blockages.
Operating engine parts, especially the muffler,
become extremely hot. Severe burns can occur
on contact and debris, such as leaves, grass,
brush, etc. can catch fire.
• Allow engine parts, especially the muffler, to
cool before touching.
• Remove accumulated debris from muffler and
engine area.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
– 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.
WARNING
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can kill
you.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
Do Not run engine indoors or in a small confined
area where dangerous carbon monoxide fumes
can collect.
• NEVER carry passengers. DO NOT operate
the mower when people, especially children, or
pets are in the area.
• 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 properly.
• Do Not change the engine governor setting or
overspeed the engine.
• Park machine on level ground. Stop engine, wait
for all moving parts to stop, remove key and
engage parking brake:
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
• Be alert, slow down and use caution when
making turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution
when crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Slope Operation
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
7
Safety
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
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 or near water.
• Do Not mow slopes greater than 15 degrees.
• Reduce speed and use extreme caution on
slopes.
• Avoid sudden turns or rapid speed changes.
• Keep the roll bar in the raised and locked
position and use seat belt.
Using the Rollover Protection System
(ROPS)
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
(Figure 3).
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 the 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.
• Raise the roll bar as soon as clearance
permits.
Figure 3
1. Safe Zone-Use the mower here on slopes less than 15
degrees
• 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.
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 or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
Maintenance and Storage
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
8
Safety
• Keep engine and engine area free from
accumulation of grass, leaves, excessive grease
or oil, and other debris which can accumulate
in these areas. These materials can become
combustible and may result in a fire.
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.
• Let engine cool before storing and Do Not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Do Not swallow electrolyte.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• In the event of an accident, flush with
water and call a doctor immediately.
• Use jack stands to support components when
required.
CAUTION
• Carefully release pressure from components with
stored energy.
If the ignition is in the “ON” position there
is potential for sparks and engagement of
components. Sparks could cause an explosion
or moving parts could accidentally engage
causing personal injury.
• 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.
Be sure ignition switch is in the “OFF”
position before charging the battery.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
• 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.
WARNING
Removing standard original equipment parts
and accessories may alter the warranty, traction,
and safety of the machine. Failure to use original
Exmark parts could cause serious injury or
death. Making unauthorized changes to the
engine, fuel or venting system, may violate EPA
and CARB regulations.
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
• Keep sparks, flames, or cigarettes away
from battery.
Replace all parts including, but not limited to,
tires, belts, blades, and fuel system components
with original Exmark parts.
• Ventilate when charging or using battery
in an enclosed space.
• Make sure venting path of battery is
always open once battery is filled with
acid.
• Always shield eyes and face from battery.
9
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 or paper, not your hands, to
find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system by placing the motion control levers
in neutral and shutting off the engine before
performing any work on the hydraulic system.
10
Safety
Safety and Instructional Decals
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• Safety signs may be affixed by peeling off the
backing to expose the adhesive surface. Apply
only to a clean, dry surface. Smooth to remove
any air bubbles.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
1-303508
1-633922
1-403005
98-5954
103-2076
11
Safety
109-6014
116-1119
107-2102
116-1496
109-3148
116-3303
12
Safety
116-6363
1. Rotate the drive release
knob to loosen, slide the
knob, and tighten.
2. Push the machine.
116-4308
1. Latch
2. Unlatch
PTO Switch Symbols
1. PTO–disengage
116-4465
1. Fast
2. Slow
3. Choke-on
4. Choke-off
13
2. PTO–engage
Safety
109-6016
1. Read the instructions before servicing or performing
maintenance
2. Time interval
4. Refer to the Operator's manual for grease instructions
5. Check hydraulic oil level and refer to the Operator's
manual or further instructions
6. Check tire pressure
3. Check oil level
116-4430
1. Park brake — engage
4. Neutral
2. Fast
3. Slow
5. Reverse
14
Specifications
Specifications
Model Numbers
Serial Nos: 312,000,000 and Higher
PNS600KA443; PNS651KA483; PNS680KC523; PNS740KC604
Systems
Electrical System
•
•
•
•
•
•
•
Engine
• Engine Specifications: See your Engine Owner’s
Manual
• Engine Oil Type: Exmark 4–Cycle Premium
Engine Oil
• RPM: Full Speed:
Kawasaki: 3750 ±50 RPM (PTO not engaged)
Idle: 1500 ±100 RPM
Charging System: Flywheel Alternator
Charging Capacity: 15 amps
Battery Type: BCI Group U1
Recommended Minimum Battery CCA: 260 CCA
Battery Voltage: 12 Volt
Polarity: Negative Ground
Fuses:
All units:
– 25 amp main fuse
– 20 amp charging system fuse
– 10 amp PTO fuse
– 15 amp accessory fuse
Kohler: 3700 ±50 RPM (PTO not engaged) Idle:
1500 ±100 RPM
Fuel System
• Capacity: 7.0 gal. (26.5 L)
• Fuel Recommendations:
– For best results, use only clean, fresh, unleaded
gasoline with an octane rating of 87 or higher
((R+M)/2 rating method).
– Oxygenated fuel with up to 10% ethanol or
15% MTBE by volume is acceptable.
– Do Not use ethanol blends of gasoline (such
as E15 or E85) with more than 10% ethanol
by volume. Performance problems and/or
engine damage may result which may not be
covered under warranty.
– Do Not use gasoline containing methanol.
– Do Not store fuel either in the fuel tank or
fuel containers over the winter unless a fuel
stabilizer is used.
– Do Not add oil to gasoline.
• Fuel Filter:
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
three heights.
– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.
Kohler: Kohler P/N 24 050 13
Kawasaki: Kawasaki P/N 49019-7005
• Fuel Shut-Off Valve:
All Units: 1/4 turn increments (“ON”, “OFF”).
15
Specifications
•
•
•
•
•
– Steering is controlled by varying the position
of the levers relative to each other.
– Moving motion control levers outward (in
slots) locks the drive system in neutral.
PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.
Parking Brake Lever: Engages parking brake.
Deck Height Adjustment Lever: Sets cutting
height to desired position.
Deck Lift Pedal: Foot pedal that lifts deck.
Transport Lock: Latching position: Automatically
latches at the transport position.
• Speeds:
– Forward:
◊ Units with 44, 48, or 52 inch decks:
0-8 mph (12.9 km/hr) forward.
◊ Units with 60 inch deck:
0-9 mph (14.5 km/hr) forward.
– Reverse:
◊ Units with 44, 48, or 52 inch decks:
0-5 mph (8.0 km/hr) reverse.
◊ Units with 60 inch deck:
0-6 mph (9.7 km/hr) reverse.
• Drive wheel release valves allow machine to be
moved when engine is not running.
Seat
• Type: Standard seat with foam padded seat
cushion with armrests and integral safety switch.
Tires & Wheels
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.
Drive
Pneumatic (Air filled)
44, 48, & 52
Deck Size
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.
• Mounting: Adjustable fore and aft on seat tracks.
• Armrests: Molded flip-up armrests.
• Seat Safety Switch:
60
Quantity
2
2
Tread
Turf Master
K500 Super Turf
Size
22 x 9.50-12
23 x 10.50-12
Ply Rating
4
4
Pressure
13 psi (90 kPa)
13 psi (90 kPa)
Front Caster
Pneumatic (Air filled)
Deck Size
Integrated seat switch. Time delay seat switch
eliminates rough ground cut-outs.
Hydrostatic Ground Drive System
• Two unitized hydrostatic transmissions:
– Units with 44, 48, or 52 inch decks:
All Units
Quantity
2
Tread
Smooth
Size
13 x 5.00-6
Ply Rating
4
Pressure
13 psi (90 kPa)
Cutting Deck
• Cutting Width:
– 44 inch Deck:
– 48 inch Deck:
– 52 inch Deck:
– 60 inch Deck:
• Discharge: Side
• Blade Size:
Hydro Gear ZT3100
– Units with 60 inch deck:
Hydro Gear ZT3400
• Hydraulic Oil Type: Exmark Premium Hydro Oil.
• Hydraulic Oil Capacity: 77 oz (2.3 L) per side
• Hydraulic Filter: P/N 109-3321
16
(111.8 cm)
(121.9 cm)
(132.1 cm)
(152.4 cm)
Specifications
– 44 inch Deck: 22.25 inches (56.5 cm) – (2 ea.)
– 48 inch Deck: 16.25 inches (41.3 cm) – (3 ea.)
52 inch Deck
60 inch Deck
Without Deck
45.8 inches
(116.3 cm)
50.4 inches
(128.0 cm)
Deflector Up
54.2 inches
(137.7 cm)
61.4 inches
(156.0 cm)
Deflector Down
64.3 inches
(163.3 cm)
72.8 inches
(185.0 cm)
– 52 inch Deck: 18.00 inches (45.7 cm) – (3 ea.)
– 60 inch Deck: 20.50 inches (52.1 cm) – (3 ea.)
• Blade Spindles: Solid steel spindles with .98 inch
(25 mm) I.D. bearings.
• Deck Drive: “B” Section belt with self-tensioning
idler.
Overall Length:
• Electric clutch:
– 44, 48, & 52 inch decks: 175 ft-lb Mag Stop
44 inch Deck
48 inch Deck
Roll Bar - Up
78.8 inches
(200.2 cm)
77.8 inches
(197.6 cm)
Roll Bar - Down
79.6 inches
(202.2 cm)
78.6 inches
(199.6 cm)
52 inch Deck
60 inch Deck
– 60 inch deck: 200 ft-lb Mag Stop w/spot brake
• 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.
– 44 inch Deck: 2 anti-scalp rollers
Roll Bar - Up
77.8 inches
(197.6 cm)
78.8 inches
(200.2 cm)
– 48 inch Deck: 3 anti-scalp rollers
Roll Bar - Down
78.6 inches
(199.6 cm)
79.9 inches
(202.9 cm)
– 52 inch Deck: 3 anti-scalp rollers
– 60 inch Deck: 4 anti-scalp rollers
Overall Height:
• Deck Depth:
– 44 inch Deck: 5.0 inches (12.7 cm)
Roll Bar - Up
Roll Bar - Down
– 48 inch Deck: 5.0 inches (12.7 cm)
71.3 inches (181.1 cm)
48 inches (121.9 cm)
– 52 inch Deck: 5.0 inches (12.7 cm)
Tread Width: (Center to Center of
Tires, Widthwise)
– 60 inch Deck: 5.5 inches (14.0 cm)
• Cutting Height Adjustment:
Foot activated lever is used to adjust the cutting
height from 1 1/2 inch (3.8 cm) to 5 inches (12.7
cm) in 1/4 inch (6.4 mm) increments.
• Mulching Kit: Optional.
44 inch Deck
48 inch Deck
Drive Wheels
36.8 inches
(93.5 cm)
36.8 inches
(93.5 cm)
Caster Wheels
26.8 inches
(68.1 cm)
33.5 inches
(85.1 cm)
52 inch Deck
60 inch Deck
Drive Wheels
36.8 inches
(93.5 cm)
39.7 inches
(100.8 cm)
Caster Wheels
33.5 inches
(85.1 cm)
38.3 inches
(97.3 cm)
Dimensions
Overall Width:
44 inch Deck
48 inch Deck
Without Deck
45.8 inches
(116.3 cm)
45.8 inches
(116.3 cm)
Deflector Up
48.2 inches
(122.4 cm)
50.7 inches
(128.8 cm)
Deflector Down
56.4 inches
(143.3 cm)
59.5 inches
(151.1 cm)
17
Product Overview
Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
44 inch
Deck
48 inch
Deck
52 inch
Deck
60 inch
Deck
49.7 inches
(126.2 cm)
48.7 inches
(123.7 cm)
48.7 inches
(123.7 cm)
49.7 inches
(126.2 cm)
Product Overview
Curb Weight:
44 inch
Deck
48 inch
Deck
52 inch
Deck
60 inch
Deck
Kawasaki 822 lb
Units
(373 kg)
862 lb
(391 kg)
873 lb
(396 kg)
948 lb
(430 kg)
Torque Requirements
Bolt Location
Torque
Blade Drive Sheave
Mounting Nut
130-160 ft-lb (176-217
N-m)
Blade Mounting Bolt
(lubricate with anti-seize)
Anti-Scalp Roller Nyloc
Nut See Figure 18
50-60 ft-lb (68-81 N-m)
Figure 4
27-33 ft-lb (37-45 N-m)
1. Rollover Protection
System (ROPS)
5. Motion control levers
2. Engine Controls (right
console)
6. Parking brake
3. Seat belt
7. Height of cut adjustment
4. Fuel cap
Anti-Scalp Roller Whizlock 27-33 ft-lb (37-45 N-m)
Nut See Figure 18
Engine Mounting Bolts
27-33 ft-lb (37-45 N-m)
Wheel Lug Nuts
70-90 ft-lb (95-122 N-m)
Rollover Protection
System (Roll Bar) 1/2
inch Mounting Bolts
77-95 ft-lb (104-129 N-m)
Clutch Retaining Bolt
49-61 ft-lb (66-83 N-m)
(secured with threadlocker)
18
Operation
Operation
position. Do Not run a warm engine with choke in
the “ON” position.
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
into the T-slot locks them in the neutral position
(Figure 5).
Figure 6
1. Throttle lever
4. Blade control switch
(power take-off)
2. Choke lever
5. Ignition switch
3. Hour meter
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
Figure 5
Located on left side of unit, just to the front of the
LH motion control lever.
1. Neutral lock position
(handles out)
4. Forward
2. Neutral operate position
(handles in)
5. Neutral (operate)
The brake lever engages a parking brake on the drive
wheels.
3. Front of unit
6. Reverse
Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the
brake.
Choke Control
Located on right console (black lever) (see Figure 6).
The unit must be tied down and brake engaged when
transporting.
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”
Ignition Switch
Located on right console (see Figure 6).
19
Operation
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.
The ignition switch is used to start and stop the
engine. The switch has three positions “OFF”, “ON”
and “START”. Insert key into switch and rotate
clockwise to the “ON” position. Rotate clockwise to
the next position to engage the starter (key must be
held against spring pressure in this position). Allow
the key to return to the “on” position immediately
after the engine starts.
Align valve handle with the fuel line to open. Rotate
90° to close.
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.
Figure 7
1. Off
2. On
3. Start
WARNING
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.)
The engine and hydraulic drive units can become
very hot. Touching a hot engine or hydraulic
drive units can cause severe burns.
Hour Meter
Allow the engine and hydraulic drive units to
cool completely before accessing the drive wheel
release valves.
Located on the control panel (see Figure 6 and
Figure 8).
Located on the left and right sides underneath the
engine deck.
The hour meter records the number of hours that
the engine has run.
During normal operating conditions, the drive wheel
release valves are positioned in front of the slots. If
the machine has to be pushed by hand, the valves
must be in the “released” position (see Figure 9).
Figure 8
1. LCD indicators
3. Hour/Voltage display
2. Low voltage indicator
light
Fuel Shut-Off Valve
Located by the lower LH ROPS tube mounting.
20
Operation
Switch must be pulled out (up) to engage the blades.
Switch is pushed in to disengage the blades.
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.
Figure 10
Figure 9
1. Front of the machine
2. Rotate bypass release knob counterclockwise to loosen
1. Transport lock handle
3. Height of cut decal
2. Height adjustment pin
4. Deck foot pedal
3. Lever position for operating the machine
Transport Lock
4. Pull lever in this direction to push the machine
5. Lever position for pushing the machine
Located on the height of cut adjustment plate (see
Figure 10).
6. Rotate bypass release knob clockwise to tighten
7. Release lever
The transport latching mechanism will automatically
engage when the deck is raised to the transport
position. To release the deck from the transport
position: push the foot pedal to remove the load from
the transport latching mechanism, pull the transport
lock handle rearward, and let the pedal come back to
lower the deck down to the desired cut height.
To release the drive system (see item 1 in Figure 9),
loosen the knob by turning counterclockwise. Then
pull the release lever on the underside of machine
towards the back of the machine and retighten the
knob to hold the release lever back in the released
state. Repeat this on each side of the machine.
Release the parking brake. The machine is now able
to be pushed by hand.
Pre-Start
To reset the drive system (see item 2 in Figure 9),
loosen the knob by turning counterclockwise. Then
push the release lever on the underside of machine
towards the front of the machine and retighten the
knob to hold the release lever in the operating state.
Repeat this on each side of the machine.
Fill fuel tanks. See Fuel Recommendations in
the Specifications section for additional gasoline
information.
Do Not add oil to gasoline.
Do Not overfill fuel tank. Fill the fuel tank to the
bottom of the filler neck. The empty space in the
tank allows gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or emission
system.
Do Not tow machine.
PTO Engagement Switch
Located on right console (see Figure 6).
21
Operation
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
1
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
2
3
4
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.
5
G014402
Figure 11
1. Roll bar upper hoop
2. Knob in “latched” position
3. Pull knob to unlatch
4. Rotate 90° to hold unlatched
5. Knob in “unlatched” position
1. The knob must be completely latched with the
tabs interlocking as shown in Figure 11 to lock
the roll bar in the raised, operate position.
2. Apply forward pressure to the upper hoop of the
roll bar.
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 be pushed forward or
pulled rearward to get both knobs fully engaged
(see Figure 12).
3. Pull the knob and rotate 90° to hold in the
unlatched position to lower the roll bar.
4. 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.
Figure 12
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.
22
Operation
Starting the Engine
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.
1. Move the motion control levers out to the neutral
lock position.
2. Pull up and back on the parking brake lever to
engage the parking brake.
3. Push down on the PTO switch to the “disengage”
position.
Important: Operator must be in seat before the
PTO can be engaged.
1. Set the throttle midway between the “SLOW” and
“FAST” positions.
Note: It is not necessary for the operator to be
in the seat to start the engine.
4. Place the throttle midway between the “SLOW”
and “FAST” positions.
5. On a cold engine, push the choke lever forward
into the “ON” position.
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.
On a warm engine, leave the choke in the “OFF”
position.
6. Turn ignition switch to the “START” position.
Release the switch as soon as the engine starts.
2. Push the PTO switch in to disengage the blades.
Stopping the Engine
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.
7. If the choke is in the “ON” position, gradually
return choke to the “OFF” position as the engine
warms up.
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” positions.
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.
Engaging the PTO
DANGER
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
The rotating blades under the mower deck are
dangerous. Blade contact can cause serious
injury or kill you.
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.
Do Not put hands or feet under the mower or
mower deck when the blades are engaged.
Driving the Machine
DANGER
An uncovered discharge opening will allow
objects to be thrown in an operator’s or
bystander’s direction. Also, contact with the
blade could occur. Thrown objects or blade
contact can cause serious injury or death.
CAUTION
Machine can spin very rapidly by positioning one
lever too much ahead of the other. Operator may
lose control of the machine, which may cause
damage to the machine or injury.
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.
• Use caution when making turns.
• Slow the machine down before making sharp
turns.
23
Operation
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 13).
When the motion control levers are moved directly
inward (together) the drive system is in the neutral
operate position.
Figure 14
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.
4. To stop, position both motion control levers in
the neutral operate position.
Driving in Reverse
Figure 13
1. Neutral lock position
(handles out)
4. Forward
2. Neutral operate position
(handles in)
5. Neutral (operate)
3. Front of Unit
6. Reverse
1. Move the motion control levers inward to the
neutral operate position.
2. To move rearward in a straight line, move both
levers rearward with equal pressure.
Driving Forward
1. Release the parking brake.
2. Move the motion control levers inward to the
center to the neutral position.
3. To move forward in a straight line, move both
levers forward with equal pressure.
Figure 15
24
Operation
Adjusting the Anti-Scalp Rollers
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.
It is recommended to change the anti-scalp roller
position, when the height of cut has changed.
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.
1. Stop the machine and move the motion control
levers outward to the neutral locked position.
3. To stop, position both motion control levers in
the neutral operate position.
2. Disengage the PTO.
Adjusting the Cutting Height
4. Stop the engine, remove the key and wait for all
moving parts to stop.
The cutting height of the mower deck is adjusted
from 1 1/2 to 5 inches (3.8 cm to 12.7 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.
3. Raise and lock the deck to the 5 inch (12.7 cm)
transport position (Figure 16).
5. After adjusting the height of cut, adjust the
anti-scalp rollers by removing the nyloc nut,
bushing, spring disc washer and whizlock nut.
3. Engage the park brake.
6. Place the rollers in one of the positions shown
(Figure 17). Rollers will maintain 3/4 inch (19
mm) clearance to the ground to minimize gouging
and roller wear or damage.
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.
Figure 17
For cutting heights above 3.5 inches (90 mm) use the
bottom hole. The rollers will still be effective against
scalping.
1. Anti-scalp roller
mounting bracket
Figure 16
1. Transport lock handle
3. Height of cut decal
2. Height adjustment pin
4. Deck foot pedal
2. Cutting height
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.
4. Insert the height adjustment pin into the hole
corresponding to the desired cutting height.
7. Be sure the whizlock nuts are installed with the
spring disc washer between the head of the nut
and the mounting bracket.
See the decal on the side of the deck lift plate for
cut heights.
5. Push the foot lever forward, pull the transport
lock handle rearward and let the deck lower
down to the predetermined cut height by slowly
decreasing foot pressure allowing the foot lever
to travel rearward.
Note: The foot operated deck lift assist lever
can be used to momentarily lift the deck to clear
objects. Be sure that PTO is disengaged.
25
Operation
8. Torque the 3/8–16 whizlock nut to 27-33 ft-lb
(37-45 N-m) (Figure 18).
WARNING
Loading a unit on a trailer or truck increases
the possibility of backward tip-over. Backward
tip-over could cause serious injury or death.
• Use extreme caution when operating a unit
on a ramp.
• Use only a single, full width ramp; Do Not
use individual ramps for each side of the unit.
• If individual ramps must be used, use enough
ramps to create an unbroken ramp surface
wider than the unit.
• Do Not exceed a 15° angle between ramp and
ground or between ramp and trailer or truck.
• Avoid sudden acceleration while driving unit
up a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing unit
down a ramp to avoid tipping backward.
9. Torque the 3/8 nyloc nut to 27-33 ft-lb (37-45
N-m).
Figure 18
1. Spring disc washer
(cone towards nut )
3. 3/8 nyloc-torque to 27-33
ft-lb (37-45 N-m)
2. Front right anti-scalp
bracket shown
4. 3/8-16 whizlock nut
torque to 27-33 ft-lb
(37-45 N-m)
Loading a Unit
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for each side of the unit. The
lower rear section of the tractor frame extends back
between the rear wheels and serves as a stop for
tipping backward. Having a full width ramp provides
a surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
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.
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck Do Not exceed 15°. A steeper
angle may cause mower deck components to get
caught as the unit moves from ramp to trailer or
truck. Steeper angles may also cause the unit to tip
backward. If loading on or near a slope, position
the trailer or truck so it is on the down side of the
slope and the ramp extends up the slope. This will
minimize the ramp angle. The trailer or truck should
be as level as possible.
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 or roadway without such
equipment may also be a violation of State laws
and the operator may be subject to traffic tickets
and/or fines.
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Do Not drive a unit on a public street or roadway.
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.
26
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could seriously
injure you or other bystanders.
The engine can become very hot. Touching a hot
engine can cause severe burns.
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
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
After the first 100 hours
• Change the hydraulic filter and fluid.
Before each use or daily
•
•
•
•
•
•
•
•
•
•
•
Check the engine oil level.
Check the mower blades.
Check the safety interlock system.
Check the rollover protections systems (roll bar) knobs.
Check the seat belt.
Check for loose hardware.
Check the hydraulic oil level in the expansion tank.
Clean the engine and exhaust system area.
Clean the hydro fan cooling guards.
Clean the grass and debris build-up from the machine and cutting deck.
Clean the grass build-up from under the cutting deck.
Every 50 hours
•
•
•
•
Check the tire pressures.
Check the condition of the belts.
Grease the deck and pump idler pivots.
Check spark arrester (if equipped).
Every 100 hours
• Change the engine oil. (May need more often under severe conditions.)
• Remove the engine shrouds and clean the cooling fins.
Every 200 hours
• Check the spark plugs.
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.)
• Change the hydraulic filter and fluid (Every 250 hours if using Mobil 1 15W50)
• Check the park brake adjustment.
Monthly
• Check the battery charge.
27
Maintenance
Periodic Maintenance
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.
Check Engine Oil Level
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).
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. 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. If the oil level is low, wipe off the area around the
oil fill cap, remove cap and fill to the “FULL”
mark on the dipstick. Exmark 4-Cycle Premium
Engine Oil is recommended; refer to the Engine
Owner's manual for an acceptable alternative. Do
Not overfill.
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6 or
greater
100%
16 volts/7
amps
No
Charging
Required
12.4 – 12.6
75–100%
16 volts/7
amps
30 Minutes
12.2 – 12.4
50–75%
16 volts/7
amps
1 Hour
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
12.0–12.2
25–50%
14.4 volts/4 2 Hours
amps
11.7–12.0
0–25%
14.4 volts/4 3 Hours
amps
Check Battery Charge
11.7 or less
0%
14.4 volts/2 6 Hours or
More
amps
Service Interval: Monthly
Recommended Jump
Starting Procedure
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.
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
Allowing batteries to stand for an extended period of
time without recharging them will result in reduced
performance and service life. To preserve optimum
battery performance and life, recharge batteries in
storage when the open circuit voltage drops to 12.4
volts.
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
Do Not attempt to jump start with loose or
corroded battery terminals or damage to the
engine may occur.
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
28
Maintenance
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.
2. Make sure the booster is a good and fully charged
lead acid battery at 12.6 volts or greater. Use
properly sized jumper cables (4 to 6 AWG) with
short lengths to reduce voltage drop between
systems. Make sure the cables are color coded or
labeled for the correct polarity.
Figure 19
1. Positive (+) cable on discharged battery
2. Positive (+) cable on booster battery
3. Negative (–) cable on the booster battery
4. Negative (–) cable on the engine block
5. Booster battery
CAUTION
6. Discharged battery
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
7. Engine block
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
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).
6. MAKE THE FINAL CONNECTION ON
THE ENGINE BLOCK OF THE STALLED
VEHICLE (NOT TO THE NEGATIVE POST)
AWAY FROM THE BATTERY. STAND BACK.
7. Start the vehicle and remove the cables in the
reverse order of connection (the engine block
(black) connection is the first to disconnect).
WARNING
Batteries contain acid and produce explosive
gases.
Check Mower Blades
• Shield the eyes and face from the batteries
at all times.
Service Interval: Before each use or daily
• Do Not lean over the batteries.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Note: Be sure the vent caps are tight and level.
Place a damp cloth, if available, over any vent
caps on both batteries. Be sure the vehicles do
not touch and that both electrical systems are
off and at the same rated system voltage. These
instructions are for negative ground systems only.
2. Lift deck and secure in raised position as stated in
the Clean Grass Build-Up Under Deck section.
4. Reinstall the blades (if they were removed) in the
following order:
3. Connect the positive (+) cable to the positive (+)
terminal of the discharged battery that is wired to
the starter or solenoid as shown in Figure 19.
A. Install the splined bushing through the blade
with the bushing flange on bottom (grass)
side of blade.
3. Inspect blades and sharpen or replace as required.
29
Maintenance
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.
Figure 20
1. Spindle
2. Blade
3. Splined bushing
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.
4. 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.
2. 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).
C. Install the splined bushing/blade assembly
and blade bolt washer assembly into the
spindle. Install blade bolt finger tight.
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.
D. Place wrench on the top spindle nut then
torque the blade bolts to 50-60 ft-lb (68-81
N-m).
WARNING
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.
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.
Again, run engine at one-third throttle, brake
engaged, and move left motion control lever
in - engine must initiate shutdown after 1/2
second has elapsed.
Always install the original Exmark blades,
blade bushings, and blade bolts as shown.
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.
Check Safety Interlock
System
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
Service Interval: Before each use or daily
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
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 neutral
30
Maintenance
Check Rollover Protections
Systems (Roll Bar) Knobs
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.
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.
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.
3. The oil drain hose on Kawasaki engines is located
on right hand side of engine at the rear. It is
located on the left hand side for Kohler engines.
Place pan under machine to catch oil. Remove
plug from end of drain hose. Allow oil to drain
and replace oil drain plug. Torque plug to 20-24
ft-lb.
4. Replace the oil filter every other oil change. Clean
around oil filter and unscrew filter to remove.
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 contacts the filter adapter then
tighten filter an additional 1/2 to 3/4 turn.
5. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
6. Use oil recommended in the Check Engine Oil
Level section. Do Not overfill. Start the engine
and check for leaks.
7. Wipe up any spilled oil from engine deck
mounting surfaces.
Figure 21
1. Engaged
2. Partially engaged — Do
Not operate with ROPS
in this condition.
Check Seat Belt
Service Interval: Before each use or daily
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 hardware
or correct the problem before operating.
Service Air Cleaner
Service Interval: Every 250 hours—Replace
the primary air cleaner
element — check
secondary air cleaner
31
Maintenance
Check Hydraulic Oil Level
Lubricate Grease Fittings
Service Interval: Before each use or daily
Note: See chart for service intervals.
1. Stop engine and wait for all moving parts to stop.
Engage parking brake.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Wait until the unit cools before checking the
hydraulic oil.
2. Lubricate fittings with one to two pumps of
NGLI grade #2 multi-purpose gun grease.
Refer to the following chart for fitting locations
and lubrication schedule.
3. Check expansion tank and if necessary add
Exmark Premium Hydro Oil to the FULL COLD
line (see Figure 22).
Lubrication Chart
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
1. Deck and
Pump Idler
Pivots
1
2
50 hours
Figure 22
1. Engine
2. Expansion tank
Check Tire Pressures
Service Interval: Every 50 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check tire pressure in drive tires.
Lubricate Caster Wheel Hubs
3. Inflate drive tires to 13 psi (90 kPa).
Service Interval: As required
4. Check tire pressure in caster tires.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
5. Inflate caster tires to 13 psi (90 kPa).
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
lower the deck to inspect deck drive belt.
3. Check under machine to inspect the pump drive
belt.
Figure 23
1. Seal guard
Note: No adjustments are required for belt
tension.
32
2. Spacer nut with wrench
flats
Maintenance
Check Spark Plugs
2. Remove caster wheel from caster forks.
3. Remove seal guards from the wheel hub.
4. Remove one of the spacer nuts from the axle
assembly in the caster wheel. Note that thread
locking adhesive has been applied to lock the
spacer nuts to the axle. Remove the axle (with the
other spacer nut still assembled to it) from the
wheel assembly.
5. Pry out seals, and inspect bearings for wear or
damage and replace if necessary.
6. Pack the bearings with a NGLI grade #1
multi-purpose grease.
7. Insert one bearing, one new seal into the wheel.
Service Interval: Every 200 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owner's
Manual.
Change Fuel Filter
Service Interval: As required
A fuel filter is installed between the fuel tank and the
engine. Replace when necessary.
Replacement Filters
Note: Seals (Exmark P/N 103-0063) must be
replaced.
8. If the axle assembly has had both spacer nuts
removed (or broken loose), apply a thread locking
adhesive to one spacer nut and thread onto the
axle with the wrench flats facing outward. Do
Not thread spacer nut all of the way onto the end
of the axle. Leave approximately 1/8 inch (3 mm)
from the outer surface of the spacer nut to the
end of the axle inside the nut.
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
10. With the open end of the wheel facing up, fill
the area inside the wheel around the axle full of
NGLI grade #1 multi-purpose grease.
11. Insert the second bearing and new seal into the
wheel.
12. Apply a thread locking adhesive to the 2nd spacer
nut and thread onto the axle with the wrench flats
facing outward.
13. Torque the nut to 75-80 in-lb (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.
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: After the first 100 hours
Every 500 hours thereafter
(Every 250 hours if using
Mobil 1 15W50)
1. Stop engine, wait for all moving parts to stop, and
allow engine to cool. Remove key and engage
parking brake.
2. Locate the two filters under the transmissions.
Remove filter guards.
3. Carefully clean area around filters. It is important
that no dirt or contamination enter hydraulic
system.
4. Unscrew filters to remove and allow oil to drain
from drive system.
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.
Important: Before reinstalling new filters,
apply a thin coat of Exmark Premium Hydro
Oil on the surface of the filters rubber seal.
Turn the filters clockwise until rubber seal
contacts the filter adapter then tighten the filter
an additional 3/4 to 1 full turn.
33
Maintenance
5. Remove the vent plug on each transmission and
fill through expansion reservoir, when oil comes
out of vent reinstall plug.
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.
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Hydro Oil
Change Interval
Exmark Premium Hydro
Oil (Preferred)
500 Hours
Mobil 1 15W50
250 Hours
Keep fingers, hands, and clothing clear of
rotating components and hot surfaces.
A. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse (5 or 6 times).
Torque plugs to 180 in-lb (244 N-m). Continue to
add oil until it reaches the FULL COLD line on
the expansion reservoir.
B. With the bypass valve closed and the engine
running, slowly move the directional control
in both forward and reverse directions (5 to
6 times). Check the oil level, and add oil as
required after stopping the engine.
C. It may be necessary to repeat steps A and B
until all the air is completely purged from
the system. When the transaxle operates at
normal noise levels and moves smoothly
forward and reverse at normal speeds, then
the transaxle is considered purged.
Figure 24
1. Oil filter
2. Vent plug
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 or been
extremely hot.
Changing oil unnecessarily could damage hydraulic
system by introducing contaminants into the system.
3. Left rear tire
6. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
Check Spark Arrester
(if equipped)
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Service Interval: Every 50 hours
WARNING
Hot exhaust system components may ignite
gasoline vapors even after the engine is stopped.
Hot particles exhausted during engine operation
may ignite flammable materials. Fire may result
in personal injury or property damage.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Do Not refuel or run engine unless spark arrester
is installed.
7. Start engine and move throttle control ahead to
1/2 throttle position. Disengage parking brake.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Wait for muffler to cool.
34
Maintenance
Adjustments
3. If any breaks in the screen or welds are observed,
replace arrester.
Note: Disengage PTO, shut off engine, wait for
all moving parts to stop, engage parking brake, and
remove key before servicing, cleaning, or making any
adjustments to the unit.
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.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be enough
support or may malfunction allowing the unit to
fall, which could cause injury.
Thread Locking Adhesives
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
• ROPS spring pin housing.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands or
equivalent support.
• Sheave and clutch retaining bolt in the end of
engine crankshaft.
• Hydro cross member mounting bolts
Deck Leveling
Thread locking adhesives are required for some
hardware on engines — see the Engine manual.
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. Carefully rotate the blades from side to side.
6. Measure between the outside cutting edges and
the flat surface (Figure 25 and Figure 26). If both
measurements are not within 3/16 inch (5 mm),
an adjustment is required; continue with this
procedure.
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.
Dielectric grease should not be applied to sealed
connectors.
Figure 25
48, 52, and 60 Inch Decks
1. Blades side to side
35
2. Measure here
Maintenance
Figure 27
Figure 26
44 Inch Deck
1. Blades side to side
1. Leveling adjust locking
nuts
2. Deck lift arm
2. Measure here
7. Set anti-scalp rollers to top holes or remove
completely for this adjustment.
Adjusting the Blade Slope
Block Height and Rake Table
Front Block
Height “A”
Rear Block
Height “B”
Rake “R”
44
2.69 inches
(6.8 cm)
2.99 inches
(7.6 cm)
1/8–3/8 inch
(3.2–9.5 mm)
48, 52, 2.77 inches
& 60 (7.0 cm)
2.81 inches
(7.1 cm)
1/16–5/16 inch
(1.6–7.9 mm)
4. Chain
11. Recheck that blocks fit just snugly under the deck
skirt. Make sure all attachment bolts are tight
12. Continue leveling the deck by checking the
front-to-rear blade slope; refer to Adjusting the
Blade Slope.
13. Recheck blades for levelness and repeat deck
leveling procedure if necessary.
8. Set the height-of-cut lever to the 3 inch (76 mm)
position. Place two “B” thick blocks (see Block
Height and Rake Table) under the rear edge of the
cutting deck skirt; one on each side of the cutting
deck. Place two “A” thick blocks under each side
of the front edge of the deck, but not under the
anti-scalp roller brackets.
Deck
Size
3. Deck hanger
1. Check the front-to-rear blade level any time you
install the mower. If the front blade tip is not
“R” (see Block Height and Rake Table in Deck
Leveling) lower than the rear blade tip, adjust the
blade level using the following instructions:
2. Park the machine on a level surface and disengage
the blade control switch.
3. Move the motion control levers outward to the
neutral position, engage the parking brake, stop
the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Check the air pressure of all four tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section.
5. Check and adjust the side-to-side blade level if
you have not checked the setting; refer to Deck
Leveling.
6. Set the height-of-cut lever to the 3 inch (76 mm)
position. Place two “B” thick blocks (see Block
Height and Rake Table in Deck Leveling) under
the rear edge of the cutting deck skirt; one on
9. Carefully rotate the blades side to side
(Figure 25 and Figure 26).
10. Loosen the leveling adjust locking nuts (item 1
Figure 27) on all four corners so that the deck is
sitting securely on all four blocks. Make sure that
the slack is removed from the deck hangers and
the deck lift foot lever is pushed back against the
stop, then tighten the four leveling adjust locking
nuts.
36
Maintenance
Check to make sure brake is adjusted properly. This
procedure must be followed after the first 100 hours
or when a brake component has been removed or
replaced.
each side of the cutting deck. Place two “A” thick
blocks (see Block Height and Rake Table in Deck
Leveling) under each side of the front edge of the
deck, but not under the anti-scalp roller brackets.
7. Loosen the leveling adjust locking nuts (item 1
Figure 27) on all four corners so that the deck is
sitting securely on all four blocks. Make sure that
the slack is removed from the deck hangers and
the deck lift foot lever is pushed back against the
stop, then tighten the four leveling adjust locking
nuts.
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.
8. Carefully rotate the blades so they are facing front
to rear (Figure 28).
4. Setup the machine to be pushed by hand (see
Drive Wheel Release Valves in the Operation
section).
9. Measure from the tip of the front blade to the flat
surface and the tip of the rear blade to the flat
surface (Figure 28). If the front blade tip is not
“R” (see Block Height and Rake Table in Deck
Leveling) lower than the rear blade tip, adjust the
front deck hanger.
5. Raise the back of the machine up and support the
machine with jack stands.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
6. Engage/disengage the brake and check each drive
tire to make sure each brake engages/disengages.
Figure 28
1. Blades front to rear
7. If adjustment is necessary, loosen the jam nut
from the yoke on the side that needs adjustment.
Remove the hairpin and clevis pin (see Figure 29).
2. Measure here
10. When the front-to-rear blade slope is correct
check the side-to-side level of the mower again;
refer to Deck Leveling.
Pump Drive Belt Tension
Self-tensioning - No adjustment necessary.
Deck Belt Tension
Self-tensioning - No adjustment necessary.
Adjusting the Parking Brake
Service Interval: Every 500 hours
37
Maintenance
Figure 30
1. Bolts
2. Washer
3. Control lever
4. Control arm shaft
5. Slotted hole
Figure 29
1. Hairpin
3. Yoke
2. Clevis pin
4. Jam nut
2. Move the control lever to the next set of holes.
Secure the lever with the hardware.
3. Repeat the adjustment for the opposite control
lever.
• Adjusting the Brake to Engage: Shorten the
linkage by turning the yoke clockwise.
Adjusting the Tilt
• Adjusting the Brake to Disengage:
Lengthen the linkage by turning the yoke
counterclockwise.
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.
8. Reinstall the clevis pin and hair pin and tighten
down the jam nut. Repeat step 6 and readjust if
necessary.
2. Loosen the lower bolt just enough to pivot the
control lever fore or aft Figure 30. Tighten both
bolts to secure the control in the new position.
9. When adjustment is complete, remove the jack
stands or equivalent support and lower the
machine.
3. Repeat the adjustment for the opposite control
lever.
10. Place the machine into the “operating” position.
Refer to the Drive Wheel Release Valves section
in Operation.
Full Forward Tracking
Adjustment
Motion Control Handle
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.
Adjusting the height:
1. Loosen the screws on a cover plate (see Figure 31).
The motion control levers can be adjusted higher or
lower for maximum operator comfort.
2. Slide the cover plate backward or forward to
adjust the travel of the lever and tighten the
screws.
1. Remove the hardware holding the control lever to
the control arm shaft (Figure 30).
3. Drive the machine and check the full forward
tracking.
4. Repeat steps 1 through 3 until desired tracking
is obtained.
38
Maintenance
Operator does not have to be in the seat. 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. The control plate tabs should touch the
return to neutral plates on the hydros. Adjust
pump control rod lengths by loosening the nuts
and rotating the turnbuckle in the appropriate
direction until the wheels slightly creep in reverse
(Figure 32). 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.
Figure 31
1. Control arm shaft
3. Tracking plate
2. Tracking plate screw
Motion Control Linkage
Adjustment
Located on either side of the unit, below the seat are
the pump control linkages. Rotating the turnbuckle
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.
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.
Figure 32
1. Nut
4. Control plate
2. Turnbuckle
5. Return to neutral plate
3. Stationary plate
6. Tabs touching return to
neutral plate
8. Tighten nuts.
9. Shut off unit. Remove jumper wire from wire
harness and plug connector into seat switch.
10. Remove the jack stands.
39
Maintenance
Electric Clutch Adjustment
11. Raise the deck and re-install the height of cut pin.
12. Check that the machine does not creep in neutral
with the park brake disengaged.
Adjusting the Seat Ride
Suspension
The number of seat springs can be changed to
maximize rider comfort. More springs should be used
with heavier operators and on rough terrain. Fewer
springs should be used with lighter operators and
when mowing smooth, well established lawns. Always
keep the number of springs on the left and right side
the same when adding and removing springs.
Figure 34
1. Armature
5. Brake spacer
2. Field shell
6. Re-gap shim
3. Rotor
7. Brake pole
4. Brake mounting bolt
Removing the Shim:
1. Stop engine, wait for all moving parts to stop,
and remove key. Engage parking brake. Allow
the machine to cool completely before starting
these instructions.
2. Using a pneumatic line, blow out any debris
from under the brake pole and around the brake
spacers.
3. Check the condition of the wire harness leads,
connectors, and terminals. Clean or repair as
necessary.
4. Verify that 12V is present at the clutch connector
when the PTO switch is engaged.
Figure 33
1. Bolt
2. Spring
3. Nut
4. Additional mounting
holes
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 35).
Up to five springs can be secured to the seat box with
a nut and bolt, see Figure 33.
Note: Do Not remove the brake pole from
the field shell/armature. The brake pole has
worn to match the armature and needs to
continue to match after the shim is removed
to ensure proper brake torque.
Refer to the Parts Manual for spring and hardware
part numbers.
40
Maintenance
Figure 37
Figure 35
1. Feeler gauge
1. Brake mounting bolt
2. Shim
• If the gap is less than 0.010 inch, then
reinstall the shim and reference the
Troubleshooting section.
B. Using needle nose pliers, or by hand, take
hold of the tab and remove the shim (Do Not
discard the shim until proper clutch function
has been confirmed).
• If the gap is sufficient, proceed to the
safety check in step F.
C. Using a pneumatic line, blow out any debris
from under the brake pole and around the
brake spacers.
F. Perform the following safety check:
a. Sit on the seat and start the engine.
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13
N-m) +/-0.5 ft-lb (0.7 N-m).
b. Make sure the blades Do Not engage with
the PTO switch “off ” and the clutch
disengaged.
E. Using a 0.010 inch thick feeler gauge, verify
that a gap is present between the rotor and
armature face on both sides of the brake pole
as shown. (Due to the way the rotor and
armature faces wear (peaks and valleys) it is
sometimes difficult to measure the true gap.)
If the clutch does not disengage,
reinstall the shim and reference the
Troubleshooting section.
c. Engage and disengage the PTO switch
ten consecutive times to ensure the clutch
is functioning properly. If the clutch
does not engage properly, reference the
Troubleshooting section.
G011733
1
Figure 36
1. Feeler gauge
41
Maintenance
Cleaning
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Slide seat all the way forward.
3. Remove accumulated debris from the hydro fan
cooling fins and upper surfaces.
Clean Engine and Exhaust
System Area
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
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.
2. 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.
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.
Clean Grass Build-Up Under
Deck
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.
Service Interval: Before each use or daily
1. Park the machine on a level surface and disengage
the blade control switch.
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
3. Raise deck to the transport (5 inch (12.7 cm)
cutting height) position. Lift the front of unit
and support unit using jack stands or equivalent
support.
Remove Engine Shrouds and
Clean Cooling Fins
CAUTION
Service Interval: Every 100 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove cooling shrouds from engine and clean
cooling fins. Also clean dust, dirt and oil from
external surfaces of engine which can cause
inadequate cooling.
3. Make sure cooling shrouds are reinstalled.
Operating the engine without cooling shrouds will
cause engine damage due to overheating.
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
4. Clean out any grass build-up from underside of
deck and in discharge deflector.
Clean Hydro Fan Cooling
Fins
Waste Disposal
Service Interval: Before each use or daily
Motor Oil Disposal
Removing debris from the hydro fan cooling fins will
allow the hydro system to run cooler and improve the
life of the hydro system.
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
42
Maintenance
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, or local laws.
If a battery is being replaced or if the unit containing
the battery is no longer operating and is being
scrapped, take the battery to a local certified recycling
center. If no local recycling is available return the
battery to any certified battery reseller.
43
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do not attempt to service or replace major
items or any items that call for special timing of 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.
Problem
Starter does not crank
Possible Cause
1. PTO is engaged.
1. Disengage the PTO.
2. Parking brake is not engaged.
3. Drive levers are not in neutral lock
position.
4. Battery does not have a full charge.
6. Fuse is blown.
7. Relay or switch is defective.
8. Faulty module.
2. Set the parking brake.
3. Ensure the drive levers are in the neutral
lock position.
4. Charge the battery. See Check
Battery Charge and Recommended
Jump Starting Procedure sections in
Maintenance.
5. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
6. Replace the blown fuse.
7. Contact an Authorized Service Dealer.
8. Replace module.
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shutoff valve is closed.
3. Oil level in the crankcase is low.
4. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. Add oil to the crankcase.
4. 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.
5. Replace the fuel filter.
6. Contact an Authorized Service Dealer.
5. Electrical connections are corroded, loose
or faulty.
Engine will not start, starts hard, or fails to
keep running
Corrective Action
5. Dirt in fuel filter.
6. Dirt, water, or stale fuel is in the fuel
system.
7. Air cleaner is dirty.
8. Seat switch is not functioning properly.
9. Electrical connections are corroded, loose
or faulty.
10.
11.
12.
13.
Relay or switch is defective.
Faulty spark plug.
Spark plug wire is not connected.
Faulty module.
44
7. Clean or replace the air cleaner element.
8. Check the seat switch indicator. Replace
seat if needed.
9. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
10. Contact an Authorized Service Dealer.
11. Clean, adjust or replace spark plug.
12. Check the spark plug wire connection.
13. Replace module.
Troubleshooting
Problem
Engine loses power
Possible Cause
Corrective Action
1. Engine load is excessive
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. Dirt in fuel filter.
6. Dirt, water, or stale fuel is in the fuel
system.
2. Clean or replace 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.
Mower pulls left or right (with levers fully
forward)
1. Tire pressure in drive tires not correct.
1. Adjust tire pressure in the drive tires.
Machine does not drive
1. Drive release handle not in “operating”
position.
1. Position handle in “operating” position;
see Drive Wheel Release Valves section
in Operation.
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.
2. Change the belt.
Uneven cutting height.
1. Blade(s) not sharp.
1. Sharpen the blade(s).
2. Cutting blade(s) is/are bent.
3. Mower deck is not level.
2. Install new cutting blade(s).
3. Level mower deck from side-to-side and
front-to-rear.
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.
4.
5.
6.
7.
Abnormal vibration
Blades do not rotate.
3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to reservoir or let it
cool down.
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.
Tips of adjacent blades are at an uneven
cutting height. Blades tips should be even
within 3/16 inch which is approximately
one blade thickness.
1. Cutting blade(s) is/are bent or unbalanced.
1. Install new cutting blade(s).
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.
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. Drive belt is worn, loose or broken.
1. Check the belt tension.
2. Deck belt is worn, loose or broken.
3. Deck belt is off pulley.
2. Install new deck belt.
3. Install belt on clutch and deck pulleys,
idlers, and tensioning idler per routing
decal on deck.
4. Replace the spring.
5. Refer to belt routing decal on deck.
4. Broken or missing idler spring.
5. Drive belt not routed correctly.
45
Schematics
Schematics
Electrical Diagram
46
Schematics
Electrical Logic Schematic
47
Pioneer S-Series Turf Equipment
2 Year Limited Commercial Warranty
4 Year 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.
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
Commercial Warranty Conditions
This warranty applies to Exmark Pioneer S-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 warranty does not cover pickup and delivery charges to and
from any authorized Exmark Service Dealer.
Consumer Warranty Conditions
This warranty applies to Exmark Pioneer S-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.
Owner’s Responsibilities
If your product requires warranty service it must be returned to an
authorized Exmark service dealer within the warranty period. This
warranty extends only to turf equipment operated under normal
conditions. You must read the operator’s manual. You must also properly
service and maintain your Exmark product as described in the operator’s
manual. Such routine maintenance, whether performed by a dealer or by
you, is at your expense.
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.
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.
Warranty Exceptions
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.
Warranty Exceptions
Warranty Period
• Bags, Belts and Tires
90 days
• Battery
1 Year Prorated
• Engine
*
* The Engine warranty is covered by the engine manufacturer. Please
refer to the engine manufacturer’s warranty statement that is included in
the literature packet.
Items and Conditions Not Covered
This warranty does not cover the following:
• Any damage or deterioration due to normal use, wear and tear, or
exposure.
• Cost of regular maintenance service or parts, such as filters, fuel,
lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or required
replacement or repair due to normal wear, accidents, or lack of proper
maintenance.
• Any repairs necessary due to use of parts, accessories or 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.
No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the
above exclusions and limitations may not apply to you.
All warranty work must be performed by an authorized Exmark Service
Dealer using Exmark approved replacement parts.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
G4500-748_A
48
Service Record
Date:
Description of Work Done:
49
Service Done By:
50
G011841
Figure 38
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 the recommended slope.
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
3. Example of how to compare slope with folded edge.
51
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
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
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
WALK-BEHIND ACCESSORIES AND OPTIONS
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
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
©2011 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4501-000 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com