Exmark Viking Hydro User's Manual

 For Serial Nos.
®
MFG. CO. INC.
VIKING HYDRO
Operators Manual
% N
: ; E
E
AA WARNING
FAILURE TO FOLLOW CAUTIOUS
OPERATING PRACTICES CAN RESULT IN
SERIOUS CPERATOR INJURY.
4A CAUTION
1. Keep all shields, guards and safety
devices (especially grass discharge
system) in place and in proper
working condition.
2. Stop engine and remove spark
plug wire(s) or remove key before
adjusting, servicing, or preforming
maintenance.
3. When mower deck becomes clogged,
stop engine and remove spark plug
wire(s) or remove key before cleaning
biockage.
4. Keep hands, feet, and clothing away
from power-dnven parts.
5. Keep off mower unless seat or
platform is provided.
6. Keep others off mower.
A WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
A HEALTH WARNING
GASOLINE
Harmful or fatal if swallowed.
Long-term exposure to vapors has
caused cancer in laboratory animals,
+ Avoid prolonged breathing of vapors.
- Keep face away from nozzle and gas
tankicontainer opening.
‚Keep away from eyes and skin.
* Never siphon by mouth.
Failure to use caution may cause
serious injury or illness,
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.
il
EXMARK PARTS PLUS® PROGRAM
EFFECTIVE DATE: September 1, 1995
Program
If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or the
part will be FREE* Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at
the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus® shipment of six (6) line items or less.
2. Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS Distributor
bills dealer for part and freight charges where applicable.
3. If distributor does not have the part(s) in stock to satisfy —
Exmark Parts Plus? order, he contacts Exmark by 3:00 p.m., central time, with an Exmark Parts Plus® order of six (6)
line items or less.
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus® and if it arrive in accordance
to the program.
6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
1. The dealer not submitting the Exmark Parts Plus® order to his Exmark distributor by 1:00 p.m, the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus® order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. if the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply -- The Exmark Parts Plus? Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. UPS has initiated a Saturday
delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to
be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser.
Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be
received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts
Plus® Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless
transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and erigine decks or any item
exceeding United Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or
Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
iil
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.
OPERATOR'S MANUAL
This manual contains assembly, operating, maintenance, adjustment
and safety instructions for your Exmark mower.
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
By following the operating, maintenance and safety instructions,
you will prolong the life of your mower, maintain its maximum
efficiency and promote safe operation.
If additional information is needed, or should you require
trained mechanic service, contact your authorized Exmark equipment
dealer or distributor.
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.
If you need to order replacement parts from your dealer, always
give the model number and serial number of your mower as well as the
quantity, part number and description of the part needed.
The serial number plate of the tractor is located on the top
front engine frame on the right hand side of the machine. We suggest
you record the numbers below for ready reference.
Model No. PASTE LABEL FROM
OR LITERATURE PACKET HERE
Serial No.
Date Purchased
Purchased From
Ww
*
TABLE OF CONTENTS
SAFETY .....4.+.. 40.440644 0 +10 au 000 a =: 5 + # + . » PAGE
1.1 Safety Alert Symbol ..... i i i i eee aaa, 1
1.2 Тха1п109 0 0 a 4 a aa 0 0 ea a 0 a 1e a a ee 0010 0 1
1.3 Preparation ........8280 00000 ue 0e 0e ea 0 0 0 0 0 0 1 0 0 ee 0 0 0 00 0 1
1.4 Operation ........2.041000 0000000 ee 0 ee es 0 0 0 0 ee 0 000 0 2 -
1.5 Maintenance & Storage ...........402 04005406 000000 4 - 5
1.6 Riding Attachments ........... a a 0 0 4 0 a 0 0 0 8 00 0 eee 5
1.7 Safety Signs.........400 00000000 KR RK 5-7
SPECIFICATIONS
2.1 Model Number ...........4444 4050000 50 0 0 1 0 0 80 0 0 80 1 0 0 0» 8
2.2 Engine......e_orecodoorcoccororrraredrderanacodardaoaornao es 8
2.3 Fuel System... iii iii i i 0 0 0 te eee 8
2.4 Safety Interlock System......... a aaaananaaaararedraroao 8
2.5 Steering/Brake Control.......ooeeocemoeoreeoereroreeraoo 8
2.6 Transmission .,...orocsxeccsosxerroroeoerorororoovarororarreorormo 8
2.7 Wheel Drive SysteM....._ooeoroosrrornrerdoooorarorcorreareo 8
2.8 Tires.....ieereaarmoendorecedororreamoraoorarncocaaaoororeoocaeo 8
2.9 DeckK...Q.eoceorerororevorrrrorrorrcaorersorervorevarreatroro o 3
2.10 Dimensions ......2444 200440 044 0e 3 03 0 0 0 1 0 1e 0e 0 0 1 0 00 0 0 0 0 9
2.11 Torque Requirements ........oeesxeeneeorosararareroeeo 10
ASSEMBLY INSTRUCTIONS
3.1 to 3.23 Assembly .....oesreonorororeooooaroraooo 10 - 14
OPERATION INSTRUCTIONS
4.1 Controls ....e._e.c_osarrooooasosrorvrorvroeresoodeoreco 15 - 17
4.2 Pre-Start .......+.+.50 00000000 008100 00 0 0 0 0 60 010000000000 17
4.3 Operation Instructions ......oe.eeceerevcorerrorooo 17 - 19
4.4 Transporting..........008000 000000000000 0000000800 00m 19
MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance ..........+4+5 500000080000 0 20 - 27
5.2 KAdjustments ......000000 0000 4 1 a 000 0 0 0 0 0 0 0 0 0 a 0006 27 - 36
TROUBLE SHOOTING
6.1 Mower Tacks Left or Right ....... cine. 36
6.2 Mower Cuts Unevenly ..... viii 01000 0 0 0 00 0 011 0 00000 0 36
6.3 Blades Do Not Stop When Disengaged.................. 36
6.4 Engine Will Not Start .......... cine. 37 - 38
WIRING DIAGRAM ......o.o.eoerrvcorerdoooaeaoedrerderdaaeaeo 39
НУОБАОЪЬТС РОТАСКАМ .................................... 40
WARRANTY .....wosrrexewdrscorercerorcocaeonooooraramoonmo 41 - 42
1.
SAFETY
1.1 SAFETY ALERT SYMBOL
THIS SAFETY ALERT SYMBOL A 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!
The safety alert symbol appears above information which alerts
you of unsafe actions or situations and will be followed by the
word DANGER, WARNING, or CAUTION.
When used with the word DANGER: IT DENOTES THAT AN EXTREME HAZARD
EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR
IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
When used with the word WARNING: IT DENOTES THAT A HAZARD EXISTS
WHICH CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT
TAKEN.
When used with the word CAUTION: IT DENOTES A REMINDER OF SAFETY
PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH CQULD
RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipment and
teach this regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself
with the controls and the proper use of the equipment.
1.2.3 Never allow children, teenagers, or people unfamiliar
with these instructions to use the mower.
1.2.4 Avoid mowing while people, especially children or pets,
are nearby. Keep in mind that the operator or user is
responsible for accidents or hazards occurring to other
people or their property.
1.3 PREPARATION
1.3.1 The use of personal protective equipment, such as (but not
limited to) protection for the eyes, ears, feet and head
is recommended.
1.3.2 While mowing, always wear substantial footwear and long
trousers. Do not operate equipment when barefoot or when
wearing open sandals.
1.3.3 Thoroughly inspect the area where the equipment is to be
used and remove all stones, sticks, wires, bones and
other foreign objects which may damage the equipment or
cause personal injury to the operator or bystanders.
1.4 OPERATION
ÁN WARNING
a Fuel is Highly Flammable. DO NOT smoke
while refueling. Refuel only in a well
ventilated area, or refuel outdoors.
= Store fuel in containers specifically
designed for this purpose.
e 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.
e 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.
Give complete, undivided attention to the job at hand.
Mow only in daylight or good artificial light. Do Not
operate the mower when children or others are in the area!
When feasible, avoid operating the equipment in wet grass.
Use EXTREME caution when mowing and/or turning on slopes as loss
of traction and/or control could occur. Mow across slopes with
walk behind mowers, never up and down. Loss of control and/or
loss of operator's footing could result in a fall with an armor
leg getting under the mower or engine deck and sustaining serious
injury. Drive slower on slopes. DO NOT operate on slopes
greater than 20 degrees. Watch for ditches, holes, rocks, dips,
and rises which can cause erratic handlebar movement and loss of
footing. Keep away from drop-offs and steep banks. Avoid sudden
starts. Look down and behind you before and while moving
backwards. DO NOT mow slopes when grass is wet - slippery
conditions create hazardous footing, affect steering, and reduce
traction and braking. The operator is responsible for safe
operation on slopes.
Stop the blades when crossing surfaces other than grass; and
when transporting the mower to and from the area to be mowed.
Never operate the mower with defective guards, shields,
or covers. Always have safety shields, guards, switches, and
other devices in place and in proper working condition.
Do Not change the engine governor settings or over speed.
the engine. Operating an engine at excessive speed may
increase the hazard of personal injury.
Place transmission in neutral, disengage blade drive before
starting engine
Start the engine carefully with feet well away from the
blades.
Keep hands, feet and clothing away from rotating parts
while the mower is being operated.
. 7.
1.4.11 Stop the engine and remove plug wire(s) or ignition key:
1.4.12
*e Before checking, cleaning or working on the mower.
e After striking a foreign object (inspect the mower
for damage and make repairs before restarting and
operating the mower).
Stop the engine:
e Before clearing blockages.
¢ Whenever you leave the mower.
*e Before removing the grass catcher.
e Before refueling.
e Before making height adjustments.
Before stopping the engine, return the throttle control
to the idle position for 30 seconds to allow the engine
to cool down.
The fuel system is provided with a shut-off valve. The
fuel shut-off valve is used to shut off the fuel when:
e The machine will not be used for a few days.
e During transport to and from the job.
* When parking inside a building.
This mower was designed for one operator only. Keep all
others away from mower during operation.
Do Not mow without the grass deflector or entire grass
collection system in place and in proper working
condition.
ÁN DANGER
» DO NOT operate the engine in a small
confined area where dangerous carbon
monoxide fumes can collect.
ÁNCAUTION
о Failure to follow safety instructions
and cautious operating practices can
result in serious injury.
ÁN CAUTION
+ Although hazard control and accident
prevention partially are dependent upon the
design and configuration of the equipment, these
factors are also dependent upon the awareness,
concern, prudence and proper training of the
personnel involved in the operation, transport,
maintenance and storage of the equipment. It is
essential that all Operator Safety Mechanisms be
connected and in operating condition prior to use
for mowing.
1.5 MAINTENANCE AND STORAGE
1.
5.
1
.10
.11
For engine maintenance, follow the engine manufacture's
recommendations precisely as stated in the engine manual.
If carburetor adjustment is necessary, stand to one side
and keep feet and hands clear while making adjustments.
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.
Store fuel in a container specifically designed for this
purpose in a cool, dry place.
Keep the mower and fuel container in locked storage to
prevent children from playing or tampering with them.
Casoline powered equipment or fuel containers should not
be stored in a basement or any enclosed area, where open
pilot lights or heat appliances are present.
Maximum mowing results and safety can only be achieved if
the mower is properly maintained and operated correctly.
Check all bolts frequently to maintain proper tightness.
Keep all guards, shields and all safety devices in place
and in safe working condition.
Frequently check for worn or deteriorating components
that could create a hazard.
All replacement parts must be the same as or equivalent
to the parts supplied as original equipment.
4\ CAUTION
e 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.
A\ CAUTION
« Hydraulic fluid escaping under pressure
may have sufficient force to penetrate
skin and cause serious injury. If foreign
fluid is injected into the skin, it must
be surgically removed within a few hours
by a doctor familiar with this type of
injury or gangrene may result.
ÁN CAUTION
+= Keep body and hands away from pin holes
or nozzles that eject hydraulic £luid
fluid under high pressure. Use paper or
cardboard, NOT HANDS to search for leaks.
ÁNCAUTION
о Safely relieve all pressure in the hydraulic
system before disconnecting lines or before
performing any work on the hydraulic system.
1.6 RIDING ATTACHMENTS
1
A GAUTION | Part No.
‚6.1
Use only Exmark riding attachments. The use of other than
Exmark riding attachments may create a hazardous condition
resulting in injury.
SAFETY SIGNS
«7,1
Keep all safety signs legible. Remove all grease, dirt
and debris from safety signs.
Safety signs must be replaced if they are missing or
illegible.
When new components are installed, be sure that current
safety signs are affixed to the replaced components.
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 bv 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.
АСАУТЮМ
AA
513746
MUFFLER AND Part No. ALLOW ENGINE
SHIELDS MAY 303293 MINUTES BEFORE
EXCEED 150 F '
313746 REFUELING )
LOCATION: On Engine Blower Housing LOCATION: On Top Right Side
Next to Muffler. of Fuel Tank
| a Part No.
DRIVE WHEEL RELEASE ar . | Part No.
LOCK
|
DO NOT OVER-TIGHTEN
OA |
SEZNAS 4
LOCATION: Upper Handle
LOCATION: Rear Center of Engine Deck
Part No.
403120
Part No.
323141
323141
LOCATION: Upper Handle Console
Part No.
403143
HYDRAULIC OL RESERYOR
USE ONLY MOBL 1 SAE 15SW-50
SYNTHETIC ENGINE OL : Part No.
513890
FEL TO TOP OF EAFFLE
LOCATION: On Top of Hydraulic Tank
DANGER
| KEEP HANDS and FEET AWAY
Part No.
403005
LOCATION: Front Corner (s)
of Mower Deck
am LOCATION: On Switch Bracket at Front
Doo Left of Fuel Tank Support
(16 hp B£S only)
LOCATION: Upper Handle
Part No.
613169
(= TU <)
y
f AWARNING |
Use Only Exmark Riding
Attachments. Use of Other
Riding Attachments May
Create a Hazardous Condition
Resulting in Injury. 103:43);
``
LOCATION: Rear Surface
on Engine Deck
(543631 ÓN
(a N : © y
CHOKE
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y
R SLOW
e |
Of |=
~~
(>) SLOW J
|| er) THROTTLE
N \
Kawasaki and Kohler Briggs & Straton
Part No. Part No.
323151 543631
LOCATION: Upper Handle Console
A WARNING
b/s. | OPEN BELT DRIVE!
Mo) STOP ENGINE BEFORE
AC REACHING UNDERNEATH
LOCATION:
LOCATION: On Top Rear Right Hand
Part No,
303517
on Engine Deck
NN
f ADANGER
e USE EXTRSME CAUTION YEN [PERATING DN SLOPES
eo KEY ACI SUE - KYR LP AO DON
< DO NOT OFSRATE ON SLOPES GREATER THAN 20°
e YATCH FOR DITOES, MOLES, ROCXS, RISES, OIPS
e KE7 МАТ РКМ RIPFES AE Si BANG
e LIX EN) YOU CRE BACKING 323525
e [RIVE SLVR ON SLOPES
e PENE TAS SLOWLY
« 00 AT KY VET SPSS
« AVDID SCORN STARTS x
. , Ann 2
AY y Ve
e KEEP ALL PEPLE QUT OF AREA VEN СК
o THROW E.ECTS (R BLADE CONTACT CAN CAL:
SERIOS INLKY CR DEATH
» (0 NOT OPERATE IN
AN ENCLOSED AREA
| SE e ENGINES PRODUCE CARSON
13 КОТО YHICH TS AN ) part No.
NN MOR ESS ПЕД. РОТ 323525
LOCATION:
Upper Handle Console
( EGIXÉ 1
SENE LUE RIVE
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| |
| os
Part No. LOCATION: 36” DECK
323427
Surface of Mower Deck
Part No, DO NOT OPERATE WITHOUT
DISCHARGE DEFLECTOR OR
303508 ENTIRE GRASS COLLECTION
Left Side of Rear Surface
Part No.
323232
\.
3 LUTION DN SLOPES
nm bo NOT PARK Da LOPES УВЕ эн S
ARE DEALS,
SYSTEM IN PLACE, DO NOT
REMOYE GRASS CATCHER UXTIL
BLADES KAYE STOPPED.
A CAUTION
1 READ ET ALE BLEONE SPC ATEO,
3. CLEAR ARA eS FLL PETS Ant Dias
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1 BEFORE STARTING [WGINE?
= VIDA WT BE DISEWZACED,
E. TA AwSb $ $10 YET EL Br NEUTRAL,
6. PLASE LIFT and MGR DRIVE LIVERS
“E Ta Toa PORTION USING
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6. TT DEF Ciega
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L BC NOT OPERATE NEWER DESI (w.FL5 ENTE
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& VIE Ca
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LOCATION: Upper Handle Console
Part No.
413214
(TRACKING LIC) Rm)
403139
LOCATION: Right Side of
Hydro Control
Crank Arm
| латов LS SEDE SEME
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AL 52° КНБ
AO «& VIK.5-59. ZE RIVE ВЕЛ
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| BATE BLT «в }
- Part No. LOCATION: 48”& 52"
DECKS
2. SPECIFICATIONS
2.1 MODEL NUMBER: VH3614KA; VH3615KC; VH4814KA;
VH4815KC; VH5216BV.
2.2 ENGINE
2.2.1 Engine Specifications:
See your Engine Owner's Manual.
2.2.2 3600 RPM (No Load).
2.3 FUEL SYSTEM
2.3.1 Capacity: 5.0 gal.(18.9 L.)
2.3.2 Type of Fuel: Regular unleaded gasoline,
87 octane or higher. In countries using the research
method, it should be a 90 octane minimum.
2.3.3 Fuel Filter: Replaceable in-line
2.3.4 Fuel Shut-Off Valve: 1/4 turn
2.4: SAFETY INTERLOCK SYSTEM
Operator must have transmission in neutral and blade clutch
disengaged to start engine. Release of OPC levers will cause
the engine to stop if hydro transmission is not in neutral
and/or blade clutch is engaged.
2.5 STEERING/BRAKE CONTROL:
Fingertip drive control levers provide independent speed
control, braking and neutral to each drive wheel for moving
forward or reverse, stopping and power turning.
2.6 TRANSMISSION:
Twin Hydrostatic Drive
2.6.1 Two Hydro Gear (Sundstrand) BDP-10L series variable
displacement pumps independently coupled to two high
efficiency Ross wheel drive motors.
2.6.2 Speed Range: Forward 0 - 6.2 mph (10.0 km/h)
Reverse 0 - 2.2 mph (3.5 km/h)
2.7 WHEEL DRIVE SYSTEM:
Drive wheels are direct coupled to Ross wheel drive
motors with 1.0" (25.4 mm) tapered shaft.
2.8 TIRES
Drive Front Caster
Size ....... 16 X 6.50-8 ......... 9 x 3.50-4
Quantity ........ PA нение... 2
Tread ....... Turfsaver ............ Smooth
Ply Rating ...... “EEE 4
Pressure .. 14 psi(97 kPa) ..... 22 psi(152 kPa)
2.9 DECK
= + + » # = = # + * & =
в в + к ев от | |. | PD +
в A&A & = BE 2 U U WwW vv + +
. 18.00 in. (45.7
. 16.25 in. (41.3
. 18.00 in. {45.7 cm)
... 35.38 in. (89.9 cm)
... 47.63 in. (121.0 cm)
... 52.00 in. (132.1 cm)
cm) .. Qty. 2
cm) .. Qty. 3
.. Qty.
Type of Drive: Manual engagement of beit with over-center
Belt tension is adjustable via turnbuckie. The 48"
3
and 52" units have an additional belt; also adjustable.
2.9.1 Cutting Width:
Model 36 in.
Model 48 in.
Model 52 in.
2.9.2 Discharge: Right Side
2.9.3 Blade Size:
Model 36 in.
Model 48 in.
Model 52 in.
2.9.4
lock.
2.9.5
2.9.6
from 1" (2.5 cm) to 4 1/4" (10.8 cm).
2.10 DIMENSIONS
2.10.1 Overall Width:
Deck Mounting: Bolted directly to the engine deck.
Cutting Height: Adjusts in 1/4" (.63 cm) increments
36" a8" Ban
Discharge chute down 46.1" 58.1" 62.7"
(117.1 cm) (147.6 cm) (159.26 cm)
Discharge chute up 36.4" 48,4" 53.0"
(Transport only) (92.5 cm) (122.9 cm) (134.62 cm)
2.10.2 Overall Length:
36" aan g2n
Overall Length 78" 74.7" 75.3"
(198.1 cm) (189.7 cm) (191.3 cm)
2.10.3 Curb Weight:
36" 48" San
Curb Weight* 433 lbs. 478 lbs. 506 lbs.
(196 kg) (217 kg) (229 kg)
* Weights will vary slightly depending on engine option.
2.10.4 Overall Height: 43.2" (109.7 cm) (all units)
2.10.5 Tread Width (to outside of tires):
36" Model
48" Model
52" Model
eco. 35.6"
encon. 39.6"
2... 39.6"
(90.4 cm)
(100.6 cm
(100.6 cm)
2.11 TORQUE REQUIREMENTS
BOLT LOCATION TORQUE
Blade/Cutter Housing Spindle Bolt .........75-80 ft/lbs.
Caster Bracket Mounts .....0ooñ¡cocscececoorsreoero 30-35 ft/lbs.
Cutter Deck/Engine Deck Mount ............. 30-35 ft/lbs.
Engine Mounting Bolts
Briggs & Stratton .................. 15-20 ft/1bs.
Kohler & Kawasaki .......... ee eee + 25-30 ft/1bs.
3. ASSEMBLY INSTRUCTIONS
3
.1
Uncrate unit, leaving it on the pallet, place upper handle
assembly, fuel tank, and drive linkages at the rear of the
machine. Place casters at the front of unit.
Place a length of 4" x 4" block between the front of the
cutter deck and the pallet.
Remove the bolt bag from the top of the fuel tank support.
Loosen the 5/16" hardware at the two (2) discharge deflector
hinge points so that the deflector is snug, but can be moved
up and down freely.
Refer to Parts Manual to help you identify and locate parts
and their proper position.
Install casters to front of deck using appropriate hardware
from the bolt bag (eight 3/8 x 3/4" bolts and eight 3/8"
whizlock nuts); tightening the lower four bolts first, then
the top four.
Apply threadlocker "Fel-Pro Nut-Type" or "Loctite
Threadlocker 242" on the two threaded studs from the bolt bag
and install into the two left holes underneath fuel tank.
Install the fuel tank on top of the fuel tank support with
the studs going through the slots in the support. Install
two 5/16 x 3/4 screws with a flatwasher and lockwasher into
the threaded holes in the right side of the fuel tank. Do
not over-tighten. Place a 1/4" flatwasher, then a spring,
over each of the studs and fasten with a 5/16 nyloc nut.
Tighten to where there is a small gap between the coils of
the springs. Do not over-tighten.
-10-
3.8 Attach the fuel tank hose to the tank fitting and secure
with the clamp provided. Make sure that fuel hose is not
between engine and throttle plate on engine.
3.9 Position the lower end of the handle assembly on the outside
of the upper rear section of the fuel tank & handle support.
Install four 3/8-16 x 1" bolts (with four spring disk
washers against the head of each bolt) from the outside in.
Secure using four 3/8" whizlock nuts on the inside of each
handle support and tighten until the spring disk washers are
flat (See Figure 1).
UPPER HANDLE
UPPER HANDLE
MOUNTING TAB
FRONT
OF UNIT
FIG. 1
UPPER HANDLE MOUNTING
3.10 Route the throttle cable along the right side of the upper
handle, under the fuel tank support, and position the cable
on the left side of the engine (Kaw & Kohler) or to the
right side of engine (B&S).
Attach throttle cable to engine:
For Kohler and Kawasaki engines with "positive" detents
in throttle cable for the full throttle and idle positions:
a) Position the throttle control lever (on console) in the
full throttle (but not choke) position. You will feel a
detent when the throttle lever is approximately 3/4" from
the upper end of the slot (this is full throttle position).
b) Loosen clamp on engine control plate (See Figures 2 & 3).
Attach inner wire of the throttle cable to the control
plate lever and position cable clamp, do not tighten clamp.
Choke Link
Clamp Control Cable
Control
Alignment Holes
Choke Adjusting Screw
Control Plate Lever
Kill Switch Adjusting Screw
Control Plate
Kill Switch
FIG 2
KOHLER SPEED CONTROL
{THROTTLE CABLE HOOK-UP)
-11-
Control Alignment Holes
с)
а)
е)
For
a)
b)
Control Cable
| Choke Adjusting Screw
Control Piate Lever
Control Plate
FIG 3
KAWASAKI SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
Pull cable upward until alignment holes in control plate
lever and control plate line up. For Kawasaki, a 15/64"
(6 mm) drill bit can be inserted through these two holes
to align them. For Kohler, use a 19/64" drill bit. Once
the holes are aligned, tighten clamp onto throttle cable.
Be sure the choke adjusting screw just contacts the choke
lever when the throttle control is in the full throttle
position. Choke link should not move when throttle control
is moved to the full throttle position. Choke must be
completely closed when throttle lever is moved to the full
forward "CHOKE" position.
This step needs to be done after the unit has been
assembled and the engine has been started. Refer to
Section 4 (Operation Instructions). Check the engine
"STOP" position by moving throttle control fully to the
rear. (Note: There is a detent toward the end of the slot
in the console for "IDLE"; the "STOP" lower position is
rearward from this detent). For Kohler, if the engine
continues to run in the "STOP" position, turn kill switch
adjusting screw inward until engine stops, then give it
an additional 1/2 to 3/4 turn to assure it will always
function properly.
(Kawasaki kill switch is not adjustable).
BES Vanguard Engines:
Position the throttle control lever (on console) 1/8"
from the upper end of the slot. Route the throttle cable
along the right side of the upper handle, under the fuel
tank support, and position the cable on the right side
of the engine between the oil fill tube and engine.
Attach the inner wire to the appropriate throttle
control lever on the engine. Loosen the cable clamp
on the engine, place the cable behind it and pull
up on the cable to move the throttle linkage to the
full throttle position. Tighten the cable clamp screw.
-12-
Cn Kaw and Kohler engines, secure fuel line to throttle control
cable with a small wire tie approximately 2" ahead of filter to
keep fuel line away from hydraulic lines to prevent vapor lock.
3.11 Install the blade engagement linkage to the bell crank on
the front, left hand side of the engine deck. Insert rod
through the hole from the outside and fasten with cotter
hairpin from bolt bag.
3.12 Note the square swivel at the end of the hydro control arm
linkage. Place the stud end of the swivel into the hole on
the end of the short crank arm located at the end of the
speed control crank (top, rear of fuel tank support).
Install a 1/4" washer and fasten with a 3/32" x 1/2" cotter
pin from bolt bag. Repeat on opposite side of unit (See
Figure 4).
SHORT = |
CRANK ARM HYDRO CONTROL
LINKAGE
DRIVE LEVER
AS VIEWED LINKAGE
FROM THE RIGHT
SIDE OF UNIT
THREADED
SWIVEL
O
|
FIG. 4
HYDRO CONTROL LINKAGE SWIVEL € DRIVE LINKAGE SWIVEL
3.13 Install the speed control rod assembly (linkage with the
yoke installed on one end) into the end of the speed control
lever located underneath the center of the console. Insert
the end of the linkage (opposite the yoke) into the end of
the lever from the right hand side and fasten with a hair
pin from bolt bag.
3.14 Connect the lower end of the speed control linkage to the
speed control crank located at the top rear of the fuel tank
support. Secure with clevis pin and hair pin from bolt bag.
3.15 Thread each drive linkage into the threaded swivel. (See
Figure 4). Connect the upper end of each drive linkage to the
drive levers. Fasten with a long clevis pin and cotter pin
from bolt bag. Be sure the clevis pin is first inserted
through the drive linkage and then through the drive lever
from the outside before installing the hairpin cotter (See
Figure 5).
- 13 -
3.16
3.21
RIGHT HAND
SIDE SHOWN
DRIVE
__— LINKAGE
FIG 5
DRIVE LINKAGE TO DRIVE LEVER
Route the long unattached wiring harness lead, up the left
hand side of the handle and connect the two terminals (in
any order) to the operator presence control switch terminals
underneath the control console.
Fasten the lead to the handle with two large wire ties from
bolt bag, one at the upper end of the handle next to the
console, and one at the very lower end of the handle where
it attaches to the fuel tank support.
If machine is shipped without muffler installed, install
muffler with hardware provided.
Service Engine: Refer to Engine Owner’s Manual.
GREASE UNIT: NOTE: UNIT IS NOT GREASED AT THE FACTORY.
Refer to 5.1.13, for locations and grease amounts.
Follow pre-start instructions as outlined in 4.2.
NOTE: After starting the engine and engaging the hydro
drive and either of the drive wheels acts sluggish or will
not rotate at all, stop engine and refer to Section 5.1.10
on the Hydraulic System Air Purge procedure.
Perform any needed adjustments as outlined in the Adjustment
Section.
- 14 -
4. OPERATION INSTRUCTIONS
4.1 Controls
4.1.1 Operator Presence Control (OPC) Levers: Located on the upper
handle assembly directly above the handle grips. When these
levers are depressed, the CPC system senses that the operator
is in the normal operator's position. When the levers are
released, the OPC system senses that the operator has moved
from the normal operating position and will kill the engine
if either the speed control lever is not in the neutral
position or the blade clutch is engaged.
Speed Control Lever: Located in middle of control console,
it controls the maximum forward speed and is infinitely
variable from neutral (0 mph) to 6.2 mph.
Drive Levers: Located on each side of the upper handle
assembly directly below the handle grips (See Figure 6).
These levers individually control the speed and direction
of each drive wheel. When the speed control lever is moved out
of the neutral position and the lock latches are moved into the
drive position, as shown in Figure 6, and the drive levers
are released, the drive wheels are engaged in the forward
direction.
Squeezing the left hand and/or right hand lever causes the
left hand and/or right hand drive wheel respectively to slow
down, stop, or reverse, depending on how far each drive
lever is "squeezed". Squeezing the drive levers beyond the
neutral position causes the drive wheels to engage in the
reverse direction regardless of the position of the neutral
lock levers and the speed control lever.
Neutral Lock Latch: Located directly above the drive levers.
These latches allow the operator to lock the drive levers
in a "neutral" position where neither of the drive wheels
are engaged in either a forward or reverse direction (See
Figure 6).
ROTATE BACK FOR
LATCHIS IN
‚ NEUTRAL LOCK POSITION
THE DRIVE
POSITION hg de N
@
AN ) NEUTRAL
CE
7
A
x
FULL SPEED >
NEUTRAL - HOLD IN THIS POSITION FORWARD
FORWARD - RELEASE DRIVE LEVER
REVERSE - SQUEEZE DRIVE LEVER
FIG. 6
DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION
-15-
. 1.
.1.
.1.
.10
.11
Blade Engagement: The "push/pull" hiade engagement knob is
located on the left side of the controi console. To engage
the blades, the knob must be pulled toward the operator
until the turnbuckle (attached to the blade engagement
idler) locks over-center. To disengage the blades, push
the knob down until the bellcrank (front, left on engine
deck) contacts the end of the slot in the deck.
Choke Control: Choke is used to aid in starting a cold engine.
On the B£S engine the choke control is located on the left
hand, front corner of the engine and is activated by pulling
the control outward. On Kawasaki and Kohler engines, the choke
is part of the throttle control lever and is activated by
moving the throttle control to the full forward position.
Once the engine has started move the choke control to the
off position and move the throttle to the medium or full
throttle position.
Throttle Control: Located on the control conscle’s right
side. The throttle is used to control engine speed. Moving
the throttle control forward will increase engine speed and
moving it to the rear will decrease engine speed. All Kohler
and Kawasaki units are equipped with throttle kill as a
standard feature. Moving the throttle to the full rear "Stop"
position will shut off the engine (B&S units use a Key switch
to shut off engine).
"Of f-Run" Switch (B&S only): Located on the front, left
corner of the fuel tank support. Turn key to the "Run"
position to allow the engine to be started. Turn key to the
"Off" position to shut engine off.
Fuel Shut-Off Valve: Located along the fuel line. The fuel
shut-off valve is used to shut off the flow of fuel when
parking inside a building, during transportation to and from
the job sites, and when the machine will not be used for a
few days.
Rotate valve 1/4 turn clockwise to shut fuel off. Rotate
valve 1/4 turn counter-clockwise to turn fuel an.
Drive Wheel Release Valves: Located on the top corner of
the hydrostatic pumps. Drive wheel release valves are used
to release the hydro-static drive system to allow the machine
to be moved by hand without the engine running. Turn valves
one-half turn counterclockwise to release the drive system.
Turn clockwise to reset the drive system. Dc Not over-tighten.
Cold Start Kit: Located on the right hand side of engine
deck, below and slightly ahead of the hydro control shield.
The cold start kit is used to ease the starting of the unit
in cold weather or when the unit has not been operated for
a period of time. The cold start kit moves the idler pulley
away from the pump belt, releasing the tension on the belt
which allows the engine to turn over with less resistance.
- 16 -
4.1.12 Tracking Adjustment Knob: Located on the right-hand side of
the rear of the fuel tank support. Can be adjusted so that
machine will "track" straight ahead with drive levers released.
4.2 Pre-Start
4.2.1 Fill fuel tank. For best results use only clean fresh
regular grade unleaded gasoline with an octane rating of
87 or higher. Regular grade leaded gasoline may also be used;
however, combustion chamber and cylinder head will require
more frequent service. See Engine Owner's Manual.
Do not add oil to gasoline.
Do not overfill fuel tank. Leave room for fuel to expand.
4.2.2 Refer to Maintenance and Adjustment Section 5 and
perform all of the necessary inspection and maintenance steps.
4.2.3 Familiarize yourself with the controls and operation of unit.
See Controls section 4.1 and Operating Instructions section 4.3.
4.3 OPERATING INSTRUCTIONS
4.3.1 Refer to Engine Owner's Manual for detailed operating
instructions regarding the engine.
4.3.2 Starting Engine: Operator must have blade drive disengaged
and transmission in neutral.
Open fuel shut-off valve.
NOTE: A cold weather starting kit has been added for ease
of starting in either cold weather or when the unit
has not been run for a period of time.
To use cold start kit:
a) Place shifter in neutral position.
b) Pull split ring straight out the side of the unit,
and hook the ring over the lower front hydro control
shield bolt.
c) Start engine. Refer to the following guidelines for
further starting suggestions.
To engage pump drive (unhook cold start kit)
a) Pull chain straight out from the side of the unit
until the split ring can be removed from the bolt.
SLOWLY release tension on chain.
For Kohler and Kawasaki engines:
On a cold engine, place the throttle in the full forward
"Choke" position. Pull recoil rope to start engine.
With a cold engine, gradually return choke to the full
throttle position after the engine starts and warms up.
NOTE: Kawasaki engines generally need to be "choked" even
when warm.
On a warm engine, place the throttle control midway between
the "Slow" and "Fast" positions.
- 17 -
4.
3
‚3.
.3.
3
For B&S engines:
Turn key to the "Run" position.
On a cold engine, place the throttle in the full forward
position, and pull the choke control, on the engine, fully
outward to the engaged position. Pull recoil rope to start
engine.
With a cold engine, gradually return choke to the full
throttle position after the engine starts and warms up.
On a warm engine, place the throttle control midway between
the "Slow" and "Fast" positions. DO NOT choke B&S when warm.
NOTE: It is helpful to have the left and right neutral lock
latches applied when starting the engine, See Controls
Section 4.1.
Stopping Engine: Disengage blade drive, shift transmission
to neutral and lock the drive levers in neutral. Move
throttle to the "Slow" position. Allow engine to idle for
30 seconds to allow cool down.
For Kawasaki and Kohler engines; after cool down time, move
throttle lever to the full rear ("Stop") position. For B&S
engines; After cool down time, turn Key to the "Off" position.
Drive Lever/Neutral Lock Latch Operation: To lock the drive
levers in neutral, squeeze the drive levers back to the
neutral position (Do Not squeeze the drive levers all the
way back as this will cause the drive wheels to go into full
reverse direction). Place thumbs on the upper portion of the
neutral lock latches and move them to the rear. Release
drive levers (See Figure 6).
A CAUTION
e Be sure the pins protruding through the slots
of each neutral lock latch are completely
engaged in the rear slot of each latch, if
not, the drive levers could unexpectedly
slip into the forward drive position.
To place the drive levers in the drive position, firmly hold
the drive levers, place thumbs on the upper portion of the
neutral lock latches and move them forward to release drive
levers. Slowly and smoothly release the drive levers.
Drive Wheel Engagement/Turning: With drive levers located
in neutral, shift speed control lever to desired forward
speed. Slowly squeeze and hold both drive levers in the
neutral position and move both neutral lock latches
from the neutral lock position. Do Not squeeze both drive
levers all the way back, this will cause the drive wheels
to be engaged in the reverse direction.
For straight ahead motion, smoothly release both drive
levers to engage drive wheels.
Squeeze the right hand drive lever to turn right.
and the left hand drive lever to turn left.
- 18 -
To make a "zero turn", squeeze either the left hand or the
ight hand drive lever back into the reverse position while
the opposite drive lever is in a forward position at an
equal but opposite speed.
To back up, squeeze both drive levers into the reverse
position.
For smooth operation of this machine, avoid quick, Jerky
movements of the drive levers. Move the drive levers
smoothly and deliberately.
4.3.6 To Stop: Squeeze drive levers back to the neutral
position. Move neutral lock latches into the neutral lock
position and release drive levers. Move the speed control
lever to the neutral position.
4.3.7 Blade Engagement: Be sure that all persons are clear of mower
deck and discharge area before engaging the blades. |
Set throttle to "midway" position. Pull the blade engagement
knob up and rearward to engage blades. Accelerate to full
throttle to begin mowing (See Section 4.1.5).
4.3.8 Blade Disengagement: Push forward and down completely on the
engagement knob to disengage the blades.
4,4 TRANSPORTING
Use a heavy duty trailer to transport the machine. Engage
neutral lock latches and block wheels.
Securely fasten the machine to the trailer with straps,
chains, cables or ropes.
Use a safety chain and be sure that the trailer has all
necessary lighting and marking as required by law.
-19-
5. MAINTENANCE & ADJUSTMENTS
ÁRNCAUTION
о Disengage blade clutch, shut off engine
and remove spark plug wire(s) before
servicing, cleaning or making adjustments.
e The engine can become very hot. Always
allow the engine to cool before servicing
or making repairs around the engine area.
5.1 PERIODIC MAINTENANCE
5.1.1
Check engine oil level.
Service Interval: See Engine Owner's Manual
a) Make sure engine is stopped and on a level surface.
hb) Check with engine cool.
c) Clean area around dipstick. Remove dipstick and wipe oil
off. Reinsert the dipstick (DO NOT screw into place for
Kohler and Kawasaki engines; DO screw into place for
B&S engines). Remove dipstick and check oil level.
d) If the oil level is low, add oil as specified in the
Engine Owner’s Manual to bring the oil level up to the
"F" mark on the dipstick.
DO NOT OVERFILL. |
IMPORTANT : DO NOT operate the engine with oil level below
the "L" mark or over the "F" mark.
Clean engine air cooling system.
Service Interval: See Engine Owner's Manual
a) Stop engine and remove spark plug wire(s).
b) Clean all debris from engine air intake screen and from
around engine shrouding.
Clean grass build-up under deck and check mower blades.
Service Interval: Daily
A CAUTION
+= When it is necessary to raise the deck
or mower for service or maintenance, DO NOT
rely solely on mechanical or hydraulic jacks
for support. Use adequate jack stands or
equivalent support.
a) Disengage blade clutch.
b) Stop engine and remove spark plug wire (s).
с) Raise deck and block up using proper safety precautions.
d) Clean out any grass build-up from underside of deck and
in deck discharge chute.
e) Inspect blades and sharpen or replace as required.
- 20 -
£) If blade removal is necessary, be careful for the sharp
cutting edges of the blades.
g) Re-install the blades (if they were removed) and torque
blade bolts to 75-80 ft.lbs. Be sure the spring
disk washer cone is installed toward the bolt head
(See Figure 7).
h) Remove jack stands (or equivalent support) and lower
deck to ground.
©
<>
T FOR
REFERENCE ONLY
«>
\
CONE TOWARDS
BOLT HEAD
UU TORQUE TC
75-80 ft. Ibs.
FIG. 7
BLADE BOLT INSTALLATION
5.1.4 Check safety interlock system.
Service Interval: Daily
a)
b)
c)
For your safety, your Exmark mower is equipped with
Operator Presence Controls (OPC). When either the mower
blades are engaged, or the speed control lever is not
in neutral and both hands are removed from the handles,
the mower engine MUST stop.
Check OPC circuits. Clear the area. Run engine at
one-third throttle, then with drive levers and neutral
lock latches in neutral lock position, move the speed
control lever out of neutral and release OPC levers -
engine MUST stop.
Again, run engine at one-third throttle, move the speed
control lever to neutral, engage blade clutch and release
OPC levers - engine MUST stop.
If machine does not pass any of these tests, DO NOT
operate. Contact your authorized EXMARK SERVICE DEALER,
A CAUTION
о Тб is essential that all Operator
Safety Mechanisms be connected and
in proper operating condition prior
to the use of the mower.
-21-
A CAUTION
s When checking starting problems, be
sure to keep body, hands and clothes
away from areas where moving parts
can suddenly engage.
5.1.5 Check for loose hardware.
Service Interval: Daily
a)
b)
Stop engine and remove spark plug wire(s).
Visually inspect machine for any loose hardware or any
other possible problem. Tighten hardware or correct the
problem before operating.
5 1.6 Service pre-cleaner element and air cleaner.
Service Interval: See Engine Owner's Manual
5.1.7 Change engine oil.
Service Interval: See Engine Owner's Manual
NOTE: Change oil after first five (5) hours of operation. Follow
a)
b)
с)
а)
е)
Е)
Я)
engine manufacturers recommendations for future oil changes.
Disengage blade clutch.
Stop engine and remove spark plug wire(s).
Drain oil while engine is warm from operation.
Remove the oil drain plug from the right hand side of
the engine. Allow oil to drain, then replace drain plug.
Replace the oil filter as per Engine Owner's Manual.
Clean around oil filter and unscrew filter to remove.
Before reinstalling new filter, apply a thin ccating of
oil on the surface of the rubber seal. Turn filter
clockwise until rubber seal contacts the filter adapter
then tighten filter an additional 2/3 to 3/4 turn.
Clean around oil fill cap and remove cap. Fill to the
specified capacity and replace cap. Use oil as specified
in Engine Owners Manual. Do not overfill,
Start the engine and check for leaks. Stop engine and
recheck oil levels.
5.1.8 Check hydraulic oil level.
Service Interval: 25 hr.
a)
b)
Stop engine.
Clean area around hydraulic reservoir cap and remove cap.
Oil level should be to the top of the baffle inside the
tank. If not, add oil.
Use Mobil 1 15W-50 synthetic motor oil.
A CAUTION
e Safely relieve all pressure in the hydraulic
system before disconnecting lines or before
performing any work on the hydraulic system.
- 22 -
A CAUTION
« Make sure all hydraulic fluid connections
are tight and all hydraulic hoses and lines
are in good condition before applying
pressure to the system.
A CAUTION
= Keep body and hands away from pin holes or
nozzles that eject hydraulic fluid under
high pressure. Use paper or cardboard,
NOT HANDS to search for leaks.
es Hydraulic fluid escaping under pressure may
have sufficient force to penetrate skin and
cause sericus injury. If foreign fluid is
injected into the skin, it must be surgically
removed within a few hours by a doctor
familiar with this type of injury or gangrene
may result.
5.1.9 Change hydraulic system filter.
Service Interval: After First 250 hrs, then each yearly
thereafter.
a)
b)
с}
а)
е)
9)
Place unit on a level surface, stop engine and remove
spark plug wire(s).
Carefully clean area around filter. It is important that
no dirt or contamination enters the hydraulic system.
Unscrew filter to remove and allow oil to drain from
reservoir. Before re-installing new filter, fill it
completely with Mobil 1 15W-50 and apply a thin
coat of oil on the surface of the rubber seal. Turn
filter clockwise until rubber seal contacts the filter
adapter. Do not tighten yet. Use only Exmark filter
element Part No. 513211.
Fill reservolr as stated in Section 5.1.8.
Loosen filter 1/2 turn and allow a small amount of oil
te leak from the oil filter (this allows air to be purged
from the oil filter and supply hose from the hydraulic
reservoir). Turn filter clockwise until rubber seal
contacts the filter adapter. Then tighten the filter
an additional 2/3 to 3/4 turn. Run machine to allow any
other air to be purged from the hydraulic system and
recheck the oil level.
If either drive wheel does not rotate, one or both of
the charge pumps (located on the top of the main pump
as shown in Figure 8) may have lost their "prime",
Refer to Section 5.1.10.
DO NOT change hydraulic system oil (except what can be
drained when changing filter) unless it is felt that oil
has been contaminated. Changing oil unnecessarily could
damage the hydraulic system by introducing contaminates
into the system.
- 23 -
5.1.10 Hydraulic system air purge procedure.
Air must be purged from the hydraulic system when any
hydraulic components, including oil filter, are removed or
any of the hydraulic lines are disconnected.
The critical area for purging air from the hydraulic
system is between the oil reservoir and each charge pump
located on the top of each variable displacement pump.
(See Figure 8).
Air in other parts of the hydraulic system will be purged
through normal operation once the charge pump is "primed".
a) Stop engine. Raise the rear of the machine up onto jack
stands high enough to raise the drive wheels off the
ground.
b) Check oil level as stated in Section 5.1.8.
c) Thoroughly clean the area around each of the charge pump
housings.
LOOSEN 1-1/2
TURNS ONLY
CHARGE PUMP
FIG. 8
CHARGE PUMP LOCATION
d) To "prime" charge pump, loosen two hex sccket head
capscrews (shown in Figure 8) 1-1/2 turns only. Make
sure engine is not running. Lift charge pump housing
upward and wait for a steady flow of oil to flow out
from under housing. Retighten capscrews. Do this for
both pumps. Note: Hydraulic reservoir can be
pressurized to up to 5 psi to speed this process.
e) Start engine and move throttle control ahead to full
throttle position. Move the speed control lever to the
full speed position and place the drive levers in the
"drive" position.
If either drive wheel still does not rotate, stop and
repeat steps (d) through (e) above for the respective
pump. If wheels rotate slowly, the system may prime after
additional running.
Е) Allow unit to run several minutes after the charge pumps
are "primed" with drive system in the full speed position.
Check oil level as stated in Section 5.1.8.
- 24 -
g) Check hydro drive linkage adjustment as stated in
Section 5.2.10.
5.1.11 Check tire pressures.
Service Interval: 25 hrs.
a) Stop engine and remove spark plug wire(s).
pressure in tires; recommended tire pressure is:
12 to 16 psi; pneumatic casters, 22 psi.
Check air
rear,
b) Inflate tires to pressures stated above. Measure
circumference of each drive tire. Adjust tire pressures
within above range to try to make the circumferences
match as closely as possible.
NOTE: Front caster tires have permanent tire sealant installed.
5.1.12 Inspect Belt wear.
Service Interval: 25 hrs.
a) Stop engine and remove spark plug wire (s).
b) Remove cutter deck belt shield to check mower primary
and secondary (48 & 52" decks) belt condition.
с) Look under engine deck to check the pump drive belt condition.
d) Check all idler arms to be sure they pivot freely.
Disassemble, clean and grease pivot bushings if necessary.
5.1.13 Lubrication
Service Interval: Refer to Chart.
a) Stop engine and remove spark plug wire (s).
b) Lubricate fittings with one to two pumps of SAE No. 2
multi-purpose gun grease (see recommended lubricants
following the lubrication chart.
Refer to the following chart for fitting locations and
lubrication schedule.
GREASE LUERICATION CHART
FITTING INITIAL | QUANTITY SERVICE
LOCATIONS PUMPS | 36" 48"52" | INTERVAL
1. Caster Wheel Bearings 12 2 | 2 | 2 | Daily
2. Caster Pivots 2 2 2 2 | Daily
3. Cutter Spindles 10 2 3 3 | + Weekly
4. Blade Engagement Lower Bellcrank 1 1 1 1 Monthly
5, Idler Pivot (Pump Drive) 2 1 1 | 1 | Weekly
6. Pump Control Bearings 2 2 2 | 2 | Weekly
7. Cutter Deck Idler Pivots 2 1 ¡2 |2 | Weekly
+ Under severe cutting conditions, two pumps of grease
twice weekly may be more beneficial.
- 25 -
Recommended SAE No. 2 Greases:
Pennzoil #705; Pennzoil #707L; Pennzoil #TTM 302
Mobil Grease CM-P; Mobilith SHC220;
Mobil Grease Special; Mobilith SHC460
(Available at Mobil Stations)
Ronex MP - (Available at Exxon Stations)
Shell Alvania #2 - (Available at Shell Stations)
Super Lube M EP #2 or Super Stay M #2
(Available at Conoco Stations)
Lubricate pivot points with a spray penetrating
с)
lubricant as directed below.
SPRAY LUBRICANT CHART
NO. OF PLACES SERVICE
P
PIVOT POINT 136" 48" 52" INTERVAL
1. Blade Engagement Upper Bellcrank 2 2 2 Weekly
5.1.14 Check spark plugs.
Service Interval: 100 hrs.
a)
Remove spark plugs, check condition and adjust plug gap
or replace with new plugs. See Engine Owner's Manual.
5.1.15 Remove engine shrouds and clean cooling fins.
Service Interval: See Engine Owner's Manual
a)
b)
c)
Stop engine and remove spark plug wire(s).
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.
Make sure cooling shrouds are properly reinstalled.
Operating the engine without cooling shrouds will cause
engine damage due to overheating.
5.1.16 Change fuel filter.
Service Interval: As Required
a)
A fuel filter is installed in the fuel line between the
fuel tank and the engine. Replace when necessary.
5.1.17 Refer to Engine Operators Manual for detailed maintenance
regarding the engine.
5.1.18 Wheel hub - slotted nut torque specification.
When tightening the slotted nut on the wheel motor tapered
shaft:
a)
b)
с)
а)
Torque the slotted nut to 100 ft. lbs.
Further tighten the nut until the next set of slots
line up with the cross hole in the shaft.
Replace cotter pin.
To aid in wheel hub removal, it is recommended that an
antisieze compound is used on the tapered shaft of the
wheel motor.
- 26 -
5.1.19 Thread locking adhesives such as "Loctite 242" or
5.1.20
5.1.21
"Fel-Pro, Pro-Lock Nut-Type" are used on the following
fasteners:
a) All belt drive pulley setscrews.
b) Square head setscrews on Hydro pump control arm.
c) OPC lever setscrews.
d) Shoulder bolts in ends of speed control crank.
e) Shoulder bolts connecting Hydro control linkages to
hydro pump control arms.
Adhesives such as "Loctite RC/609 or RC/680" or
"Fal-Pro Pro-Lock Retaining I or Retaining II" are
used on the following:
а) OPC lever hubs and cross-shaft
NOTE: Care must be used not to bond the bearing, next to
each OPC hub, to the cross shaft which could cause
binding of the OPC levers and erratic operation.
b) Transmission drive pulley on the engine PTO shaft.
An anti-seize compound is used on the blade drive pulley
hub, located on the engine PTO shaft (this allows for
ease of removal of the pulley). It also used on tapered
shaft of wheel hub mounts.
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
5.2 ADJUSTMENTS
5.2.1
A CAUTION
se Disengage blade clutch, shut off engine
and remove spark plug wire(s) before
servicing, cleaning or making adjustments.
Blade Spacers:
Blades may be adjusted for cutting height by using the
four 1/4" spacers found on the blade spindle bolts
(factory setting is two above and two below). This allows
a 1" range in 1/4" increments of cutting height in any axle
position. The same number of blade spacers must be used on
all blades to achieve a level cut (two above and two below,
one above and three below, etc.).
For the best cut and discharge a minimum of two spacers
should be placed between the blade and spindle shaft.
The highest quality cut can be achieved with all four
spacers between the blade and the spindle shaft.
If the mulching kit is installed, the highest quality cut
can be obtained with 3 spacers between the blade and
spindle (minimum is 1 for a good cut).
If you need to cut higher or lower than what the spacers
will allow, it will be necessary to adjust the rear axle
height and caster position. See Section 5.2.2 below.
-27-
5.2.2 Axle height and caster spacer position:
Desired cutting height range can be obtained by adjusting
the rear axle and placing caster spacers above or below the
caster arm (See Figure 9).
To adjust rear axle:
a) Stop engine and remove spark plug wire(s).
b) Raise the rear of the machine up onto jack stands and
remove the drive wheels.
М} слотом
e When it is necessary to raise the deck
or mower for service or maintenance, DO NOT
rely solely on mechanical or hydraulic jacks
for support. Use adequate jack stands or
equivalent support.
c) Loosen but do not remove the top two bolts on each
hydraulic motor mounting bracket, DO NOT remove
(See Figure 9).
d) Remove the bottom sets of hardware for each bracket.
e) Reposition the mounting bracket to the desired height
and reinstall the bottom hardware.
f) Tighten all hardware and remount drive wheels.
AXLE CASTER
ADJUSTMENT ADJUSTMENT 1 (4 ea.) 4/2" SPACERS
| —
LOOSEN, BUT TU (1 ea.) 3/16" SPACER
. DO NOT REMOVE
a PUS CASTER
SUPPORT
~~
DAT
Q ——
B—""
FIG. 9
AXLE and CASTER HEIGHT ADJUSTMENT
Refer to the following chart to properly adjust desired
cutting height.
- 28 -
CUTTING HEIGHT ADJUSTMENT (i" to 4 1/4")
AXLE NO. OF SPACERS NUMBER OF 1/4" BLADE SPACERS
POSITION BELOW CASTER BELOW SPINDLE
(FIG. 9) 1/2" 3/16" 4 3 2 1 0
A 0 0 1" 1 1/4" 1 1/2" 1 3/4" 2"
A 0 1 1 1/8" | 1 3/8" | 1 5/8" | 1 7/8" | 2 1/8"
A 1 0 1 3/8" 1 5/8" | 1 7/8" | 2 1/8" | 2 3/8"
B 0 1 1 3/8" | 1 5/8" | 1 7/8" | 2 1/8" | 2 3/8"
B 1 0 1 5/8" 1 7/8" | 2 1/8" | 2 3/8" | 2 5/8"
B 1 1 1 3/4" 2" 2 1/4" 2 1/2" | 2 3/4"
B 2 0 2" 2 1/4" | 2 1/2" | 2 3/4" 3"
C 1 1 1 7/8" | 2 1/8" | 2 3/8" | 2 5/8" | 2 7/8"
С 2 0 2 1/8" | 2 3/8" | 2 5/8" | 2 7/8" | 3 1/8"
C 2 1 2 1/4" | 2 1/2" | 2 3/4" 31 3 1/4"
с 3 0 2 1/2" | 2 3/4" 3" 3 1/4" | 3 1/2"
D 2 1 2 3/8" | 2 5/8" | 2 7/8" | 3 1/8" | 3 3/8"
D 3 0 2 1/2" | 2 3/4" 3" 3 1/4" | 3 1/2"
D 3 1 2 3/4" 3" 3 1/4" | 3 1/2" | 3 3/4"
D 4 0 3" 3 1/4" | 3 1/2" | 3 3/4" 4"
E 3 1 2 7/8" | 3 1/8" | 3 3/8" | 3 5/8" | 3 7/8"
4 0 3 1/8" | 3 2/8" | 3 5/8" | 3 7/8" | 4 1/8"
4 1 3 1/4" | 3 1/2" | 3 3/4" 4 4 1/4"
IMPORTANT: To achieve the highest quality of cut, blades should
be level with the ground, or tipped slightly down at the front.
SPRING DISC
WASHER
(CONE TOWARDS
BOLT HEAD)
FRONT LEFT
ANTI-SCALP BRACKET
TORQUE TO 40-45 ft/ibs.
5.2.3 Anti-scalp Roller Adjustment:
FIG 10
ANTI-SCALP ROLLER ADJUSTMENT (52" MODELS ONLY)
(52% models only)
For maximum deck flotation, rollers should maintain
1/4-1/2 in. clearance to ground. Do Not adjust
rollers to support the deck. Be sure roller bolts
are tight or loss of roller may result (See Figure 10).
- 29 -
5.2.4
5.
‚2.
2
.6
Blade engagement Linkage: Located between the blade
engagement bellcrank and blade engagement assist arm
beneath the front, left hand corner of the engine deck.
a) Stop engine and remove spark plug wire(s).
b) With blade drive engaged, adjust the linkage length to
obtain 1/8" to 3/16" clearance between the lower end of
the bellcrank and the axle support gusset (See Figure 11).
VIEWED TT] Ja sauce
FROM RIGHT SIDE
OF UNIT
SWITCH IS LOCATED
BENEATH THE
ENGINE DECK
BLADE
1/8" TO 3/16” “SAFETY SWITCH
CLEARANCE
FIG. 11
BLADE ENGAGEMENT LINKAGE
Blade Safety Switch:
a) Stop engine and remove spark plug wire(s).
b) With blades disengaged and the bellcrank touching the
rear of the slot in the engine deck, adjust the blade
safety switch mounting bracket (if needed) until the
bellcrank depresses the plunger by 1/4".
с) Be sure the bellcrank DOES NOT touch the switch body or
damage to the switch could occur.
d) Retighten switch blade mounting bracket.
Engine to Cutter Deck Belt:
a) Stop engine and remove spark plug wire(s).
b) Check belt guides under rear engine and front mower deck
to see that they are properly set (See Section 5.2.8.
с) Belt must be tight enough so it does not slip during
heavy loads while cutting grass. Over-tensioning will
reduce belt and spindle bearing life. To adjust belt
tension, loosen the 5/16" whizleck nut on turnbuckle
and rotate the turn buckle; rotate turnbuckle toward
rear of mower to tighten, and toward front of mower
to loosen belt tension (See Figure 12).
Check belt tension after the first hour of operation and
at least twice during the first 24 hours of operation.
Adjust as necessary.
- 30 -
ADJUSTMENT 5/16" WHIZLOCK
NUT /
\ |. 48" DECK
/ USED FOR
cit” À ré REFERENCE ONLY
TENSION ROD A |
/ Qui
O
> 7 "B"
o go o
o a "A" o Lu
FIG. 12
CUTTER DECK BELT ADJUSTMENT
e) For the 14 and 15 hp engines, proper belt tension will
require about 10 lbs. side pull on belt, halfway between
pulleys to deflect belt 1/2". For the 16 hp engines,
proper belt tension will require about 12 lbs. of pull to
deflect belt 1/2". (See Figure 12, Point A).
5.2.7 Secondary Belt: (48" and 52" units only)
a)
b)
Stop engine and remove spark plug wire(s).
The secondary drive belt is adjusted via the belt tension
rod (See Figure 12). The 5/16" nylock adjustment nut is
located at the rear, right corner of engine deck.
Proper belt tension (for the secondary belt) will require
about 10 lbs. side pull on belt, halfway between pulleys
to deflect belt 1/2". (See Point B, Figure 12).
5.2.8 Belt Guide Adjustment:
a)
b)
с)
а)
Stop engine and remove spark plug wire(s).
Engage the blade drive belt.
Check belt guide clearance on the mower deck. The four
welded belt guides on the mower deck should be located
1/8" from belt. Adjust if necessary.
Check belt guides under the engine deck for proper
adjustment (See Figures 13 and 14). Adjust as necessary.
The disengaged belt should not drag or fall off pulley
when guides are properly adjusted.
NOTE: Belt guides are not installed on the same bolts on
the
36" model ag on the 48" and 52" models.
-31-
1 1/4" CLEARANCE 11/4" CLEARANCE
CENTER OF SLOT 1/4" CENTER OF SLOT 1/4”
CLEARANCE CLEARANCE
1/8"
CLEARANCE END OF SLOT CLEARANCE END OF SLOT
FIG. 13 FIG. 14
BELT GUIDE LOCATION BELT GUIDE LOCATION
36" MOWER DECK 48" £ 52"
(Under Rear Deck) (Under Rear Deck)
5.2.9 Pump Drive Belt Tension Adjustment:
No adjustment necessary.
5.2.10 Hydro Drive Linkage Adjustment:
a) Adjust Speed Control Linkage and neutral safety switch
1. Move the speed control lever (located on the console)
to the full forward position and check the orientation
of the tabs on the ends of the speed control crank
fig. 16). These tabs should be pointing straight down
at the 6 o’clock position or slightly forward. Adjust
the threaded yoke at the bottom of the speed control
link until the tabs are positioned correctly.
2. Pull the speed control lever back to neutral. Check
that the neutral safety switch actuating tab has
depressed the plunger of the switch so that there is
about 5/16" between the tab and the switch. See fig.
15. If necessary, move the switch fore and aft.
HS A — >| |< 5/16"
©
AS VIEWED <
FROM THE LEFT =
SIDE OF UNIT |
S NEUTRAL
О SWITCH
FIG. 15
NEUTRAL SAFETY SWITCH ADJUSTMENT
b) Adjust Neutral Control Linkages
1. Raise the rear of the machine up onto jack stands high
enough to raise the drive wheels off of the ground.
„32.
2.
Start the engine and move the throttle ahead to the
full throttle position. Place the neutral lock levers in
the drive position as shown in Figure 6 and move the
speed control lever to the "mid-speed" position. Note:
The OPC levers must be held down whenever the speed
control lever is out of the neutral position or the
engine will kill.
Squeeze the respective drive lever until an increased
resistance is felt, this is where neutral should be.
Make sure you have not reached the end of the thumb latch
slot. If you have, shorten the drive lever linkage. If
the wheel turns while holding the drive lever in neutral,
the neutral control linkages need to be adjusted. If
wheel stop then go to step 7.
SPEED
CONTROL
DRIVE LEVER CRANK
LINKAGE À
| Y prep
HYDRO CONTROL / CONTROL
LINKAGE Q LINKAGE
NEUTRAL CONTROL
LINKAGE
ADJUST
HERE
AS VIEWED > |
FROM THE LEFT A LOOSEN
SIDE OF UNIT NUT
4.
o о | YOKE
o
FIG. 16
HYDRO DRIVE LINKAGE ADJUSTMENT
Loosen the nut against the neutral control linkage
yoke as shown in Figure 16.
Adjust the neutral control linkage until the respective
drive wheel stops when the lever is pulled against the
neutral spring (neutral position). Turn the adjusting
bolt clockwise if the wheel is turning in reverse or
turn the bolt counter-clockwise if the wheel is turning
forward. Release the drive lever to the forward drive
position and squeeze back into the neutral position.
Check to see if the wheel stops. If not, repeat the
above adjustment procedure.
. Make this adjustment on both sides.
After adjustments are made and the wheel stops when
the drive lever is in the neutral position, tighten the
nut against the yoke.
c) Adjust Hydro Control Linkages:
1.
Place the speed control lever in the "neutral"
position. This adjustment is again made with rear of
machine on jack stands and engine running at full
- 33 -
throttle. OPC levers will have to be held down
whenever speed control levers are moved out of the
neutral position.
2. Loosen the front nut on left hydro control linkage as
shown in Figure 16. Turn the rear control linkage
adjusting nut counter-clockwise until wheel rotates
forward. Turn the rear nut of left control linkage
clockwise 1/6 of a turn at a time, stopping to move
the speed control forward and back to neutral, until
left wheel stops rotating forward. Turn the rear nut
an additional 1/2 turn and tighten the front nut
making sure not to put a bind on the linkage. Make
sure flat part of linkage is perpendicular to pin part
of swivel. See Fig. 17.
LEFT SIDE
SHOWN END VIEW
FIG. 17
HYDRO CONTROL LINK/SWIVEL ADJUSTMENT
After adjusting the left hydro control linkage, move
the speed control lever to the mid-speed position and
then back to the neutral position. Recheck the left
drive wheel rotation to see if further adjustment is
necessary - be sure the speed control lever is in the
neutral position.
If inconsistent neutral occurs, check to be sure both
springs are properly tightened on the speed control
lever under the console - especially the rear pivot
spring.
Repeat above adjustments if necessary.
LJ
Place the speed control lever in neutral. Adjust the
right side linkage by turning the quick track knob
counter-clockwise until the tire begins to rotate
forward. Begin to retighten the knob clockwise about
1/4 turn at a time, stopping to move the speed control
forward and back to neutral. Recheck the drive wheel
rotation to see if further adjustment is necessary.
4. The spring that keeps tension on the knob should
normally not need adjustment. However, if adjustment
is needed, adjust to where length of spring is about
1" between the washers. Adjust spring length by
turning nut at front of spring.
d) Drive Lever Linkage Adjustment
1. With rear of machine still on jack stands and engine
running at full throttle, move the speed control lever
- 34 -
e)
to the midway position. Move the respective drive lever
upward until it reaches the neutral position and engage
neutral lock latches. See fig. 18. If the tire rotates
in either direction, the length of the drive lever link
will need to be adjusted.
3. Adjust the linkage length by releasing the drive lever
and removing clevis pin and rotating the linkage in the
lower swivel. Lengthen the linkage if the tire is
turning in reverse and shorten the linkage if the tire
is creeping forward. Rotate the linkage several turns
if the tire is rotating fairly fast. But as the
adjustment gets closer, adjust the linkage in 1/2 turns.
Release and re-engage neutral lock latch checking that
the tire stops. Continue these process until the tire
is at a dead stop.
FIG. 18
DRIVE LEVER AND LATCH IN NEUTRAL POSITION
4. Replace the hairpin back into each clevis pin.
5. Make this adjustment for both sides.
Tracking Adjustment
Stop engine, Raise the rear of the machine, remove jack
stands and carefully lower the machine to the ground.
Check the drive tire pressures and tire circumferences.
See 5.1.11.
Run the unit and observe the tracking on a level, smooth,
hard surface such as concrete or asphalt.
If the unit tracks to one side or the other, turn the
quick track knob . Turn the knob right to "steer" right,
turn the knob left to "steer" left.
5.2.11 Hydro Pump Spring Tension Setting:
a)
b)
For medium or heavy duty drive conditions such as operation
with a sulky on steep slopes, a higher spring force may be
required on the hydro pump control arms to prevent the
drive system from stalling.
For a heavier drive setting, relocate the spring anchor
links to either the "medium" or "heavy duty" positions as
- 35 -
shown in Figure 19. The spring anchor links are attached
to the upper rear corner of the hydro drive shields on
the left and right hand sides of the machine.
Note: In the "medium" or "heavy duty" positions, the drive
lever forces at the upper handle will also be increased.
Retaining
Bolt Standard
Medium
Heavy Duty
Spring
FIG. 19
HYDRO PUMP SPRING TENSION SETTING
6. TROUBLE SHOOTING
6.1 MOWER TRACKS TO LEFT OR RIGHT.
a) Check the drive tire pressures and circumferences.
See 5.1.11.
b) Turn knob on the right hydro control linkage in the
direction that the mower needs to be adjusted to. Turn
the knob in 1/4 turn increments until the mower tracks
correctly.
6.2 MOWER CUTS UNEVENLY.
a) Check the drive tire pressures and circumferences.
See 5.1.11.
2 more uniform cutting height may be obtained with higher
tire pressure on rough terrain. A lower tire pressure
provides more flotation.
b) Check blade spacers, they must be equal on each blade.
c) Check caster mounting brackets to be sure all bolts
are tight.
d) Check blades tip to tip for straightness. (They should be
within 3/16", or one blade width from being in line.)
6.3 BLADES DO NOT STOP WHEN DISENGAGED.
a) Check belt guides under rear deck to make sure they are
properly set (See Section 5.2.8) and check the
blade engagement adjustment (See Section 5.2.4.
- 36 -
6.4 ENGINE WILL NOT START.
a) Check that the choke is in the "ON" position for a cold
engine or in the "OFF" position for a warm engine. See
4.3.2.
NOTE: Kawasaki engines may need to be choked even when
warm.
b) Make sure the key switch is in the "ON" position
(B&S engine only).
c) Make sure transmission is in "true neutral" position.
(See 5.2.10).
d) Check that the blades are disengaged and the blade switch
is depressed.
e) Check that there is fuel in the tank and that the fuel
valve is open.
Е) Check that the spark plug wire (s) are properly connected.
g) Check for loose or faulty wiring connections. If it is
necessary to disconnect wire connectors, Do Not pull on
the wires while disconnecting.
h) Check for corrosion at all wiring connections.
Even minor corrosion may cause a faulty connection.
Clean connector terminals thoroughly with electrical
contact cleaner, apply dielectric grease and reconnect.
A CAUTION
e It is essential that all operator safety
mechanisms be connected and in proper
operating condition prior to mower use.
NOTE: After carefully checking the above steps, attempt
to start the engine. If it does not start, contact your
authorized Exmark service dealer.
ENGINE TROUBLESHOOTING
A CAUTION
¢ When checking starting problems, be
sure to keep body, hands and clothes
away from areas where moving parts
can suddenly engage.
ÁN CAUTION
. When performing maintenance, servicing
or repairing the unit, allow the engine
ample time to cool down. Serious burns
can result from hot metal.
-37-
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 or adjustment
procedures (such as valves, governor, etc.). Have this
work done by your Engine Service Dealer.
ENGINE TROUBLESHOOTING TABLE
PROBLEM | 25 | “rm | nin | “Wma | On | EERE | me | Con | am
PLUG FILTER LEVEL SCREEN
Will not start X X X X X
Hard starting X X X X x X X
Stops suddenly X X X X X X
Lacks power X X X X X X X X
Operates x x Y x X x Y
erratically
Knocks or pings X X
Skips or misfires X X X X X
Backfires X X X
Overheats X X X X X
High fuel x x x X
consumption
„38.
7. WIRING DIAGRAM
B &S VANGUARD TRANSMISSION SWITCH
—
FROM SAFETY
INTERLOCK MODULE
и
BLUE — ED
ORANGE A BLADE
YELLOW SWITCH
No,
RED .
N
BLACK
BROWN
ОРС SWITCH
NO,
CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED ENGINE
М.О. = NORMALLY OPEN KILL
GROUND SWITCH
ENGINE
KAWASAKI
TRANSMISSION SWITCH
Я 8 NO.
= =
2 =
FROM SAFETY | |
INTERLOCK MODULE BLUE NE
— ORANGE mE Sy
BLADE
| SWITCH
= NO,
"re
! a OPC SWITCH
58 NG.
A | ENGINE KILL
RED CRD JJ
CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED ENGINE
N.O, = NORMALLY OPEN GROUND
TRANSMISSION SWITCH
KOHLER Е E NO.
FROM SAFETY =
INTERLOCK MODULE $
|| BLADE
SWITCH
NO,
етой
ORANGE
“az ENGINE KILL
STE
e ENGINE
GROUND
CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED
М.О. = NORMALLY OPEN
HYDRAULIC DIAGRAM
8.
AMOS ISIAH
»I8NSS9Hd HOIH aANSS3d HOIH
y
— dp
MNVL
OMNVEHGAH
ЧУ.
|=
ISI4AJY
JYNSSHHd HOIH
АА О
OA)
|
ot
ha Л BR
X
À
da yMaO:
FHUNSSIHd HOIH
- 40 -
9. WARRANTY
Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg. Co. Inc.
("Exmark") warrants on the terms and conditions herein, that it will repair,
replace or adjust any part manufactured by Exmark and found by Exmark(in the
exercise of its reasonable discretion)to be defective in factory material or
workmanship.
This warranty is limited to one year from the date of original retail purchase
(90 days for rental use) for any Exmark mower that is used for commercial or
any other income producing purpose. The hydrostatic traction drive system will
be warranted for two full years from date of original retail purchase against
defects in materials or workmanship excluding hoses. Exmark Mfg will extend
the Peerless 5-speed transmission manufacturer's warranty from 90 days to one
year. Belts and tires are warranted for 90 days against defects in materials or
workmanship.
The engine warranty is covered by its respective engine manufacturer. Please
refer to the engine manufacturers warranty statement that is included in the
literature packet. Exmark is not authorized to handle warranty adjustments on
engines. Engine warranties should be referred to the nearest authorized
service outlet of the engine manufacturer.
This warranty extends only to the original retail purchaser of the equipment.
The warranty may not be assigned or transferred without the prior express
written consent of Exmark. The warranty commences upon the date of the
original retail purchase.
The Exmark turf equipment, including any defective part, must be returned to an
authorized Exmark service dealer within the warranty period. The warranty shall
extend to cost to repair or replace (as determined by Exmark) the defective
part, including labor. The expense of delivering the mower to the dealer for
warranty work and the expense of returning it back to the owner after repair or
replacement will be paid for by the owner. Exmark's responsibility in respect
to claims is limited to making the required repairs or replacements, and no
claim of breach of warranty shall be cause for cancellation or rescission of
the contract of sale of any Exmark mower. Proof of purchase may be required by
the dealer to substantiate any warranty claim. All warranty work must be
performed by an authorized Exmark service dealer.
This warranty extends only to turf equipment operated under normal conditions
and properly serviced and maintained. The warranty expressly does not cover:
(i) any defects, damage or deterioration due to normal use, wear and tear, or
exposure; (ii) normal maintenance services, such as oil change, cleaning,
lubrication, adjustment; (iii) replacement of service items, such as oil,
lubricants, spark plugs, belts, rubber hoses or other items subject to normai
service replacement; (iv) damage or defects arising out of or relating to
misuse, neglect, alteration, negligence or accident; (v) repair or replacement
arising from operation of or use of the turf equipment which is not in
accordance with operating instructions as specified in the operator's manual or
other operational instructions provided by Exmark; (vi) repair or replacement
arising as a result of any operation from turf equipment that has been altered
or modified so as to, in the determination of Exmark, adversely affect the
operation, performance or durability of the equipment or that has altered,
modified or affected the turf equipment so as to change the intended use of the
product; (vii) repair or replacement necessitated by use of parts, accessories
or supplies, including gasoline, oil or lubricants, incompatible with the turf
- 41 -
equipment or other than as recommended in the operator's manual or other
operational instructions provided by Exmark; (viii) repalrs or replacements
resulting from parts or accessories which have adversely affected the
operation, performance or durability of the turf equipment; or (ix) damage or
defects due to or arising out of repair of turf equipment by person or persons
other than an authorized Exmark service dealer or the installation of parts
other than genuine Exmark or Exmark recommended parts.
As a condition to this warranty, customer shail have read the operator's manual
and shall have returned to Exmark, within the prescribed time, the enclosed
warranty registration card.
The sole liability of Exmark with respect to this warranty shall be repair and
replacement as set forth herein. Exmark shall have no liability for any other
cost, loss or damage, including but not limited to, any incidental or
consequential loss or damage. In particular, Exmark shall have no liability or
responsibility for: (i) expenses relating to gasoline, oil or lubricants; (ii)
loss, cost or expense relating to transportation or delivery of turf equipment
from the location of owner or location where used by owner to or from any
authorized Exmark service dealer; (iii) travel time, overtime, after hours
time or other extraordinary repair charges or charge relating to repairs or
replacements outside of normal business hours at the place of business of the
authorized Exmark service dealer; (iv) rental of like or similar replacement
equipment during the period of any warranty, repair or replacement work; (v)
any telephone or telegram charges or travel charges; (vi) loss or damage to
person or property other than that covered by the terms of this warranty; (vii)
any claims for lost revenue, lost profit or additional cost as a result of a
claim of breach of warranty; or (viii) attorney's fees.
There are no representations or warranties which have been authorized and
provided to the buyer of the turf equipment, other than as set forth in this
warranty. Any and all statements or representations made by any seller of this
equipment, including those set forth in any sales literature or made orally by
any sales representative, are superseded by the terms of this warranty. Any
affirmation of fact or promise made by Exmark or any of its representatives to
the buyer which relates to the goods that are the subject of this warranty
shall not be regarded as part of the basis of the bargain and shall not be
deemed to create any express warranty that such goods shall conform to the
affirmation or promise.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES,
EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING THE
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED HEREIN,
RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.
This warranty applies to all Exmark turf equipment sold in the United States
and Canada and intended to be used for commercial purposes.
-42.
SEE EXMARK'S COMPLETE
LINE OF PRODUCTS FOR TURF CARE
LAZER Z
EXPLORER
TURF RANGER
TURF TRACER HYDRO
TURF TRACER HP
VIKING 5-SPEED
VIKING HYDRO
METRO
SELF STEERING SULKY
GRASS CATCHER
MICRO-MULCHING ACCESSORY
EXMARK MFG. CO. INC. PART NO. 850435
INDUSTRIAL PARK BOX 808 (402) 223-4010
BEATRICE, NE. 68310 FAX (402) 223-4154
ALL RIGHTS RESERVED PRINTED IN U.S.A. AT
MFG. CO. INC.