Exmark 820 Lawn Mower User Manual

PHAZER
™
For Serial Nos.
820,977 & Higher
Part No. 4500-488 Rev. C
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
Important: IMPORTANT The engine in this
product is not equipped with a spark arrester
muffler. It is a violation of California Public
Resource Code (CPRC) Section 4442 to use
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 Canadian
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.
©2010 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.
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Figure 1
1. Model and serial number location
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/manuals.htm
Model No.
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
Waste Disposal .............................................. 32
Troubleshooting ................................................... 33
Schematics ........................................................... 35
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 10
Specifications ....................................................... 13
Model Numbers ............................................ 13
Systems ......................................................... 13
Dimensions................................................... 14
Torque Requirements .................................... 15
Product Overview ................................................ 15
Operation ............................................................. 16
Controls ........................................................ 16
Pre-Start........................................................ 17
Operating Instructions .................................. 18
Transporting ................................................. 20
Maintenance ......................................................... 22
Recommended Maintenance Schedule(s) ........... 22
Periodic Maintenance ....................................... 23
Check Engine Oil Level ................................. 23
Check Battery Charge .................................... 23
Check Mower Blades ..................................... 24
Check Safety Interlock System ....................... 25
Check for Loose Hardware ............................ 25
Service Air Cleaner ........................................ 26
Change Engine Oil ........................................ 26
Check Hydraulic Oil Level ............................. 26
Check Tire Pressures ..................................... 26
Check Condition Of Belts.............................. 26
Lubricate Grease Fittings............................... 27
Lubricate Caster Wheel Hubs ........................ 27
Check Spark Plugs ......................................... 28
Change Hydraulic System Filter ..................... 28
Thread Locking Adhesives............................. 29
Mobil HTS Grease (Or Food-Grade
Anti-seize)................................................. 29
Dielectric Grease........................................... 29
Adjustments ..................................................... 30
Deck Leveling ............................................... 30
Pump Drive Belt Tension............................... 30
Deck Drive Belt Tension................................ 30
Electric Clutch Adjustment............................ 30
Motion Control Linkage Adjustment ............. 30
Adjust Throttle Lever Tension ....................... 31
Cleaning ........................................................... 31
Clean Engine Air Cooling System................... 31
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 31
Clean Grass Build-Up Under Deck ................ 31
4
Safety
Safety
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
Safety Alert Symbol
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
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
1. has read and understands the Operator’s
Manual and recognizes the risks involved;
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS 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.
Figure 2
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
Preparation
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
• 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.
CAUTION
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.
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.
Safe Operating Practices
Wear hearing protection when operating this
machine.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
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.
5
Safety
DANGER
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
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.
• Fill the fuel tank outdoors on level ground,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
• Always place gasoline containers on the
ground away from your vehicle before
filling.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• 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.
• Do Not fill the fuel tank completely full.
Fill the fuel tank to the bottom of the filler
neck. The empty space in the tank allows
gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or
emission system (if equipped).
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by spark.
• 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.
• Store gasoline in an approved container
and keep it out of the reach of children.
• 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.
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add
fuel when engine is running or when the
engine is hot.
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
WARNING
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
6
Safety
Operation
– Before clearing blockages.
– Whenever you leave the mower.
WARNING
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
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.
– 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
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can kill
you.
• NEVER carry passengers. DO NOT operate
the mower when people, especially children, or
pets are in the area.
Do Not run engine indoors or in a small confined
area where dangerous carbon monoxide fumes
can collect.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• 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.
• 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.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
• 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.
Maintenance and Storage
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
• Keep engine, engine area, and pump drive belt
compartment free from accumulation of grass,
leaves, excessive grease or oil, and other debris
which can accumulate in these areas. These
materials can become combustible and may result
in a fire.
• Let engine cool before storing and Do Not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Use jack stands to support components when
required.
• Carefully release pressure from components with
stored energy.
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
negative terminal first and the positive last.
Reconnect positive first and negative last.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
(Figure 3).
Figure 3
1. Water
2. Danger Zone-Use a walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs, and water.
3. Safe Zone-Use the mower here on slopes less than 15
degrees
• 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.
8
Safety
• 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,
or using non-Exmark replacement parts and
accessories may alter the warranty, traction, and
safety of the machine. Failure to use original
Exmark parts could cause serious injury or
death.
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.
• 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.
Replace all parts including, but not limited to
tires, belts, and blades with original Exmark
parts.
WARNING
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury. Fluid
accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene may
result.
DANGER
• 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.
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.
• 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.
CAUTION
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
Be sure ignition switch is in the “OFF”
position before charging the battery.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
9
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Safety signs may be affixed by peeling off the
backing to expose the adhesive surface. Apply
only to a clean, dry surface. Smooth to remove
any air bubbles.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
93-8069
1. Hot surface/burn hazard—stay a safe distance from the
hot surface.
1-303508
98-5954
1-403005
103-1077
1-513747
109-2356
1-513748
1. Fast
2. Slow
10
3. Neutral
4. Reverse
Safety
109-2463
109-2992
109-2465
116-0950
109-2467
109-2490
Hour Message Display
1. Hour Meter
2. PTO
3. Parking Brake
109-2862
11
4. Neutral
5. Operator’s presence
switch
6. Battery
Safety
116-1400
12
Specifications
Specifications
Model Numbers
Serial Nos: 820,977 and Higher
PHZ19KA343; PHZ19KA343CA
Systems
• 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.
Engine
• Engine Specifications: See your Engine Owner’s
Manual
• RPM: Full Speed: 3750 ±100 RPM (No Load)
Idle: 1400 RPM
Operator Controls
Fuel System
• Steering and Motion Control:
• Capacity: 7.7 gal. (29.1 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
• Fuel Filter: In-line Kawasaki P/N 49019–7001
• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,
“OFF”)
Electrical System
•
•
•
•
•
•
•
Charging System: Flywheel Alternator
Charging Capacity: 13 amps
Battery Type: BCI Group U1
Battery Voltage: 12 Volt
Polarity: Negative Ground
Fuses:
– 30 amp main fuse
– 25 amp charging system fuse
– 10 amp clutch fuse
•
•
•
Note: Motion control levers are adjustable to
two heights.
– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.
– Steering is controlled by varying the position
of the levers relative to each other.
– 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 Assist Lever: Foot pedal that assists
in raising the deck.
Seat
• Type: Standard seat with high back, foam padded,
(internal suspension) and armrests.
• Mounting: Hinged to tilt up for access to battery
and other components. Held in tilted position
with lanyard. Adjustable fore and aft seat track.
• Armrests: Standard–foam padded flip-up
armrests.
• Seat Safety Switch: Incorporated into the
Safety Interlock System. Time delay seat switch
eliminates rough ground cut-outs.
Safety Interlock System
• LCD indicators appear for the PTO, park brake,
drive levers, and operator presence in the message
display on the center console.
• 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.)
13
Specifications
Hydrostatic Ground Drive System
• Deck Depth: 5.0 inches (12.7 cm)
• Hydrostatic Drive: Two Hydro Gear ZT2800
Integrated drive systems.
• Cutting Height Adjustment:
Foot operated deck lift lever is used to adjust the
cutting height from 1 inch (2.5 cm) to 5 inches
(12.7 cm) in 1/4 inch (6.4 mm) increments.
• Hydraulic Oil Type: Use Exmark Premium Hydro
Oil.
The cutting height adjustment handle has a
transport position and all adjustments can be
made while the operator remains seated.
• Speeds:
– 0-7.2 mph (11.6 km/hr) forward.
– 0-4.0 mph (6.4 km/hr) reverse.
• Mulching Kit: Optional.
• Drive wheel releases allow machine to be moved
when engine is not running and brake is off (left
and right sides of engine).
Dimensions
Tires & Wheels
Overall Width:
Front Caster
Without Deck
34.5 inches (87.6 cm)
Pneumatic
(Air-Filled)
Semi-Pneumatic
Deflector Up
35.0 inches (89.0 cm)
Deflector Down
44.0 inches (111.8 cm)
Quantity
2
2
Tread
Turf Mate
Smooth
Size
18 x 7.00-8
11 x 4.00-5
Ply Rating
4
Pressure
13 psi (90 kPa)
Drive
Overall Length:
70.0 inches (177.8 cm)
Overall Height:
39.0 inches (99.1 cm)
Cutting Deck
• Cutting Width: 34.5 inches (87.6 cm)
Tread Width: (Center to Center of
Tires, Widthwise)
• Discharge: Side
• Blade Size: (2 ea.) 17.50 inches (44.5 cm)
Drive Wheels
26.5 inches (67.3 cm)
• Blade Spindles: Solid steel spindles with 1 inch
(25.4 mm) I.D. bearings.
Caster Wheels
29.0 inches (73.7 cm)
Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
• Deck Drive:
– Electric clutch mounted on vertical engine
shaft.
45.0 inches (114.3 cm)
– Blades are driven by one belt
(w/self-tensioning idler) direct from
the engine.
Curb Weight:
570 lb (258.5 kg)
• Deck:
Full floating deck is attached to out-front support
frame.
Two optional anti-scalp rollers.
Deck design allows for bagging, mulching or side
discharge.
14
Product Overview
Torque Requirements
Bolt Location
Torque
Cutter Housing Spindle
Nut
140-145 ft-lb
(190-197 N-m)
Blade Mounting Bolt
115-120 ft-lb
(156-163 N-m)
Anti-Scalp Roller Nyloc
Nut
40-45 ft-lb (54-61 N-m)
Engine Mounting Bolts
25-30 ft-lb (34-41 N-m)
Wheel Lug Nuts
90-95 ft-lb (122-129 N-m)
Product Overview
Clutch Retaining Bolt
55-60 ft-lb (75-81 N-m)
(secured with threadlocker)
Figure 4
1. Fuel Cap
2. Motion Control Lever
3. Controls
15
4. Parking Brake Lever
5. Height-of-Cut Foot Lever
Operation
Operation
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 will put the choke in the “OFF” 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
Throttle Control
Motion Control Levers
Located on the center of the console (to the left side
of the choke).
The motion control levers located on each side of the
console control the forward and reverse motion of
the machine. The levers control the flow of hydraulic
oil from the hydrostatic pump to the drive wheel
motor for each side.
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 levers forward or backward turns the
wheel on the same side forward or in reverse. Wheel
speed is proportional to the amount the lever is
moved.
Brake Lever
Located on left side of the console.
The brake lever engages a parking brake on the drive
wheels.
Moving the levers outward from the center position
into the T-slot locks them in the neutral position
(Figure 7).
Note: The LCD indicator appears in the message
display on the RH console when the park brake is
engaged (see Figure 6).
When the motion control levers are in the neutral
position, the LCD indicator appears in the message
display on the center console (see Figure 6).
Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the
brake.
The unit must be tied down and brake engaged when
transporting.
Ignition Switch
Located right of center on the console.
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).
Figure 5
1. Handles Out (Neutral
Lock)
2. Handles In (Neutral)
3. Front of Unit
4. Forward
5. Neutral
Note: Brake must be engaged, motion control levers
out (neutral lock position) and PTO switch “OFF” to
start engine. (It is not necessary for the operator to
be in the seat to start the engine.)
6. Reverse
7. Neutral Lock
Hour Meter
Choke Control
Located right of center on the console (below ignition
switch).
Located on the center of the console.
16
Operation
Drive wheel release levers are used to release the
hydrostatic drive system to allow the machine to be
pushed without the engine running.
The hour meter records the number of hours that
the engine has run.
Pull each lever rearward and outward to lock. Pull
each lever inward and push forward to reset. Do Not
tow machine.
PTO Engagement Switch
Located right of center on the console (left side of
ignition switch).
Figure 6
Switch must be pulled out to the “ROTATE”
position to engage the blades. Switch is pushed in to
the “STOP” position to stop the blades.
1. LCD Indicators
2. Low voltage indicator light
3. Hour/Voltage display
The LCD indicator will appear when the PTO switch
is disengaged (see Figure 6).
The hour meter is recording when the decimal point
is flashing in Hour/Voltage display.
Low Voltage Indicator
Hours are displayed when the key is off or when the
machine is running.
Located on the center console in the message display
(see Figure 6).
Note: If the ignition key is turned to the “ON”
position for a few seconds before cranking the
engine, the battery voltage will display in the area
where the hours are normally displayed.
A low voltage condition (less than 12.3 volts) exists
when the low voltage indicator light appears on the
message display while the engine is running.
If the ignition key is turned to the “ON” position for
a few seconds before cranking the engine, the battery
voltage will display in the area where the hours are
normally displayed.
Note: The LCD indicators appear when each
control meets the “safe to start” mode (e.g. the
indicator turns on when the operator is in the seat.)
Note: The indicator normally appears when the
engine is off and the key switch is turned to the
“ON” position.
Note: This switch is not a low oil sensor and will not
alert the operator if the engine oil is low.
Fuel Shut-Off Valve
Pre-Start
The valve is located in the fuel line midway between
the fuel tank and the engine behind the seat.
Fill fuel tank on level ground. For best results use
only clean, fresh regular grade unleaded gasoline with
an octane rating of 87 or higher.
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.
Important: Never use methanol, gasoline
containing methanol, gasohol containing more
than 10% ethanol, premium gasoline, or white
gas because the fuel system could be damaged.
Rotate the valve 1/4 turn clockwise to shut off fuel.
Rotate the valve 1/4 turn counterclockwise to turn
on fuel.
Do Not add oil to gasoline.
Do Not overfill fuel tank. Fill the fuel tank to the
bottom of the filler neck. The empty space in the
tank allows gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or emission
system (if equipped).
Drive Wheel Release Levers
Located at the rear of the mainframe.
17
Operation
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Engaging the PTO
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
The rotating blades under the mower deck are
dangerous. Blade contact can cause serious
injury or kill you.
Operating Instructions
Do Not put hands or feet under the mower or
mower deck when the blades are engaged.
DANGER
Open the Fuel Shut-Off Valve
DANGER
Rotate the valve 1/4 turn counterclockwise to turn
on fuel.
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.
Starting the Engine
1. Move the motion control levers out to the neutral
lock position.
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.
2. Pull up and back on the parking brake lever to
engage the parking brake.
3. Push in on the PTO switch to the “STOP”
position.
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.
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.
Important: Operator must be in seat before the
PTO can be engaged.
1. Set the throttle to the “MIDWAY” position.
2. Pull the PTO switch outward to the “ROTATE”
position.
3. Place the throttle in the “FAST” position to begin
mowing.
5. On a cold engine, push the choke lever forward
into the “ON” position.
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.
Disengaging the PTO
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.
1. Set the throttle to the “MIDWAY” position.
2. Push the PTO switch in to the “STOP” position
to disengage the blades.
Stopping the Engine
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. Disengage the PTO.
3. Move the motion control levers out to the neutral
lock position.
4. Engage the parking brake.
5. Place the throttle midway between the “SLOW”
and “FAST” positions.
18
Operation
6. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
8. Close the fuel shut-off valve when the machine
will not be in use for a few days, when
transporting, or when the unit is parked inside
a building.
Driving the Machine
CAUTION
Figure 7
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.
1. Handles Out (Neutral
Lock)
2. Handles In (Neutral)
3. Front of Unit
4. Forward
5. Neutral
6. Reverse
7. Neutral Lock
• Use caution when making turns.
• Slow the machine down before making sharp
turns.
Driving Forward
1. Release the parking brake.
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.
2. Move the motion control levers inward to the
center to the neutral unlocked position.
3. To move forward in a straight line apply equal
forward pressure to both levers.
To turn left or right, pull the motion control lever
back toward neutral in the direction desired.
When levers are centered in the T-slot the drive
system is in the neutral position. With levers moved
out in the T-slot the drive system is in the neutral lock
position (Figure 7).
The machine will move faster the farther the
motion control levers are moved away from
neutral.
Note: The “N” LCD indicator appears when both
levers are in the neutral lock position.
4. To stop, pull the motion control levers back to
the neutral position.
19
Operation
The deck can be raised by pushing down on the
foot operated deck lift assist lever 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 9
1. Transport position and 5 inch (12.7 cm) cutting height
position
Figure 8
1. Handles Out (Neutral
Lock)
2. Handles In (Neutral)
3. Front of Unit
4. Insert the height adjustment pin into the hole
corresponding to the desired cutting height and
install the hairpin cotter pin.
4. Forward
5. Reverse
See the decal on the side of the deck lift plate for
cut heights.
1. Move the motion control levers inward to the
center to the neutral unlocked position.
5. Move the deck height lever out of the transport
position (or 5 inch (12.7 cm) cutting height) and
down onto the height adjustment pin to mow at
selected height.
2. To move rearward in a straight line applying equal
pressure pull both motion control levers rearward.
6. To transport, move lever back up to transport (or
5 inch (12.7 cm) cutting height) position.
Driving in Reverse
To turn left or right, release pressure on the
motion control lever toward the direction desired.
Transporting
3. To stop, push the motion control levers to the
neutral position.
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.
Adjusting the Cutting Height
The cutting height of the mower deck is adjusted
from 1 inch to 5 inches (2.5 cm to 12.7 cm) in 1/4
inch (6.4 mm) increments.
1. Stop the machine and move the motion control
levers outward to the neutral locked position.
2. Disengage the PTO.
3. Raise the deck height lever to the transport
position (also the 5 inch (12.7 cm) cutting height
position)(Figure 9).
20
Operation
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.
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.
Loading a Unit
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for each side of the unit. The
lower rear section of the tractor frame extends back
between the rear wheels and serves as a stop for
tipping backward. Having a full width ramp provides
a surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck Do Not exceed 15°. A steeper
21
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 250 hours
• Change the hydraulic filter.
Before each use or daily
•
•
•
•
•
•
Check the engine oil level.
Check the mower blades.
Check the safety interlock system.
Check for loose hardware.
Clean the engine air cooling system.
Clean the grass build-up from under the deck.
Every 25 hours
• Grease the belt idlers.
Every 40 hours
•
•
•
•
Every 50 hours
• Service the air cleaner. (May need more often under severe conditions. See the Engine
Owner’s Manual for additional information.)
Every 80 hours
• Remove engine shrouds and clean cooling fins.
Every 100 hours
• Change the engine oil. (May need more often under severe conditions.)
Every 160 hours
• Grease the brake handle pivot.
• Check the spark plugs.
Every 500 hours
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)
Monthly
Yearly
Check the hydraulic oil level.
Check the tire pressures.
Check the condition of the belts.
Grease the deck pivots.
• Check the battery charge.
• Grease the front caster wheel bearings.
• Grease front caster pivots.
• Lubricate the caster wheel hubs.
22
Maintenance
Periodic Maintenance
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).
Check Engine Oil Level
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. Clean area around dipstick. Remove dipstick and
wipe oil off. Reinsert the dipstick. Screw into
place. 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. Use oil as specified in
Engine Owner’s Manual. Do Not overfill.
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Check Battery Charge
Service Interval: Monthly
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
12.0–12.2
25–50%
14.4 volts/4 2 Hours
amps
11.7–12.0
0–25%
14.4 volts/4 3 Hours
amps
11.7 or less
0%
14.4 volts/2 6 Hours or
More
amps
Recommended Jump
Starting Procedure
WARNING
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.
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.
CAUTION
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
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.
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.
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.
Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the battery in
the table and charge the battery for the recommended
time interval to bring the charge up to a full charge
of 12.6 volts or greater.
Do Not jump start a weak battery if these
conditions exist.
23
Maintenance
2. Make sure the booster is a good and fully charged
lead acid battery at 12.6 volts or greater. Use
properly sized jumper cables (4 to 6 AWG) with
short lengths to reduce voltage drop between
systems. Make sure the cables are color coded or
labeled for the correct polarity.
CAUTION
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
Figure 10
1.
2.
3.
4.
5.
6.
7.
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
Note: The following instructions are adapted
from the SAE J1494 Rev. Dec. 2001 – Battery
Booster Cables – Surface Vehicle Recommended
Practice (SAE – Society of Automotive
Engineers).
Positive (+) cable on discharged battery
Positive (+) cable on booster battery
Negative (–) cable on the booster battery
Negative (–) cable on the engine block
Booster battery
Discharged battery
Engine block
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
6. MAKE THE FINAL CONNECTION ON
THE ENGINE BLOCK OF THE STALLED
VEHICLE (NOT TO THE 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.
• Shield the eyes and face from the batteries
at all times.
• Do Not lean over the batteries.
Note: Be sure the vent caps are tight and level.
Place a damp cloth, if available, over any vent
caps on both batteries. Be sure the vehicles do
not touch and that both electrical systems are
off and at the same rated system voltage. These
instructions are for negative ground systems only.
Check Mower Blades
Service Interval: Before each use or daily
Important: Mower blades are sharp. Wrap the
blade or wear gloves, and use extra caution when
servicing them.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lift deck and secure in raised position as stated in
the Clean Grass Build-Up Under Deck section.
3. Inspect blades and sharpen or replace as required.
4. Install blade bolt and spring disc washer. Be sure
the spring disc washer cone is installed towards
the bolt head. Place a block of wood between
front or rear baffles and the blade then torque
the blade bolts to 115–120 ft-lb (156–163 N-m)
(Figure 11).
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 10.
24
Maintenance
levers in the neutral lock position - starter must
not crank.
Try to start with operator in seat, parking brake
engaged, PTO engaged and motion control
levers in the neutral lock position - starter must
not crank.
Try to start with operator in seat, parking
brake engaged, PTO disengaged, and the left
motion control lever in, starter must not crank,
repeat again with the right lever in, then with
both levers in - starter must not crank.
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).
Figure 11
1. Do Not use wrench here for blade installation. Maintain
140–145 ft-lb (190–197 N-m)
2. Use 1 inch wrench here to hold spindle for blade
replacement.
3. Cone towards bolt head
4. Torque to 115–120 ft-lb (156–163 N-m)
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
1/2 second has elapsed.
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.
Repeat again moving the right lever in, then
moving both levers in - engine must initiate
shutdown whether operator is on seat or not.
Always install the original Exmark blades,
spring disc washers, and blade bolts as
shown.
Note: If machine does not pass any of these tests,
Do Not operate. Contact your authorized EXMARK
SERVICE DEALER.
Check Safety Interlock
System
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
Service Interval: Before each use or daily
Note: To prevent engine cut-outs on rough terrain
the seat kill switch has a 1/2 second delay.
Check for Loose Hardware
1. Check starting circuit. Starter should crank with,
parking brake engaged, PTO disengaged and
motion control levers moved out in the neutral
lock position. The operator does not need to be
in the seat to start the engine.
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.
Try to start with operator in seat, parking brake
disengaged, PTO disengaged and motion control
25
Maintenance
Service Air Cleaner
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Allow engine to cool.
Service Interval: Every 50 hours—Service
the air cleaner. (May
need more often under
severe conditions. See
the Engine Owner’s
Manual for additional
information.)
2. Clean area around hydraulic expansion reservoir.
Oil level should be at the FULL COLD line on
expansion reservoir. If not, add oil. Use only
Exmark Premium Hydro oil. Replace hydraulic
reservoir cap and tighten until snug. Do Not
overtighten. Do Not overfill.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Check Tire Pressures
2. See Engine Owner’s Manual for cleaning
instructions.
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Change Engine Oil
2. Check tire pressure in drive tires.
Service Interval: After the first 5 hours
3. Inflate drive tires to 13 psi (90 kPa).
Every 100 hours/Yearly
(whichever comes first)
(May need more often
under severe conditions.)
4. Semi-pneumatic caster tires do not need to be
inflated.
Note: Do Not add any type of tire liner or foam
fill material to the tires. Excessive loads created by
foam filled tires may cause failures to the hydro drive
system, frame, and other components. Foam filling
tires will void the warranty.
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 is located on right hand side of
engine. Place pan under machine to catch oil. Fit
hose in literature pack over oil drain valve. Rotate
valve 1/4 turn counterclockwise and gently pull
outward to open valve. Allow oil to drain, then
close valve by pushing inward and rotating 1/4
turn clockwise. Remove and retain the hose for
future use.
Check Condition Of Belts
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check under engine deck to check pump drive
belt.
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 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.
3. Remove left and right belt shields on deck and lift
up floor pan to inspect deck drive belt.
4. For belt adjustment, see the Pump Drive Belt
and Deck Belt Tension Adjustment sections.
5. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
6. Use oil recommended in engine owner’s manual.
Do Not overfill. Start the engine and check for
leaks. Stop engine and recheck oil level.
Check Hydraulic Oil Level
Service Interval: Every 40 hours
26
Maintenance
Lubricate Grease Fittings
pump with grease until it oozes out around top
bearing. Remove grease zerk and thread plug back
in. Place cap back on.
Note: See chart for service intervals.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lubricate fittings with one to two pumps of
NGLI grade #2 multi-purpose gun grease.
Lubricate Caster Wheel Hubs
Service Interval: Yearly
Refer to the following chart for fitting locations
and lubrication schedule.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Lubrication Chart
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
1. Belt
Idlers
1
2
25 Hours
2. Deck
Pivots
1
4
40 Hours
3. Front
Caster
Wheel
Bearings
*0
2
*Yearly
4. Front
Caster
Pivots
*0
5. Brake
Handle
Pivot
1
Figure 12
1. Seal guard
2
*Yearly
2. Spacer nut with wrench
flats
2. Remove caster wheel from caster forks.
1
160 Hours
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.
* See step 3 for special lubrication instructions on
the front caster pivots and the Lubricate Caster
Wheel Hubs section for special lubrication
instructions on the front casters wheel hubs.
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.
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.
3. Lubricate front caster pivots once a year. Remove
hex plug and cap. Thread grease zerk in hole and
27
Maintenance
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
Change Hydraulic System
Filter
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.
Service Interval: After the first 250 hours
Every 500 hours/Yearly
(whichever comes
first) thereafter
(Every 250 hours/Yearly if
using Mobil 1 15W50)
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.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Locate the two filters under the transmissions.
Remove filter guards.
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.
3. Carefully clean area around filters. It is important
that no dirt or contamination enter hydraulic
system.
14. Reinstall the seal guards over the wheel hub and
insert wheel into caster fork. Reinstall caster bolt
and tighten nut fully.
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 filter,
apply a thin coat of Exmark Premium Hydro
oil on the surface of the rubber seal.
Turn the filters clockwise until rubber seal
contacts the filter adapter then tighten the filter
an additional 1/2 to 3/4 turn.
5. Remove the vent plug on each transmission and
fill through expansion reservoir, when oil comes
out of vent reinstall plug. Torque plugs to 180
in-lbs (20 N-m).
Check Spark Plugs
Service Interval: Every 160 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 tanks and the
engine. Replace when necessary.
Replacement Filters
Kawasaki
Kawasaki P/N
49019–7001
Figure 13
Left Side Shown
1. Left rear tire
2. Oil filter
28
3. Vent plug
Maintenance
Fuel Tank — Mounting
Hardware Specifications
6. Add oil until it reaches the FULL COLD line on
the expansion reservoir.
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
Service Interval: As required
When installing the nuts on the fuel tank studs, fully
tighten the nyloc nut and back off 1/2 turn. This
allows for normal fuel tank expansion and contraction
with changes in temperature and fuel levels.
Thread Locking Adhesives
7. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
CAUTION
• Clutch retaining bolt in the end of engine
crankshaft.
Raising the mower for service or maintenance
relying solely on mechanical or hydraulic
jacks could be dangerous. The mechanical or
hydraulic jacks may not be enough support
or may malfunction allowing the unit to fall,
which could cause injury.
• Caster wheel spacer nuts.
• Cutter housing spindle nut.
Adhesives such as “Loctite RC/609 or RC/680” or
“Fel-Pro Pro-Lock Retaining I or Retaining II” are
used on the following:
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Fuel tank studs, where studs are inserted into tank.
8. Start engine and move throttle control ahead to
1/2 throttle position. Disengage parking brake.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
A. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse (5 or 6 times).
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
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).
• Between the cutter housing spindle and bearings.
• Between the cutter housing spindle and sheave.
• Under top cutter housing bearing guard.
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.
Dielectric Grease
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
Note: Do Not change hydraulic system oil (except
for what can be drained when changing filter), unless
it is felt the oil has been contaminated or been
extremely hot.
Changing oil unnecessarily could damage hydraulic
system by introducing contaminates into the system.
29
Maintenance
Adjustments
Motion Control Linkage
Adjustment
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.
Note: There are two lever height options available.
Place the levers in the top two holes to increase
height of the levers, or in the bottom two holes to
decrease the height of the levers.
Deck Leveling
1. Align the levers front/rear position. With the
levers in the neutral position, loosen the hardware
and adjust the levers sliding and/or tilting the
lever(s) forward or backward until properly
aligned and tighten hardware (Figure 14).
1. Position mower on a flat surface.
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
3. Check tire pressure in drive tires. Proper inflation
pressure for tires is 13 psi (90 kPa). Adjust if
necessary. Semi-pneumatic caster tires Do Not
need to be inflated.
4. Set anti-scalp rollers to top holes (if installed) or
remove them completely for this adjustment.
5. Lower the deck to the 1 1/2 inch (3.8 cm) height
position. Place two 1 1/8 inch (2.9 cm) thick
blocks under the rear edge of the cutting deck
skirt; one on each side of the cutting deck.
6. Place a 1 inch (2.5 cm) block under the center
front edge, but not under the anti-scalp roller
brackets.
7. Loosen the four bottom chain bolts in slots until
the deck is supported by the blocks. Take the
slack out of the chains and retighten the hardware.
8. Recheck that blocks fit just snugly under the
deck skirt and that the tension on all the chains
is approximately equal. Make sure all chain
attachment bolts are tight.
9. Reposition anti-scalp rollers (if installed) and
tighten securely.
Figure 14
1. Motion control levers
2. Spring disc washer
3. 3/8-16 x 1 inch screw
2. If the ends of the levers hit against each other,
while in the drive position (levers rotated in as
far as possible), make adjustments by moving the
levers outwards to the neutral lock position and
carefully bending them outward. Move them back
to the drive position and check for clearance.
Repeat if necessary.
Note: When above adjustments have been made,
the front of the deck will be slightly lower than the
rear of the deck.
3. If the machine turns right or left when handles are
pushed forward together, adjust the stop on the
side opposite the direction of turn (see Figure 15).
Move the stop back until the unit drives straight.
Readjust handles if necessary.
Pump Drive Belt Tension
Self-tensioning - No adjustment necessary.
Deck Drive Belt Tension
Self-tensioning – No adjustment necessary.
Electric Clutch Adjustment
No adjustment necessary.
30
Maintenance
Cleaning
Clean Engine Air Cooling
System
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
CAUTION
Excessive debris can cause the engine and
hydraulic system to overheat which can create
a fire hazard.
Figure 15
1. Adjust stop
Clean all debris from around the engine and
hydraulic pumps daily.
Adjust Throttle Lever
Tension
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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 and from around engine shrouding.
2. Tension in throttle lever can be adjusted by
adjusting the tightness of the lever pivot bolt,
which is located under the console (Figure 16).
Remove Engine Shrouds and
Clean Cooling Fins
Service Interval: Every 80 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove cooling shrouds from engine and clean
cooling fins. Also clean dust, dirt and oil from
external surfaces of engine, which can cause
improper cooling.
Figure 16
1.
2.
3.
4.
Hex bolt
Spring disc washers
Tab washer
Friction washer
3. Make sure cooling shrouds are properly
reinstalled. Operating the engine without
cooling shrouds will cause engine damage due to
overheating.
5. Lever
6. Bracket
7. Hex locknut
Clean Grass Build-Up Under
Deck
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
31
Maintenance
2. Raise deck to the transport (maximum cutting
height) position. Lift the front of unit and support
unit using jack stands or equivalent support.
3. Clean out any grass build-up from underside of
deck and in discharge chute.
Waste Disposal
Motor Oil Disposal
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
recycling center or according to your state and local
regulations.
Battery Disposal
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.
32
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.
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.
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.
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shutoff valve is closed.
3. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. 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.
4. Replace the fuel filter.
5. Contact an Authorized Service Dealer.
5. Electrical connections are corroded, loose
or faulty.
Engine will not start, starts hard, or fails to
keep running
4. Dirt in fuel filter.
5. Dirt, water, or stale fuel is in the fuel
system.
6. Air cleaner is dirty.
7. Seat switch is not properly adjusted.
8. Electrical connections are corroded, loose
or faulty.
9. Relay or switch is defective.
10. Faulty spark plug.
11. Spark plug wire is not connected.
Engine loses power
Corrective Action
6. Clean or replace the air cleaner element.
7. Adjust the seat switch.
8. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
9. Contact an Authorized Service Dealer.
10. Clean, adjust or replace spark plug.
11. Check the spark plug wire connection.
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. Vent hole in the fuel cap is plugged.
6. Dirt in fuel filter.
7. 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. Clean or replace the fuel cap.
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
33
Troubleshooting
Problem
Engine overheats
Possible Cause
Corrective Action
1. Engine load is excessive
1. Reduce the ground speed.
2. Oil level in the crankcase is low.
3. Cooling fins and air passages for the
engine are plugged.
2. Add oil to the crankcase.
3. Remove the obstructions from the cooling
fins and air passages.
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.
2. Motion control stops need adjustment.
2. Adjust the motion control stops.
Machine does not drive
1. Drive wheel release is not closed.
1. Close the drive wheel release.
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.
7. Belt is damaged.
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.
7. Install new belt.
1. Drive belt is worn, loose or broken.
1. Check the belt tension.
2. Drive belt is off pulley.
2. Check belt for damage; replace if
necessary. Install drive belt and check
adjusting shafts and belt guides for correct
position.
3. Install new deck belt.
4. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
5. Replace the spring.
6. Contact an Authorized Service Dealer.
3. Deck belt is worn, loose or broken.
4. Deck belt is off pulley.
5. Broken or missing idler spring.
6. PTO clutch does not engage.
34
Schematics
Schematics
Electrical Diagram
35
Schematics
Electrical Logic Schematic
36
Exmark Commercial Turf Equipment
2 Year Limited Warranty
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
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 for a period of two years.
This warranty applies to Exmark commercial turf equipment
sold in the U.S. or Canada. This warranty may only be
assigned or transferred to a second (or third) owner by an
authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.
Warranty Exceptions
Warranty Period
• Bags, Belts and Tires
90 days
• Battery
1 Year Prorated
• Engine
2 years*
* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.
This warranty only includes the cost of parts and labor.
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.
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.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized
Exmark Service Dealer.
• Any damage or deterioration due to normal use, wear and
tear, or exposure.
• 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.
All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charges relating to repairs or
replacements outside of normal business hours at the place
of business of the authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the
period of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that
covered by the terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
• Attorney's fees.
No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.
Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
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.
G4500-589_B
37
38
G011841
Figure 17
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.
39
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.
©2010 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-488 Rev. C
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com