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Exmark Lazer Z XP Lawn Mower User Manual

1. ANIL AY TS Jm 19904 XLS omid ADD gd Om fol E d ka ER BEE a E DR D o ANJA JHM WO AIMA SHOLOANNOO 228 se6ers See S355 ges s See LLON Ek g does SHE pi SI was 2 Buy BEE S g z ET 1 1 Tret a e e gt RI ap mem NG ra AENA AD An 2a A NA ama H pas CO ye H QIN aa 9 ma 1 me ON Em WMG HLIK CSOD UM Da EI 1 fal yg NOLLISO4 9007 mm NI Ges BEN SN S9431 TIND ALTA CSOT 381 E sh CN DINI SHINS DIKUJ NOTION 108 cad i EEN NOTLOW HA Lim SV BANTd AROS oo Es real Ge tri etj HILIAS ATS Boot Dld IONAD ogy me A339 OL mme 170 vumm ATWO EM E IDIA OL IOWA NI HILTAS Bpi NA VE mih EN stita 11S E EINEN 27 ROT b Atxl vie wa e E ES HJLIMS INON 430 1 OW NOLLINII DWN LIT NOILISOd 03s T YJE KOTA j XTYNIHSSL en pore Lawan J AE ue A TWNIWAAL Ce NAN mom Sr a on DEET WK NAOH ric l Be e a E 8 ouwen de A d val STEE Ce Die BESS g SE SKS DG SE SE Sieg E D Lee L di Org HOTT 22566 S gyra Fy Ga 456 z 2 Maa 31 THOJNE at ALYAS T wus SS 33 S ds 3 8 e d a22 L ZS ECKE E 3 da 2 3332y gz Fu D Bas SS Z z3 SS x d 95 padgg E SM B SES S S Fans T A HOLINS Old 8313 SMH A WNIWASL 30010 JINON HJLIMS LIIL Ap 1Y3S KAMEN c A 7 A ei l Ay wo mg a AVTIS LaVIS S WNIWaSL JMISS Op AWS AVR SOLWNGSLY 211 mu 20 am INOOH SEENEN 10 Ha 110 ATLL TW TL 2 ois AVG 1Y3S KJO LVS 4 AdILIY
2. A WARNING POTENTIAL HAZARD e Engine coolant is hot and pressurized e Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system or touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD 4 Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system Ah CAUTION POTENTIAL HAZARD e Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD 4 Do not swallow Keep out of reach of children and pets 1 6 SAFETY SIGNS 1 6 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels 1 6 2 Safety signs must be replaced if they are missing or illegible 1 6 3 When new components are installed be sure that current safety signs are affixed to the replaced components 1 6 4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc 1 6 5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to aclean dry surface Smooth to remove any air bubbles 1 6 6 Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower RELEASE CRY A WARNING To avoid serious
3. 29 a Stop engine wait for all moving parts to stop and remove key b Tilt seat up and tilt hood forward to gain access to the engine area c Drain oil while engine is warm from operation d Remove the oil drain plug There are two oil drain plugs available One drain plug is located at the front of the engine the other is located on the right side Either drain plug can be used Allow oil to drain then replace the drain plug e Replace the oil filter every other oil change f Clean around oil filter and unscrew filter to remove g Before reinstalling a new filter apply a thin coating of fresh clean oil on the surface of the gasket h Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 full turn i Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual DO NOT overfill j Start the engine at idle for 5 minutes Stop engine and wait three minutes then check the oil level If required add oil to bring level to the FULL mark on the dipstick DO NOT overfill k Check for leaks including around the oil filter 5 1 12 Change engine coolant Service Interval 4 years 4000 hours Dex Cool extended life coolant orange color It is recommended to service at whichever interval happens first a Stop engine wait for all moving parts to stop and remove key Machine must be posi
4. WHAT CAN HAPPEN Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning o HOW TO AVOID THE HAZARD Keep the roll bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely necessary Do not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 1 4 15 1 4 16 e Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water e Check carefully for overhead clearances i e branches doorways and electrical wires before driving under any objects and do not contact them Use EXTREME caution when backing up LOOK BEHIND YOU 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 damaged 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 overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury Disengage PTO before starting engine Start the engine carefully with feet well away from the blades Keep hands feet and clothing away from
5. to 114 4 8 6 4 mm gap can no longer be achieved because there is no clearance between nyloc nut below the spring and the jam nut above the trunion or there are no threads left on the bottom nyloc nut the length of the brake rod can be adjusted Remove a pin from a yoke at either end of the brake rod and lengthen or shorten the brake rod until 3 16 to 1 4 4 8 6 4 cm gap can be achieved by following steps e and f LEVER UP A ENGAGED ki LEVER DOWN DISENGAGED JAM NUT ABOVE TRUNION ROLLER REMOVE PIN ADJUST ROD LENGTH FOR ADDITIONAL BRAKE ADJUSTMENT SPRING RETAINER BRACKET 3he ai Mr v NYLOCNUT BELOW SPRING TRUNION NYLOC NUT BELOW ROLLER TRUNION ROLLER FIGURE 16 BRAKE ADJUSTMENT 40 5 2 10 Adjust Throttle Lever Tension a Stop engine wait for all moving parts to stop and remove key b Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt which is located under the console See Figure 17 LEVER TAB WASHER BELLEVILLE WASHERS IN FIGURE 17 THROTTLE TENSION 5 2 11 Electric Clutch Adjustment No adjustment is necessary 5 2 12 Reverse Indicator Adjustment a Stop engine wait for all moving parts to stop and remove key b Tilt seat forward c Begin with either the left or right motion control lever Move lever to the neutral positi
6. 1 2 9 13 mm while applying 22 pounds of force to the belt midway between fan and alternator Belt Guide Adjustment a Stop engine wait for all moving parts to stop and remove key b Remove the belt shield on the right side of mower deck c Locate belt guide bolted to deck near the shield support stud and right hand pulley Guide should be 1 8 3 mm away from the belt with bolt end of guide near end of slot See Figure 15 39 d If adjustment is necessary loosen the bolt securing the belt guide and make proper adjustment Tighten hardware BELT GUIDE 0 END o 9 6 e SLOT A gt mY FIGURE 15 BELT GUIDE POSITIONING 5 2 9 Brake Link Adjustment Check to make sure brake is adjusted properly a Disengage brake lever lever down b Measure the length of the spring Measurement should be 2 75 7 cm See Figure 16 c If adjustment is necessary adjust the nyloc nut at the bottom of the spring to achieve 2 3 4 7 cm d Engage the brake lever lever up e The space between the brake spring bracket and the nyloc nut under the spring should measure 3 16 to 1 4 4 8 6 4 mm f If adjustment is necessary loosen jam nut above the trunion roller Adjust the nyloc nut under the trunion roller until 3 16 to 1 4 4 8 6 4 mm exists between the spring retainer bracket and the adjacent nyloc nut Tighten the jam nut above the trunion roller g Ifa 316
7. See section 5 2 12 and 5 2 13 7 2 MOWER CUTS UNEVENLY a Check air pressure in drive tires 10 psi Semi pneumatic casters do not require inflation A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation Check deck support chains Check deck leveling See Adjustments Section 5 2 2 Note The front of the mower deck will be approximately 1 4 6 4 mm lower than the back of the mower deck This is the rake of the deck Check blades tip to tip for straightness they should be within 3 16 or one blade width from being in line 7 3 ENGINE WILL NOT START Make sure the battery has a full charge See section 5 1 3 for charging instructions Be sure the throttle control is in the correct position See section 4 3 3 Make sure there is fuel in the fuel tank and that the fuel valve is open Make sure the parking brake is set and motion control levers are moved out neutral lock position Check that the PTO is disengaged Check for loose or faulty wiring connections 45 PROBLEM 2 g 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 NOTE When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors NOTE After carefully checking the above
8. arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer 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 50 Owner s Responsibilities The Exmark turf equipment including any defective part 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 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 As acondition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost loss or damage including but not limited to a
9. coils of the spring on the spring loaded idler pulley measures as listed below See Figure 14 Left Side Spring 5 3 4 1 8 14 8 0 3 cm Right Side Spring 5 1 2 1 8 14 0 0 3 cm If the spring does not have the correct measurement loosen the nut holding the adjustable idler pulley on each side so they can move up and down in the slot Relieve pressure on the spring loaded idler pulleys Reposition the adjusting pulleys lower in the slot and tighten the nut Re check to make sure the coils of the spring on the spring loaded idler pulley have the correct measurement Repeat as necessary on both sides of the unit m ADJUSTABLE IDLER PULLEY STRETCHED SPRING LENGTH NOTE MEASURE FULL COILS ONLY RH SIDE X 51 2 41 8 ADJUSTABLE 14 0 0 3 cm IDLER PULLEY LH SIDE X 53 4 44 8 14 6 0 3 om SPRING LOADED IDLER PULLEY FIGURE 14 MULE DRIVE BELTS ADJUSTMENT Deck Belt Tension a The deck belt is tensioned by a self tensioning idler no adjustment is necessary Alternator belt tension a Stop engine wait for all moving parts to stop and remove key b Remove engine access panel and rubber flap assembly located behind seat c To tighten alternator belt loosen both upper and lower alternator mounting bolts Rotate alternator out away from engine and re tighten hardware to secure in place d When properly tensioned the alternator belt will deflect 3 8
10. extreme caution on slopes Avoid sudden turns or rapid speed changes 1 4 5 e See inside the back cover to determine the approximate slope angle of the area to be mowed e Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water These areas can be dangerous see Figure 1 Fa Safe Zone G0075 Figure 1 SAFE ZONE FOR MOWING e Progressively greater care is needed as the slope increases e Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope e Avoid sudden starts when mowing uphill Mower may tip backwards e Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control e Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability A Rollover Protection System roll bar is installed on the unit AA WARNING POTENTIAL HAZARD There is no rollover protection when the roll bar is down
11. injury or death e Read and understand the operatorOs manual before using this machine Do NOT operate unless trained to safely use this machine Do NOT operate under the inBuence of alcohol or drugs e Do NOT operate without shields guards and safety devices in place and working e Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system e Stop engine and remove key before adjusting servicing or cleaning machine and attachments ENGAGE e Hearing protection is recommended PART NO 103 3794 LOCATION LH Side of Console OFF STOP Ei UN aw 20 4 20 Xmark ENGINE WATER GLOW PLUGS _ IN FUEL PART NO 103 5455 LOCATION Top Front of RH Fuel Tank ITEM NAME 1 ROLLER 2 BUSHING z 3 SPRING WASHER 4 3 8 16 X4 BOLT 5 MOUNT BRACKET 6 FLAT WASHER es 7 WHIZLOCK NUT MUST BE GRADE 8 BOLT AND WASHERS MUST BE INSTALLED AS SHOWN INDIAGRAM TORQUE NUT X TO 35 45 FT LBS Type A Anti Scalp Rollers See Figure 12 PART NO 1 323540 LOCATION Left Rear Corner Top of Mower Deck Engage and disengage 103 5455 at 1 2 throttle I N 103 3794 PART NO 103 3979 To avoid serious injury or death e Pick up objects that could be thrown by the blades lt Do NOT mow when people and pets are in the area D ADANGER To avoid serious injury or death Avoid blades unless engine and blades are sto
12. locked position and use seat belt 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 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 94 DO NOT attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 5 MAINTENANCE amp ADJUSTMENTS dh WARNING POTENTIAL HAZARD e While maintenance or adjustments are being made someone could start the engine WH
13. or other contaminants in the fuel can severely damage fuel pump and or other engine components Glow Plug Light Located on the right fuel tank The glow plug light comes on when the ignition switch is turned to the ON position The glow plug light indicates the glow plugs are preheating the combustion chamber Wait for the glow plug light to go out before starting the engine Warning Buzzer Located behind the seat on the left hand side behind the engine access panel The buzzer is a warning signal for the following circumstances a When the engine is not running and the ignition switch is turned to the ON position the buzzer emits intermittent beeps The intermittent beeps remind the user that the switch is ON and the hourmeter is running A switch left ON could also drain the battery b When the engine is running and the buzzer emits a continuous beep the buzzer is warning the user that the engine is overheating Perform the following steps 1 Disengage the mower blades and idle down the engine 46 Look at the temperature gauge to determine if temperature continues to increase If it does turn the unit off and allow the engine and engine components to cool Check the coolant level If necessary fill with coolant as described in Section 5 1 2 Remove any debris on or around the radiator that may restrict airflow Check to see if the water pump alternator belt is intact If belt is missing do not run unit as unit can ove
14. putting away for winter storage a Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT When charging the battery make sure the negative battery cables are disconnected and the battery charger has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings 26 5 1 4 Voltage Percent Maximum Reading Charge Charger Settings 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 amps 2 Hours 11 7 12 0 0 25 14 4 volts 4 amps 3 Hours 11 7orless 0 14 4 volts 2 amps 6 Hours or More Clean engine cooling system Service Interval Daily or more often in dry conditions a Wipe debris from screen in engine cover Rotate engine cover forward and wipe debris from radiator core as required Inspect seals in engine cover and replace as necessary Clean grass build up under deck Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Raise deck to the transport 5 12 7cm cutting height position Lift the front of unit and support unit using jack stands or equivalent support AA CAUTIO
15. rotating parts while the mower is being operated Stop engine wait for all moving parts to stop and remove key 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 e Before clearing blockages e Whenever you leave the mower Stop the engine and wait for all moving parts to stop e Before refueling e Before dumping the grass catcher Before stopping the engine move the throttle control to the SLOW position Keep on running at idle for a short time approximately one minute then stop the engine The fuel system is provided with a shut off valve Shut off the fuel e When the machine will not be used for a few days e During transport to and from the job e When parked inside a building This mower was designed for one operator only Keep all others away from mower during operation 1 4 17 1 4 18 1 4 19 1 4 20 1 4 21 DO NOT mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Be Aware of the mower discharge and direct discharge away from others DO NOT operate the mower under the influence of alcohol or drugs Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision If jump starting is required a connect the positive power cable from the
16. slow moving vehicle emblem These items are required to drive on a public street or roadway WHAT CAN HAPPEN e Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury e 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 HOW TO AVOID THE HAZARD e Do not drive a unit on a public street or roadway WARNING POTENTIAL HAZARD 4 Loading a unit on a trailer or truck increases the possibility of backward tip over WHAT CAN HAPPEN Backward tip over of the unit could cause serious injury or death HOW TO AVOID THE HAZARD Use extreme caution when operating a unit on a ramp 4 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 e Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward e 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 Because of the increased potential for accidents during the loading and unloading process keep the roll bar in the raised and
17. steps attempt to start the engine If it does not start contact your authorized Exmark service dealer IMPORTANT It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer TROUBLESHOOTING TABLE FUEL IMPROPER FUEL WATER OR DIRT IN FUEL LINE DIRTY AIR FILTER ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL INSUFFICIENT BATTERY CHARGE FAN PUMP BELT MISSING DIRTY RADIATOR CORE Willinotstart X X X X x Jx Hardstarting X X X xX x Jx f Stops suadeny x XIII tacks power JIKJKJKJIKJKJ Operates erraticay x x x x x _ skips or mistives x x x _ overheats x x x x x_ High tuet consumption x x I 7 4 ENGINE WARNING SYSTEMS 7 4 1 7 4 2 7 4 3 Water in Fuel Light Located on the right fuel tank An illuminated water in fuel light signals water in the diesel fuel Water should be drained from the fuel filter if the light is on IMPORTANT Water
18. this publication 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 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 EXMARK PARTS PLUS 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 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 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program 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 Ifthe part does not arriv
19. to mount the bottom of the upper roll bar tube to the crate Remove the 1 2 13 x 3 1 4 capscrews and 1 2 13 hex flange lock nuts from the two brackets at each end of the upper roll bar tube and retain for later use Raise the rear of the unit and support it with jack stands or equivalent support AA CAUTION POTENTIAL HAZARD e Raising the rear of the unit for assembly relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN e The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD e DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Remove the wheel nuts from both sides of the unit and retain for later use Install the two lower roll bar tubes a Locate the left and right lower roll bar tubes b Align lower roll bar tubes along the rear engine frame as shown in Figure 2 c LOOSELY install lower roll bar hardware four 3 8 16 x 1 capscrews four spring disk washers and four 3 8 16 whizlock nuts from the bolt bag to the tubes on each side as shown in Figure 2 NOTE Be sure the spring disk washer cone is installed towards the head of the capscrew 38 16 A Woch S NUTS SPRING DISK WASHERS CAPSCREWS Sees k i 4 FIGURE 2 LOWER ROLL BAR INSTALLATION Install the upper u shaped section of the roll bar Refere
20. to stop and remove key Tilt seat up Lift the rubber flaps on front side of the engine to check pump drive belt and alternator drive belt Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt Remove bumper and check under machine to inspect the two mule drive belts and fan pump drive belt See Sections 5 2 3 through 5 2 7 for belt adjustments 5 1 16 Lubricate grease fittings Service Interval Refer to chart Stop engine wait for all moving parts to stop and remove key Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule 32 LUBRICATION CHART LOCATIONS PUMPS PLACES INTERVAL 2 Front Caster Pots Jo 2 men 3 Height Adj Shaft Bearings 1 TO hors D Bei Drive Beli er Arm Ja 1 Yearly IO Th 5 Brake Brackets a 1a 2 J 200 hours 8 Deck Rear Struts LL 2 4hrs 9 Mule Drive Belt Idler Arms 1 2 Yeaty See Section 5 1 16 c for special lubrication instructions on the front caster pivots and Section 5 1 17 for special lubrication instructions on the front casters wheel hubs No 6 Fan Pump Belt Idler Arm Access through hole in bumper plate No 7 Pump Drive Belt Idler Arm Located Under Seat c PoP N Lubricate front caster pivots once a year Remove hex p
21. turn off and turn the ignition switch to the START position Release the switch as soon as the engine starts IMPORTANT DO NOT crank the engine continuously for more then ten 10 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 c Move the throttle to the SLOW if in FAST and let the engine warm up a few minutes before moving the throttle to the FAST position BEER 4 3 4 4 3 5 4 3 6 Engaging PTO AA DANGER POTENTIAL HAZARD The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN e Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD e DO NOT put hands or feet under the mower or mower deck when the blades are engaged A DANGER POTENTIAL HAZARD An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with blade could occur WHAT CAN HAPPEN 4 Thrown objects or blade contact can cause serious injury or death HOW TO AVOID THE HAZARD 4 Never operate mower with discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and in proper working condition The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge a
22. 3552 LOCATION Top of Hydraulic Reservoir SERVICING OR CLEANING DECK Bi 1 633313 ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE PART NO 1 633313 ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm D GROUND CLEARANCE LOCATION RH Side on Top i Front Mower Deck i CUTTING HEIGHT INCHES mm I 2 0 51 2 5 64 BELT ROUTING 38 S SE ES FOR MAXIMUM FLOTATION ROLLERS MAY BE 1 633127 ap a ee POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM 163336652 OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION ee THE ROLLERS TO SUPPORT THE MOWER DECK SE m NA KON DIS I PART NO 1 633706 Ge W Ko ek b 1 E LOCATION LH Side of Cutting RAEE a ene Se ma Height Adjustment Plate PART NO 1 643222 LOCATION Left of Center on Mower Deck Under Floor Pan MERCURY SWITCH PART NUMBER 1 633782 SEE OPERATOR S MANUAL FOR DISPOSAL INSTRUCTIONS E 1643401 PART NO 1 643401 LOCATION On Tilt Switch FA CAUTION ROTATING BLADES STOP ENGINE BEFORE REACHING UNDERNEATH 1 643253 N PART NO 1 643253 LOCATION LH and RH Sides of Radiator Mount Plate AA CAUTION Loose or Damaged Blade Bolt may allow blade to come out from under deck at HIGH SPEED Replace Blade Bolt after striking a foreign object Torque Blade Bolt to 115 120 FT LBS 156 163N m SEE OPERATOR S MANUAL 103 1077 PART NO 103 1077 LOCATION Top LH Side of Mower Deck next to Stiffener PART
23. 639 Ibs 743 kg 72 Deck 1657 lbs 752 kg 2 12 TORQUE REQUIREMENTS Bolt Location Jack Shaft Spindle Nut Engine Deck Front Frame Mount Anti Scalp Roller See Figure 12 Type A Whizlock Nut Type B Nyloc Nut Type B Hex Capscrew Starter Mounting Bolts M10 Water Separator Mounting Bolts M8 Hydraulic Oil Filter Head Mounting Bolts M6 Wheel Lug NJ S einer sst ee Sege CC ee Wheel Motor Mounting Bolts Torque Cutter Housing Spindle Nut Secured with threadlocker 140 145 ft lbs 190 197 N m Blade Mounting Re EE 115 120 ft lbs 156 163 N m 75 80 ft lbs 102 108 N m 30 35 ft lbs 41 48 N m 40 45 ft lbs 54 61 N m 30 35 ft lbs 41 47 N m 50 55 ft lbs 68 75 N m 22 27 ft lbs 30 37 N m 11 14 ft lbs 15 19 N m Ee 60 72 in lbs 7 8 N m 90 95 ft lbs 122 129 N m 72 77 ft lbs 98 104 N m Wheel Hub Slotted Nout minimum125 ft lbs 169 N m Rollover Protection System Roll Bar Mounting Bolts 30 35 ft lbs 41 47 N m Clutch Retaining Bolt secured with threadlocker 55 60 ft lbs 75 81 N m 13 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE MOWER 3 2 INSTALL ROLLOVER PROTECTION SYSTEM ROLL BAR 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 Disassemble roll bar from the crate a Remove roll bar tubes from sides of crate and remove screws that attach the wheel hub retaining plate to the bottom of the crate b Remove the two brackets used
24. ASSEMBLY 1 2 13X31 4 CAPSCREW oer FIGURE 3 UPPER ROLL BAR INSTALLATION 3 3 INSTALL DRIVE WHEELS 3 3 1 Mount drive wheels with the valve stem to the outside of the unit Secure using four 4 1 2 20 wheel nuts removed in step 3 2 3 for each wheel Torque to 95 ft lbs 128 N m Lower the unit from jackstands 3 4 CHECK TIRE PRESSURE 3 4 1 Check tire pressure in drive tires Proper inflation pressure for tires is 10 psi 69 kPa Adjust if necessary Semi pneumatic caster tires do not need to be inflated 3 5 SERVICE BATTERY WARNING Battery posts terminals and related accessories contain lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling The machine is shipped with a filled lead acid battery 15 3 5 1 3 5 2 3 5 3 Tilt seat up to gain access to the battery DANGER POTENTIAL HAZARD e Charging the battery may produce explosive gases WHAT CAN HAPPEN Battery gases can explode causing serious injury HOW TO AVOID THE HAZARD Keep sparks flames or cigarettes away from battery Ventilate when charging or using battery in an enclosed space 4 Make sure venting path of battery is always open once battery is filled with acid Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval t
25. AT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the ignition switch before you do any maintenance dh WARNING POTENTIAL HAZARD e The engine can become very hot WHAT CAN HAPPEN e Touching a hot engine can cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before service or making repairs around the engine area 5 1 PERIODIC MAINTENANCE 5 1 1 Check engine oil level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure machine is on a level surface b Check with engine cold c Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level d Ifthe oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick 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 5 1 2 Check engine coolant level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure machine is on a level surface b Tilt seat up and tilt hood forward to gain access to the cooling area c Check with engine cold d View c
26. E H WNIWaSL THAI INIHJYW 8 SOLWNSSL TY LHII NDLYAYdIS V TWNIWGSL Ier NI ad HLIN Gast say One SNOTLISNNOI WEI HJLIAS NOILINDI 48 9 HYDRAULIC DIAGRAM NWud ISVO LIINI dw vd ADYVHO 20200 HOIH LT E YNVL ONNVYCAH LI Sj YOLYIQYY NI i YNVL Y31009 H pi e oa I f ences Cah Mall 1 SIF UN 5 er er ca tt diNNd NVd ELE SYNSSIHd HEH EELER IHNSSIHA HEH G0108 QHYMUO 20200 HOIH LINN dO INOS QHYMHO AYNSSAYd HOIH 49 10 2 Year Limited Warranty Exmark Turf Equipment For units purchased on or after October 1 2004 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 manufactured by Exmark 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 turf equipment purchased on or after October 1 2004 sold in the US 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 reta
27. For Serial Nos 510 000 amp Higher al MFG CO INC OPERATOR S MANUAL CONGRATULATIONS on the purchase of your new Exmark mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor 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 part number description and quantity of the part needed The Serial No plate is located on the right side of the console For ease of ordering and reference we suggest that you record the information requested in the following identification table Place Model No and Serial No Label Here Engine Model No and Spec No Code Included in Literature Pack or Fill in Below Engine Serial No E No Model No Date Purchased Serial No Part No 103 7372 Rev B AA WARNING POTENTIAL HAZARD 4 This product is a piece of power equipment WHAT CAN HAPPEN e Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD e Keep all shields guards and safety devices especially the grass discharge system in place and in proper working condition Stop engine and wait for all moving part
28. Make sure all chain attachment bolts are tight Reposition anti scalp rollers and tighten securely Re Place locking pliers Z 7 here to hold spring L hy a 11 1 2 gt Remove force on Apply downward N L deck springs by pressure here a k loosening nuts here O O O E O E LES E 1 UN o O AV Df VA IN Jam nut 7 v W Swivel Socket head 4 h 4 Front of Unit G0122 adjusting screw oe FIGURE 13 We __ gt SWIVEL ADJUSTMENT SPRING COMPRESSION ADJUSTMENT Raise deck lift lever to the 5 cutting height position See Figure 8 Adjust spring compression until proper distance is obtained between the two large washers See Figure 10 Adjustment is made by turning the nut at the front of each spring clockwise will shorten the spring counter clockwise will lengthen the spring Lock in position with jam nuts NOTE When above adjustments have been made the front of the deck will be slightly lower than the rear of the deck 38 5 2 3 5 2 4 5 2 5 VIEW FROM REAR OF UNIT 5 2 6 5 2 7 5 2 8 Wheel Drive Pump Belt Tension Self tensioning No adjustment necessary Fan Pump Belt Tension Self tensioning No adjustment necessary Mule Drive Belts Tension Adjustment Self tensioning idlers adjust as follows a b Stop engine wait for all moving parts to stop and remove key Check to make sure the
29. N POTENTIAL HAZARD 4 Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN e The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD e DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Charging Interval c Clean out any grass build up from underside of deck and in discharge chute Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 5 1 5 c Inspect blades and sharpen or replace as required d Re install the blades if they were removed by placing a block of wood between the front or rear baffles and the blade then torquing the blade bolts to 115 120 ft lbs 156 13 N m Be sure the spring disc washer cone is installed toward the bolt head See Figure 8 927 AA CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck causing serious injury or property damage HOW TO AVOID THE HAZARD Replace the blade bolt after stri
30. NO 103 0261 LOCATION RH Front of Console Top of Mower Deck This cooling system protected by Shell DEN COOL Extended Life Antifreeze Coolant Top off only with Shell DEX COOL Extended Life Antifreeze Coolant Suggested change interval is at 4 years or 4 000 hours of service Do not mix with conventional coolants Shell DEX COOL Extended Life Antifreeze Coolant is available at your local auto parts store See rei Cork Another Product Innovation From PART NO 103 0223 LOCATION LH Side on Top of Radiator ROTATING MECHANICAL DEVICES CAN CAUSE SERIOUS INJURY DO NOT operate without guards in place Stop engine before opening cover 103 5881 PART NO 103 5881 LOCATION Engine Access Panel Behind the Seat lt GREASE LUBE POINTS AT INTERVALS SHOWN CHECK HYDRAULIC FLUID AT INTERVAL SHOWN USE ONLY MOBIL 1 15W 50 SYNTHETIC MOTOR OIL SEE ENGINE OPERATOR S MANUAL FOR SERVICING ENGINE 3 CHECK TIRE PRESSURE AT INTERVAL SHOWN 10 PSI REAR DRIVE TIRES CHECK TIRE PRESSURE AT INTERVAL SHOWN 13 PSI FRONT PNEUMATIC CASTER TIRES SEE OPERATORS MANUAL FOR ADDITIONAL DETAILS 40 HOURS lt 40 HOURS 3 40 HOURS EJA 200 HOURS 200 HOURS lt 40 HOURS lt 1 r P gt 40 HOURS YEARLY KA 40 HOURS lt A YEARLY lt A 40 HOURS 40 HOURS 103 6320 For Units with S N 465 000 and Higher PART NO 103 6320 LOCATION Bottom Side of F
31. OW TO AVOID THE HAZARD e Use caution when making turns e Slow the machine down before making sharp turns 4 1 3 Tracking Adjustment Knob Located under the seat on the LH pump control link Rotating this knob allows fine tuning adjustments so that the unit tracks straight with the drive levers in the full forward position 19 Stop machine and wait for all moving parts to stop Engage park brake Tilt seat forward to gain access to the tracking knob Rotate the knob clockwise as viewed from the rear of the machine to cause the machine to track more to the right and counterclockwise to cause the machine to track more to the left Adjust in quarter turn increments until the machine tracks straight Check that the machine does not creep when in neutral with the park brakes disengaged IMPORTANT Do not rotate the knob too far as this may cause the unit to creep in neutral Refer to section 5 2 13 for control linkage adjustment PTO Engagement Switch Located on right fuel tank 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 Throttle Control Located on right fuel tank Throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Brake Lever Located on left side of unit just to the front of the console The brake leve
32. 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 only Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug DO NOT overtighten NOTE The baffle has two levels The upper level represents the HOT level and the lower level represents the COLD level The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is a225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 5 1 14 Check tire pressures w d O S Service Interval 40 hrs Stop engine wait for all moving parts to stop and remove key Check tire pressure in drive tires Inflate drive tires to 10 psi 69 kPa 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 5 1 15 Check condition of belts Service Interval 40 hrs Stop engine wait for all moving parts
33. 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 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 If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 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 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 1 3 2 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended AA CAUTION POTENTIAL HAZARD e This machine produces sound lev
34. bring the levers back to neutral The wheel must stop turning or slightly creep in reverse See Figure 19 Shut off unit Remove jumper wire from wire harness connector and plug connector into seat switch Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1 4 of a turn to properly set the pre load on the bearings If disassembled 85 make sure the spring washers are reinstalled as shown in Figure 20 G0091 FIGURE 20 CASTER ADJUSTMENT 43 6 WASTE DISPOSAL 6 1 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 6 2 ENGINE COOLANT DISPOSAL Ah CAUTION POTENTIAL HAZARD e Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow e Keep out of reach of children and pets Engine coolant is a 50 50 mixture of Dex Cool ethylene glycol anti freeze with addititives and water Ethylene glycol is a pollutant Dispose of used engine coolant according to your state and local regulations 6 3 MERCURY SWITCH DISPOSAL AA CAUTION POTENTIAL HAZARD 4 The mercury contained in the tilt switch is poisonous WHAT CAN HAPPEN Exposure to mercury can cause severe illness HOW TO AVOID THE HAZARD 4 Never attempt to open or repair the tilt switch e Avoid contact w
35. ce Interval Daily a Stop engine wait for all moving parts to stop and remove key b Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service air cleaner Canister type 2 stage cleaner Service Intervals First service interval 50 hrs Normal service interval 100 hrs Replacement interval 600 hrs more often under heavy load or high temperatures a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up to gain access to the air cleaner c Remove engine access panel d Loosen retaining clips and remove air cleaner compartment cover e Remove paper element Check the condition of the paper element Replace if dirty bent or damaged f Check the condition of the inner element Replace whenever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine g DO NOT wash or use pressurized air to clean paper element or inner element h Reinstall paper element Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change engine oil Service Intervals First service interval 50 hrs Normal service interval 100 hrs yearly if operated less than 100 hrs more often under heavy load or high temperatures
36. cuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must stop after approx 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must stop after 1 2 second has elapsed 28 5 1 10 5 1 11 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 stop after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever in engine must stop Repeat again moving the right lever in then moving both levers in engine must stop whether operator is on seat or not NOTE If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER IMPORTANT It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check rollover protections systems roll bar pins Service Interval Daily a Make sure latch pin and hair pin are fully installed and lanyard is in good condition b Check that the seat latch closes and latches securely c Check the operation and condition of seat belt If seat belt webbing is worn or frayed replace immediately Part Number 103 4469 Check for loose hardware Servi
37. d Dex Cool coolant allowing some room approximately 1 2 1 27 cm for expansion Add 50 50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle POTENTIAL HAZARD Engine compartment contains open belt drives and fans Rotating components can cause injury WHAT CAN HAPPEN Fingers hands loose clothing or jewelry can get caught by the rotating fan and drive shaft HOW TO AVOID THE HAZARD Do not operate machine without the covers in place Keep fingers hands and clothing clear of rotating components Shut off engine wait for all moving parts to stop and remove the ignition key before performing maintenance With the cap off the radiator start the engine Refer to Section 4 3 3 Operate engine until the engine thermostat opens and coolant is circulating through the radiator core As air is purged from the engine block and the coolant level drops add additional coolant to the radiator When the radiator is completely full and no additional coolant can be added continue running the engine and install the radiator cap Make sure that the cap is completely seated by pressing down firmly while turning until the cap stops Once the cap is installed the engine may be stopped 31 5 1 13 Check hydraulic oil level a b Service Interval 40 hr Stop engine and wait for all moving parts to stop Clean
38. deck lift assist lever 36 5 2 2 SPRING DISC WASHER o g CONE TOWARDS BOLT HEAD p Sa TYPE B 38 24 x 2 GR8 TORQUE TO 50 55 fits 68 75 N m FOR CUTTING HEIGHTS ABOVE 3 5 38 mm NOTE When changing cutting height positions always come to a complete stop and disengage the PTO LEVER IN TRANSPORT AND 5 12 7 cm CUTTING HEIGHT POSITION FIGURE 11 CUTTING HEIGHT POSITION Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter See decals on the side of deck lift plate Move lever out of the transport or 5 12 7 cm cutting height position and down onto height adjustment pin to mow at selected height To transport move lever back up to transport or 5 12 7 cm cutting height position Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure the PTO is disengaged Adjust anti scalp rollers for Normal Operating Conditions Place rollers in one of the positions shown in Figure 12 Rollers will maintain 3 4 in 19 mm clearance to the ground to minimize gouging and roller wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts and nuts are installed with the spring disc washer between head of the bolt and mounting bracket Two types of anti scal
39. e connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery Mim VATE Ah WARNING BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN 16 3 6 INSTALL MOTION CONTROL LEVERS 3 6 1 Loosen and remove the two 2 378 x1 bolts and spring disk washers which attach the motion control levers to the control arm shafts for shipping and the two 2 3 8 x 1 bolts and spring disk washers which are screwed into the control arm shafts a Install the left motion control lever onto the control arm shaft See Figure 5 on the left side of the console Place the lever with the mounting plate towards the rear on the outside of the control arm shaft and secure with the bolts and washers Position the lever so the bolts are in the center of the slots on the lever mounting plate and tighten until snug Repeat on opposite side of unit NOTE There are two lever height options available Place the levers in the top two holes to increase height of the levers or the bottom two holes to decrease the height of the levers If the levers do not align with each other
40. e front of each spring See Figure 13 Lower the deck to the 1 1 2 height position Force the left rear deck support arm downward about 1 4 to get the deck to rest at the 1 1 2 height position Place locking pliers between the rear swivel and spring stop to hold the deck in this position See Figure 13 Place a 3 4 thick block of wood under each of the two 2 rear anti scalp roller brackets and place one under one of the front center anti scalp roller brackets Loosen the two 2 top chain bolts in slots in the rear deck lift arms Loosen jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose Turn the socket head adjusting screws in until slack is taken out of each chain Tighten the jam nuts Tighten the chain bolts in the deck lift arms making sure they don t move while tightening Loosen the four 4 nuts which secure the front swivels two per side until the front chains are loose and front of deck is supported by the 3 4 block Do not loosen the front chain hardware On left side adjust front swivel using the locking nut behind the swivel until the front chain is tight and all slack is removed from linkage Do not lift front of deck off 3 4 block Secure front swivel using locking nut in front of swivel Repeat for right side Recheck that the 3 4 blocks fit just snugly under the brackets and that the tension on all the chains are approximately equal
41. e 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 Parts Plus service is available only in the 48 contiguous United States 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 access
42. e removing the radiator cap or servicing any component of the cooling system Ah CAUTION POTENTIAL HAZARD e Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow e Keep out of reach of children and pets With machine on level surface and with cool engine remove radiator cap under hood and add a 50 50 mix of water and Dex Cool extended life coolant until liquid level is as high as possible without overflowing Reinstall radiator cap making sure that the cap is completely seated by pressing down firmly while turning until the cap stops Add 50 50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle NOTE Units should only be filled with Dex Cool extended life coolant which can be identified by its orange color 3 10 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reservoir Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug DO NOT overtighten NOTE The baffle has two levels The upper level represents the HOT level and the lower level represents the COLD level The oil level
43. el with a cetane rating of 40 higher NOTE Do not use kerosene or gasoline instead of diesel fuel Failure to observe this caution will damage the engine DO NOT add oil to fuel DO NOT overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 4 2 2 Make sure you understand the controls their locations their functions and their safety requirements 4 2 3 Refer to Maintenance Section 5 and perform all the necessary inspection and maintenance steps 4 3 MOWING 4 3 1 Operate units with the roll bar in the raised and locked position and use seat belt There is no rollover protection when the roll bar is down If it is necessary to lower roll bar do not wear the seat belt Raise the roll bar as soon as clearance permits 4 3 2 Open fuel shut off valve left or right tank 4 3 3 Starting Engine a Brake must be engaged motion control levers out neutral lock position and PTO switch OFF to start engine Itis not necessary for the operator to be in the seat to start the engine b On a warm engine place the throttle in the SLOW position On a cold engine below 14 F 10 C place the throttle in the FAST position Note Do not use fuel left over from summer c Turn the ignition switch to the ON position The glow plug light will turn on Wait for the glow plug light to
44. els in excess of 85 dBA at the operator s ear when in operation WHAT CAN HAPPEN e Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine 133 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals 1 3 4 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 POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide can kill you HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect POTENTIAL HAZARD 4 In certain conditions gasoline and diesel fuel are flammable and can be highly explosive WHAT CAN HAPPEN A fire or explosion from gasoline or diesel fuel can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where fuel fumes may be ignited by spark e Refuel only outdoors Store fuel in an approved container and keep it out of the reach of children e Add fuel before starting the eng
45. fts 2 8 3 Hydraulic Oil Type Synthetic Mobil 1 15W 50 2 8 4 Hydraulic Oil Capacity 4 qt 3 8 L 2 8 5 Hydraulic Filter Replaceable cartridge type P N 103 2146 25 microns No bypass 2 8 6 Speeds 0 12 0 mph 19 3 km hr forward 0 8 0 mph 12 9 km hr reverse 2 8 7 Drive wheel release valves allow machine to be moved when engine is not running 2 9 TIRES AND WHEELS 2 9 1 Tires Drive Front Caster Pneumatic Air Filled Semi P neumatic Quantity 2 2 Tread Multi Trac C S Smooth Size 26 x 12 0 12 13 x 6 50 6 Ply Rating 4 Pressure 10 psi 69 kPa 2 10 CUTTING DECK 2 10 1 Cutting Width 72 in 182 9 cm 60 in 152 4 cm 2 10 2 Discharge Side 2 10 3 Blade Size 3 each w 60 Deck 20 5 in 52 1 cm w 72 Deck 24 5 in 62 2 cm 2 10 4 Blade Spindles Solid steel spindles with 1 I D bearings 2 10 5 Deck Drive Electric clutch mounted on horizontal engine shaft 2 A Section belts with self tensioning idlers from electric clutch to transfer shaft mounted on deck Blades are driven by one B Section belt w self tensioning idler from transfer shaft on deck to blade spindles 2 10 6 Deck Full floating deck is attached to out front support frame Six anti scalp rollers provide maximum turf protection Deck design allows for bagging mulching or side discharge 2 10 7 Deck Depth 5 5 14 0 cm 12 2 10 8 Cutting Height Adjustment an extra long cushioned lever is used to adjust the cutting hei
46. ght from 1 1 2 3 8 cm to 5 10 2 cm in 1 4 6 4 mm increments The cutting height adjustment handle has a transport position and all adjustments can be made while the operator remains seated Units also have a foot operated deck lift assist lever to aid in raising the deck 2 10 9 2 11 DIMENSIONS 2 11 1 Overall Width Mulching Kit Optional without deck deflector up deflector down 60 Deck 54 5 in 138 4 cm 61 4 in 156 0 cm 72 2 in 183 4 cm 72 Deck 58 5 in 148 6 cm 73 2 in 185 9 cm 84 3 in 214 1 cm 2 11 2 Overall Length Roll Bar Up Roll Bar Down 60 Deck 82 2 in 208 8 cm 92 3 in 234 4 cm 72 Deck 86 0 in 218 4 cm 96 1 in 244 1 cm 2 11 3 Overall Height Roll Bar Up Roll Bar Down 60 Deck 73 7 in 187 2 cm 55 6 in 141 2 cm 72 Deck 73 7 in 187 2 cm 55 6 in 141 2 cm NOTE Height will vary slightly depending on seat setting 2 11 4 Tread Width center to center of tires widthwise Drive Wheels Casters 60 Deck 42 8 in 108 7 cm 38 9 in 98 8 cm 72 Deck 46 8 in 118 9 cm 47 6 in 120 9 cm 2 11 5 Wheel Base center of caster to center of drive tire 60 Deck 54 0 in 137 2 cm 72 Deck 56 8 in 144 3 cm 2 11 6 Curb Weight 60 Deck 1
47. he coolant temperature gauge monitors the temperature of the engine coolant An engine overheating condition is indicated by the red area on the gauge and an alarm will sound See Section 4 1 17 Voltmeter Located next to the Coolant Temperature Gauge at the front of the left fuel tank The voltmeter measures the voltage output of the alternator Both high and low voltages will potentially damage the battery Water in Fuel Light Located on the right fuel tank An illuminated water in fuel light signals water in the diesel fuel Water should be drained from the fuel filter if the light is on IMPORTANT Water or other contaminants in fuel can severely damage fuel pump and or other engine components Glow Plug Light Located on the right fuel tank The glow plug light comes on when the ignition switch is turned to the ON position The glow plug light indicates the glow plugs are preheating the combustion chamber Wait for the glow plug light to go out before starting the engine Warning Buzzer Located behind the seat on the left hand side of the engine air deflector The buzzer is a warning signal for the following circumstances a When the engine is not running and the ignition switch is turned to the ON position the buzzer emits intermittent beeps The intermittent beeps remind the user that the switch is ON and the hourmeter is running A switch left ON could also drain the battery b When the engine is running and the buzzer em
48. ient 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 TABLE OF CONTENTS 1 SAFETY PAGE 1 Safety Alert Symbol eet suedi ives eg Seu nda ta ENEE EE red Ee hte 1 EC Ve ln e WEE 1 E SN Ge E 1 2 UR fe EE 3 6 1 5 Maintenance amp Storage ege Seege Seege 6 7 To Safety le LEE 8 10 2 SPECIFICATIONS 2 1 Model NUDE PS aicearra i t at aA 11 e AE 11 239 Fuel Systeme ak Pa ge t e ed sh 11 2 4 En Ge e sai vs cen ve hd dh 11 2 5 Cooling SS ca cause acta tek oe cacay arse tc egaetee ceased eed ees 11 le Ass v sis vet bre r oh eit toe ential 11 12 SE SO AI ete eegene e e ar st 12 2 8 Hydrostatic Ground Drive Gvstem ne 12 29 Tires amp Wheels ca dhom n e h ht 12 20 ACUMING BR 12 13 21 DIMENSIONE pr se e ee 13 2 12 Torque Requirement AEN sive enen eneve eee 13 3 ASSEMBLY INSTRUCTIONS 3 1 Uncrate MON Ps a as ne eas Md eae 14 3 2 Install Rollover Protection System Roll Bar cceeeeeeeeeeenees 14 15 3 3 Install DriveWWNGClS seggt deet ekger ah n s tienes 15 34 Check Tire EE 15 3 5 Service BALL Ty ss ss ne d aep e h 15 16 3 6 Install Motion Control Levers aa uuu ohhaaaaaaaaaa nanen enen nenen eee eve eve
49. il purchase Products Warranty Period e All Products except as noted below 2 years e All Attachments and Accessories 1 year e Metro 21 Series 1 year e Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer e Battery e Engine Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are not authorized to handle warranty adjustments on engines This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e 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 e 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 All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to
50. ine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot e Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 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 e Do not operate without entire exhaust system in place and in proper working condition 1 4 OPERATION Although hazard control and accident prevention are partially 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 AWARNING POTENTIAL HAZARD Operating engine parts especially the muffler become extremely hot WHAT CAN HAPPEN Severe burns can occur on contact e Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching e Remove accumulated debris from muffler and engine area 4 Install and maintain in working order a spark arrester before using equip
51. ing transport to and from the job site and when parked inside a building The valve has three positions Each position is made in 1 4 turn increments Reference the table below for the correct locations FUEL FLOW VALVE POSITION OFF RIGHT RIGHT TANK ON DOWN LEFT TANK ON LEFT Note The operator must prime the fuel system when the fuel tanks have gone empty The primer pump is the gold button located under the seat next to the console in the front left hand corner To prime the system push down on the primer pump until the tension becomes firm approximately 10 15 pushes 20 4 1 4 1 4 1 4 1 4 1 4 1 4 1 Fuel Gauge Located on the left fuel tank The fuel gauge monitors the amount of fuel in the left tank only Use the fuel from the right fuel tank first When the right fuel tank is empty switch to the left fuel tank Fuel gauge will monitor the remaining fuel Drive Wheel Release Valves Located on the top right front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Tilt seat up to gain access to pumps With a 5 8 wrench turn both valves one turn counter clockwise to release drive system Turn clockwise to reset system DO NOT overtighten DO NOT tow machine Coolant Temperature Gauge Located at the front of the left fuel tank T
52. ith the mercury The tilt switch PN 1 633782 on this unit contains mercury a hazardous material Mercury that is outside a sealed container vaporizes at room temperature The vapors are harmful Mercury can be absorbed through the skin Do not attempt to open or repair this switch A very small amount of mercury is contained in a hermetically sealed body The steel switch is then potted in a hard epoxy in a plastic case It is unlikely that the mercury will ever escape from the enclosure These high performance and reliable switches are recyclable Mercury is an important and beneficial compound but requires special care in handling and disposal When used and managed properly mercury is not a threat to people or the environment This information is presented to users so that they are aware that these switches contain mercury and will apply sound disposal practices when these devices reach their normal end of life or are damaged Several states have passed laws concerning the disposal of devices containing mercury In all the remaining states it is advisable to follow similar procedures The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused recycled or otherwise managed to insure that it does not become part of solid waste or waters Management and disposal practices must be within relevant federal state or local laws Return the swi
53. its a continuous beep the buzzer is warning the user that the engine is overheating Perform the following steps 1 Disengage the mower blades and idle down the engine 2 Look at the temperature gauge to determine if temperature continues to increase If it does turn the unit off and allow the engine and engine components to cool 3 Check the coolant level If necessary fill with coolant as described in Section 5 1 2 Remove any debris on or around the radiator that may restrict airflow 5 Check to see if the water pump alternator belt is intact If belt is missing do not run unit as unit can overheat and damage the engine See Engine Service Dealer 21 c When the engine is running and the buzzer emits intermittent beeps the buzzer is warning the user that the engine oil pressure is low or the alternator is not charging Perform the following steps 1 Turn the unit off allow the engine and engine components to cool 2 Check the oil level and fill if necessary as described in Section 5 1 1 3 Check for oil leaking from engine If the engine is leaking see Engine Service Dealer 4 Check to see if the water pump alternator belt is intact If belt is present there could be a charging problem see Engine Service Dealer If belt is missing do not run as unit can overheat and damage the engine See Engine Service Dealer 4 2 PRE START 4 2 1 Fill fuel tanks For best results use only clean fresh diesel fu
54. king a foreign object Use only Exmark replacement parts PN 103 0862 blade bolt and PN 103 0865 spring disk washer DO NOT lubricate the threads of the bolt or spindle before assembly Torque the blade bolt to 115 120 ft lbs 156 163 N m DO NOT USE WRENCH HERE BLOCK OF WOOD BETWEEN TORQUE TO FOR BLADE INSTALLATION FRONT OR REAR BAFFLES amp BLADE oe 115 120 ft Ibs MAINTAIN TORQUE ON THIS NUT 140 145 ft lbs 190 197 N m 156 163 N m CONE TOWARDS BOLT HEAD AT ES TORQUE TO 1 115 120 ft lbs Le 156 163 N m G0084 FIGURE 8 BLADE BOLT INSTALLATION 5 1 7 Check safety interlock system a Service Interval Daily 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 Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank Check the kill cir
55. lons 7 6 L 2 6 OPERATOR CONTROLS 2 6 1 Steering and Motion Control 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 NOTE Motion control levers are adjustable to two heights 2 6 2 PTO Engagement Switch Engages electric clutch to drive belts which engage mower blades 11 2 6 3 2 6 4 2 6 5 2 7 SEAT 2 7 1 2 7 2 2 7 3 2 7 4 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 Type Deluxe suspension seat with high back low profile foam in place cushion dampened adjustable spring suspension and armrests Mounting Hinged to tilt up for access to hydraulic pumps battery and other components Held in tilted position with prop rod Adjustable fore and aft seat track Armrests Molded adjustable flip up armrests Seat Safety Switch Incorporated into the Safety Interlock System Time delay seat switch eliminates rough ground cut outs 2 8 HYDROSTATIC GROUND DRIVE SYSTEM 2 8 1 Hydrostatic Pumps Two Hydro Gear BDP 21L variable displacement piston pumps 2 8 2 Wheel Motors Two Parker Ross with 1 1 4 tapered sha
56. loorpan DECK DRIVE BELT ROUTING BELT 103 0881 103 1596 PART NO 103 1596 LOCATION Center Inside of the Rear Bumper PUMP BELT ROUTING AWARNING TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked position and use seat belt THERE IS NO ROLL OVER PROTECTION WHEN THE ROLL BAR IS DOWN Lower the roll bar necessary Do not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Read and follow slope operation instructions and warnings 107 2102 PART NO 107 2102 LOCATION Inside Surface of Upper Roll bar IMPORTANT WARNING BUZZER IF ALARM SOUNDS SHUT DOWN UNIT AND CONSULT OPERATOR S MANUAL FOR FURTHER INSTRUCTION OR ENGINE DAMAGE MAY OCCUR ooo EN _ LOWOIL ALTERNATOR PRESSURE NOT CHARGING KI ENGINE OVERHEATING CONTINUO PART NO 103 3276 LOCATION Engine Access Panel behind seat LH Side next to Buzzer A WARNING Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning To avoid loss of control and possibility of rollover Do NOT operate near drop offs or near water Do NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed change
57. lug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thread plug back in Place cap back on 5 1 17 Lubricate caster wheel hubs Service Interval Once Yearly Stop engine wait for all moving parts to stop and remove key Remove caster wheel from caster forks Remove seal guards from the wheel hub Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from the wheel assembly Pry out seals and inspect bearings for wear or damage and replace if necessary 0 SPACER NUT WITH SES WRENCH FLATS FIGURE 10 CASTER WHEEL ASSEMBLY Pack the bearings with a NGLI grade 1 multi purpose grease Insert 1 bearing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced If the axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to 1 spacer nut and thread onto the axle with the wrench flats facing outward Do not thread spacer nut all of the way 33 5 1 18 5 1 19 5 1 20 5 1 21 onto the end of the axle Leave approximately 1 8 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut i Insert the assembled nut and axle into the wheel on the side of the wheel with the
58. m Gasoline or diesel fuel 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 POTENTIAL HAZARD e Hydraulic fluid escaping under pressure can penetrate skin and cause injury WHAT CAN HAPPEN 4 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 HOW TO AVOID THE HAZARD 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 e Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper and not hands to find hydraulic leaks e 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
59. ment on forest covered grass covered or brush covered unimproved land POTENTIAL HAZARD e Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN e Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working 4 Keep hands feet hair jewelry or clothing away from rotating parts 1 4 1 1 4 2 1 4 3 1 4 4 Give complete undivided attention to the job at hand Mow only in daylight or good artificial light keeping away from holes and hidden hazards NEVER carry passengers 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 tip over could occur The operator is responsible for safe operation on slopes POTENTIAL HAZARD DANGER Mowing on wet grass or steep slopes can cause sliding and loss of control WHAT CAN HAPPEN Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning HOW TO AVOID THE HAZARD o d 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
60. motion control bronze bushings Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Tilt seat up c Lubricate bronze bushings on flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant Drain fuel filter Service Interval When Water in Fuel warning light is ON a Stop engine wait for all moving parts to stop and remove key b Place a drain pan under the fuel filter and loosen the drain plug approximately 1 turn c Water should drain d When fuel begins to flow from the filter tighten the drain plug e Prime the fuel system See Section 5 1 23 f Start engine Make sure warning light goes out Check for leaks IMPORTANT Water or other contaminants in fuel can severely damage fuel pump and or the other engine components 34 5 1 22 5 1 23 5 1 24 5 1 25 Replace fuel filter Service Interval 800 hrs A fuel filter is installed between the fuel tank and the injector pump and is located under the seat in the left hand front corner of engine deck a Close fuel shut off valve Disconnect the sensor wire remove the drain plug and discard the o ring c Remove fuel filter with a filter wrench Screw new filter on by hand until gasket contact the housing then tighten 1 3 turn more e Install the drain plug with new O ring and connect the sensor wire f Bleed air from fuel line by using the priming pu
61. mp See section 5 1 23 then start the engine to check for leaks es Replacement Components 27 HP Daihatsu Diesel Fuel Filter Briggs amp Stratton P N 820311 27 HP Daihatsu Diesel Drain Plug O ring Briggs amp Stratton P N 820348 Fuel priming procedure Service Interval As required The primer pump is the gold button located under the seat next to the console in the front left hand corner a Repeatedly push down on the primer pump until the resistance becomes firm approximately 10 15 pushes Change hydraulic system filter Service Interval After First 250 hrs Then yearly thereafter NOTE Use only Exmark Part No P N 103 2146 a Stop engine wait for all moving parts to stop and remove key b Raise seat c Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system d Unscrew filter to remove and allow oil to drain from reservoir IMPORTANT Before reinstalling new filter fill it with Mobil 1 15W 50 and apply a thin coat of clean oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn e Fill reservoir as stated in Section 5 1 13 f Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely g Start engine and move throttle control ahead to full throttle position Move the speed contr
62. n 17 3 7 Position Discharge nt 17 3 8 SERVIER ne UE 17 3 9 Service Engine COON EE 17 18 3 10 Service Hydraulic EE 18 4 OPERATION INSTRUCTIONS AG e ene 18 22 42 E Ee eebe 22 4 amp 3 S M WING tesh a A A R 22 23 AA Transporting e kd t EEE 23 25 5 MAINTENANCE amp ADJUSTMENTS 5 1 Periodic Een le 25 36 e TEE nn 36 43 6 WASTE DISPOSAL ET Molor Ol DISHOSal sve Ph ee 44 6 2 Engine Coolant Disposal erer aber Mouton eae eerie date 44 6 3 Mercury Switch DISPOSA 1 una vendet g i es 44 6 4 Battery DispOSsall e eee eee de et eS 45 7 TROUBLE SHOOTING aaa aaa aaaaaaaaaaaaaaaaaaaaaaane ses enet ete tee tete tete tete rere reres 45 47 8 ELECTRICAL DIAGRAN S aaa aaa aaa nn nana enes vere eee ene re eter e eee tezen ee rere eee 48 9 HYDRAULIC DIAGRAM co cent cee dare nas ACEL 49 10 WARRANT V ca hd hh atal E ce sua aaeadeesds 50 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 to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Black lettering Orange
63. n equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line Movement of the left lever forward will cause the left drive wheel to rotate in a forward direction Movement of the right lever forward will cause the right drive wheel to rotate in a forward direction To stop forward travel pull the levers back to the neutral position To turn left while moving forward move the left lever back toward neutral to slow the left drive wheel To turn right while moving forward move the right lever back toward neutral to slow the right drive wheel To make a zero turn to the left pull the left lever back beyond neutral while holding the right lever slightly ahead of neutral To make a zero turn to the right pull the right lever back beyond neutral while holding the left lever slightly ahead of neutral Pulling the levers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction spring tension can be felt when moving into reverse from neutral To turn to the left while backing move the left lever forward toward neutral To turn to the right while backing move the right lever forward toward neutral CAUTION POTENTIAL HAZARD e Machine can spin very rapidly by positioning one lever too much ahead of the other WHAT CAN HAPPEN Operator may lose control of the machine which may cause damage to the machine or injury H
64. nce Figure 3 for alignment and installation instructions below 14 a Locate the latch pin assemblies pin and hairpin connected with a lanyard b Install a 1 2 13 x 3 1 4 capscrew in the washer on the lanyard of each pin assembly Note Make sure the bent tab in the washer is towards the head of the bolt b Lightly oil the inside surfaces of the ear shaped plates at the upper end of the lower roll bar tubes c Locate the upper u shaped section of the roll bar Install the upper roll bar section using the two 1 2 13 x 3 1 4 capscrews from step b and two 1 2 13 hex flange lock nuts Do not over tighten Make sure upper roll bar can pivot freely Notes e Make sure the capscrew and nuts are installed with the nut to the inside of the roll bar e Make sure the tab on the lanyard washer is installed as shown and points toward the front of the unit d Raise the roll bar into the upright position and secure with the latch pin assemblies on each side Install the latch pin from the outer surface of the roll bar assembly and secure with the hairpin to the inside e Tighten the front knobs against the upper roll bar ends f Torque all lower roll bar hardware attached to the machine frame to 30 35 ft lbs 41 47 N m UPPER ROLL 1 2 13X31 4 BAR TUBE CAPSCREW LATCH PIN ASSEMBLY lt APPLY OIL TO INSIDE SURFACE OF EAR SHAPED PLATES 4 213 HEX FLANGE LOCK NUTS e LATCH PIN
65. new seal and bearing j 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 k Insert the second bearing and new seal into the wheel I Apply a thread locking adhesive to the 2 spacer nut and thread onto the axle with the wrench flats facing outward m Torque the nut to 75 80 in lbs 8 9 N m loosen then re torque to 20 25 in lbs 2 3 N m Make sure axle does not extend beyond either nut n Re install the seal guards over the wheel hub and insert wheel into caster fork Re install caster bolt and tighten nut fully IMPORTANT To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Re apply threadlocking adhesive Lubricate brake handle pivot Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil Lubricate brake rod bushings Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings Lubricate
66. nual 2 2 2 RPM Full Speed 3850 RPM No Load Idle 1750 RPM 2 3 FUEL SYSTEM 2 3 1 Capacity 15 5 gal 56 8 L 2 3 2 Type of Fuel Diesel fuel 40 cetane or higher Note Do not use kerosene or gasoline instead of diesel fuel Failure to observe this caution will damage the engine 2 3 3 Fuel Filter Replaceable Canister 10 micron Briggs amp Stratton P N 820311 2 3 4 Fuel Shut Off Valve 1 4 turn increments Left tank Right tank OFF 2 4 ELECTRICAL SYSTEM 2 4 1 Charging System External Alternator 2 4 2 Charging Capacity 40 Amps 2 4 3 Battery Type BCI Group Size 26 2 4 4 Battery Voltage 12 Volt 2 4 5 Polarity Negative Ground 2 4 6 Fuses One 40 amp and one 20 amp blade type 2 4 7 Safety Interlock System PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged 2 4 8 Tilt Switch Shuts off the engine when the unit is tilted more than 60 from horizontal 2 5 COOLING SYSTEM 2 5 1 Fan Hydraulic continuous operation with engine running 2 5 2 Coolant Liquid 50 50 mix of Dex Cool extended life antifreeze and water 2 5 3 Coolant Capacity 2 gal
67. ny incidental or consequential loss or damage In particular we shall have no liability or responsibility for e Expenses related to gasoline oil or lubricants e 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 e Rental of like or similar replacement equipment during the period of any warranty repair or replacement work e Any telephone or telegram charges or travel charges e Loss or damage to person or property other than that covered by the terms of this warranty e Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e 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 There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment which is the subject of this 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 warran
68. o bring the charge up to a full charge of 12 6 volts or greater IMPORTANT When charging the battery make sure the negative battery cables are disconnected and the battery charger has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Percent Maximum l Reading Charge Charger Settings Ge 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 amps 2 Hours 11 7 12 0 0 25 14 4 volts 4 amps 3 Hours 11 7orless 0 14 4 volts 2 amps 6 Hours or More AA CAUTION POTENTIAL HAZARD Ifthe ignition is in the ON position there is potential for sparks and engagement of components WHAT CAN HAPPEN e Sparks could cause an explosion or moving parts could accidentally engage causing personal injury HOW TO AVOID THE HAZARD 4 Be sure ignition switch is in the OFF position before charging the battery Connect the negative battery cables NOTE If the positive cable is also disconnected connect the positive red cable to the positive terminal on the battery first then connect the negative black cable to the negative terminal Slip insulator boot over the positive terminal NOTE If time does not permit charging the battery or if charging equipment is not availabl
69. ol levers to the full soeed and run for several minutes Shut down machine and recheck oil level 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 Wheel hub slotted nut torque specification Service Interval 500 hrs When tightening the slotted nut on the wheel motor tapered shaft 35 a Torque the slotted nut to 125 ft lbs 169 N m b Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 25 cm or less should be showing c If more than two threads 0 1 2 5 mm are showing remove nut and install washer PN 1 523157 between hub and nut d Torque the slotted nut to 125 ft lbs 169 N m e Then tighten nut until the next set of slots line up with the cross hole in shaft f Replace cotter pin Note Do not use antisieze on wheel hub 5 1 26 Fuel Tank mounting hardware specification 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 5 1 27 Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners a Pump drive sheave set screws b S
70. on and pull lever back until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on spring See Figure 18 d Check where lever is relative to notch in console should be centered allowing lever to pivot outward to the neutral lock position e If adjustment is needed loosen the nut against the yoke and while applying slight rearward pressure on the motion control lever turn the head of the adjustment bolt in the appropriate direction until lever is centered keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position Tighten lock nut fi Repeat on opposite side of unit FRICTION WASHERS LEVER CENTERED IN NOTCH REVERSE INDICATOR KE O a yun DA TURN BOLT HERE LOOSEN HERE G0050 FIGURE 18 REVERSE INDICATOR ADJUSTMENT 41 5 2 13 M otion control linkage adjustment POTENTIAL HAZARD Engine must be running and drive wheels must be turning A WARNING so motion control adjustment can be performed WHAT CAN HAPPEN e Contact with moving parts or hot surfaces may cause personal injury HOW TO AVOID THE HAZARD e Keep fingers hands and clothing clear of rotating components and hot surfaces AA CAUTION POTENTIAL HAZARD 4 Raising the mower deck for service or maintenance relying solely on mechanical or hydra
71. oolant level in overflow bottle on the left side of the engine Coolant level should be at the indicator line on the overflow bottle 25 e Ifthe coolant level is low remove the cap to the overflow bottle and fill to the indicator line Use coolant specified in Section 2 5 2 NOTE Units should only be filled with Dex Cool extended life coolant which can be identified by its orange color A WARNING POTENTIAL HAZARD e Engine coolant is hot and pressurized e Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system or touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system CAUTION POTENTIAL HAZARD e Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets Check battery charge Service Interval Monthly Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before
72. ory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine 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 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 effic
73. p roller assemblies are available See Figure 12 to determine which assembly has been installed on the unit Torque hardware as specified or loss of roller may result Type A Torque the 3 8 whizlock nut to 40 45 ft lbs 54 61 N m Type B Torque the 3 8 nyloc nut to 30 35 ft lbs 41 47 N m Torque the 3 8 24x2 Gr 8 hex capscrew to 50 55 ft lbs 68 75 N m G0266 TYPE A I TYPE B mi ANTI SCALP ROLLER E MOUNTING BRACKET _ FRONT LEFT ANTI SCALP N CUTTING HEIGHT BRACKET SHOWN N INCHES mm Ca Na K a ae OS 20 51 lan Q 2 5 64 Hn i ef 3 0 76 Bez PS Ke Sch O 3 5 90 TYPE A 3 8 WHIZLOCK TORQUE TO 40 45 ft lbs 54 61 N m USE THE BOTTOM HOLE THE ROLLERS WILL TYPE B 3 8 NYLOC TORQUE TO 30 35 ftibs 41 47 N m STILL BE EFFECTIVE AGAINST SCALPING ANTI SCALP ROLLER ANTI SCALP ROLLER INSTALLATION ADJUSTMENT FIGURE 12 ANTI SCALP ROLLER ADJUSTMENT Deck Leveling a Position mower on a flat surface 37 Stop engine wait for all moving parts to stop and remove key Check tire pressure of drive tires If needed adjust to 10 psi 69 kPa Semi pneumatic caster tires do not need to be inflated Set anti scalp rollers to top holes or remove them completely for this adjustment Raise the deck to the 5 height position also transport position and take all force off of the two large deck lift springs by loosening the nuts at th
74. positive post on the booster battery to the positive post on the battery b connect the negative or ground cable from the negative post on the booster battery to the engine block as far away from the battery as possible c disconnect battery cables in the reverse order after starting 1 5 MAINTENANCE AND STORAGE 1 5 1 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 1 5 10 1 5 11 1 5 12 For engine maintenance follow the engine manufacturer s recommendations precisely as stated in the engine manual Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 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 flammable 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 the
75. pped CUTTING A WARNING T e Do NOT carry passengers Look behind and to the side before changing directions bh e Before leaving the operatorOs position 103 3979 Disengage PTO Move drive levers out to neutral position Engage park brake Stop engine LOCATION RH Side of Console KEE E PART NO 103 3679 LOCATION Right of Throttle Control on RH Fuel Tank KEEP HANDS and FEET AWAY PART NO 1 403005 LOCATION Left and Right Corners of Mower Deck 8 dh VVARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 203508 PART NO 1 303508 LOCATION RH Side on Top Rear of Mower Deck NO STEP 1 513742 PART NO 1 513742 LOCATION Top of Mower Deck Belt Shields Left and Right Sides ACAUTION DO NOT OPERATE WITHOUT GUARD IN PLACE PART NO 1 513748 LOCATIONS Bottom Side of Floorpan A CAUTION MUFFLER AND SHIELDS MAY EXCEED 150 F 746 PART NO 1 513746 DIESEL ONLY HYDRAULIC OIL USE ONLY MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILL TO TOP OF BAFFLE A CAUTION LOCATION Rear RH Side of Engine Deck 4 WARNING DISENGAGE BLADE CLUTCH SHUT OFF ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS PART NO 103 1636 LOCATION Top of Fuel 2y LN HOT SURFACE PART NO 1 52
76. quare head setscrews on Hydro pump control arms c Sheave retaining bolt in the end of engine crankshaft d Engine mount retaining bolts e Stub shaft to flywheel retaining bolts f Front engine crankshaft hub retaining bolts g Fuel tank bulkhead fitting threads h Caster wheel spacer nuts i Cutter housing spindle nut Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining or Retaining II are used on the following a Fuel tank studs where studs are inserted into tank 5 1 28 Mobil HTS grease or a food grade antisieze is used in the following locations a Between the jackshaft and bearings b Between the jackshaft and sheaves c Between the cutter housing spindle and bearings d Between the cutter housing spindle and sheaves e Under top cutter housing bearing guard f On the fan pump shafts and motor shafts next to the seal 5 1 29 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 5 2 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine and remove key before servicing cleaning or making any adjustments to the unit 5 2 1 Cutting Height Adjustment a Stop machine and move drive levers out to neutral lock position b Disengage PTO c Raise the deck lever to the transport position also the 5 12 7 cm cutting height position See Figure 11 The deck can be raised by pulling the deck lever up and or by pushing on the
77. r engages a parking brake on the drive wheels 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 on the right fuel tank The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert the 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 NOTE A glow plug light located to the right of the ignition switch will illuminate when the switch is turned to the ON position The glow plug light indicates the glow plugs are preheating the combustion chamber Wait until the light goes out before rotating the key to the START position Brake must be engaged motion control levers out neutral lock position and PTO switch OFF to start engine Itis not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right fuel tank The hour meter records the number of hours that the engine has run If the ignition switch is left ON without engine running the hour meter will continue to run Fuel Shut Off Valve Located directly below right of console The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days dur
78. rea before engaging PTO IMPORTANT Operator must be in seat before the PTO can be engaged Set throttle to midway position Pull outward on the switch to the ROTATE position Accelerate to full throttle to begin mowing Stopping PTO Set throttle to the midway position Push in on the switch to the STOP position stopping the cutting blades Stopping Engine a Bring unit to a full stop Disengage the PTO move motion control levers out to the neutral lock position and engage parking brake b Before stopping the engine move the throttle control to the SLOW position Keep on running at idle for a short time approximately one minute then stop the engine c Rotate ignition switch to OFF position Remove the key to prevent children or other unauthorized persons from starting engine d Close fuel shut off valve when machine will not be used for a few days when transporting and when the unit is parked inside a building 4 4 TRANSPORTING 4 4 1 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 SE 4 4 2 CAUTION POTENTIAL HAZARD 4 This unit does not have proper turn signals lights reflective markings or a
79. rheat and damage the engine See Engine Service Dealer c When the engine is running and the buzzer emits intermittent beeps the buzzer is warning the user that the engine oil pressure is low OR the alternator is not charging Perform the following steps 1 Turn the unit off wait for all moving parts to stop and remove key Allow the engine and engine components to cool Check the oil level and fill if necessary as described in Section 5 1 1 Check for oil leaking from engine If the engine is leaking see Engine Service Dealer Check to see if the water pump alternator belt is intact If belt is present there could be a charging problem see Engine Service Dealer If belt is missing do not run unit as unit can overheat and damage the engine See Engine Service Dealer 47 8 ELECTRICAL DIAGRAM IN HEI OOINI108 144 NU div OZ Leit ut Nu day 07 5Md KOT OUER HIT 31813319 SJlaviS ONDD HILIMS dW
80. s There is no roll over protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warning Q PART NO 107 2112 LOCATION Top Center of Floorpan HOT MMMM SURFACE 103 2076 PART NO 103 2076 LOCATION Top of Radiator Trim Plate LH amp RH Sides A DANGER BELT 103 2600 103 5304 COVER IS MISSING DO NOT OPERATE 98 5954 S THIS UNIT WHEN COVER IS NOT IN PLACE PART NO 103 5304 LOCATION Engine Access Panel Behind Seat MOTION CONTROL PART NO 98 5954 LOCATION Under LH and RH Belt Shields Radiator Fan Pump Idler Arm On Engine Belt Guard behind Seat On Pump Mounting Plate behind Seat MOTION CONTROL 103 5200 WHEEL RELEASE or sparks could cause battery to explode WARNING not charge or use booster cables or t post connections with g In event of and and call a physician ly Keep out of reach of children Use 5 8 wrench One turn counterclockwise to release Do not over tighten Battery cont sulfuri and alvvays shield eyes clothing from battery Never attempt to open or repair switch I Avoid contact with mercury E See operator s manual for E disposal guide PART NO 103 5200 LOCATION Top of console 10 2 SPECIFICATIONS 2 1 MODEL NUMBER LZ27DD604 LZ27DD724 2 2 ENGINE 2 2 1 Engine Specifications See your Engine Owner s Ma
81. s to stop Remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided 4 Keep others off mower IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer 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
82. tch to your Exmark dealer if it is faulty and is being replaced or if the unit containing the switch is no longer operating and is being scrapped If the switch is damaged or broken open use extreme caution in handling Call your local waste management authority or Exmark Customer Service for instructions 44 6 4 BATTERY DISPOSAL POTENTIAL HAZARD 4 Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns AA DANGER WHAT CAN HAPPEN e Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do not swallow electrolyte 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 7 TROUBLE SHOOTING 7 1 MOWER PULLS LEFT OR RIGHT W LEVERS FULLY FORWARD a b c Refer to Tracking Adjustment Section 4 1 3 Check air pressure in drive tires 10 psi Semi pneumatic casters do not require inflation Check reverse indicator and motion control linkage adjustment
83. tioned on level surface b Tilt seat up and tilt hood forward to gain access to the cooling area POTENTIAL HAZARD e Engine coolant is hot and pressurized e Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system or touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system Ah CAUTION POTENTIAL HAZARD e Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow e Keep out of reach of children and pets 30 Drain coolant when engine is cool Coolant may be drained from the radiator by loosening the drain cock in the right rear corner The engine block may be drained by removing the rear radiator hose and or by removing the drain plug from the engine block The plug may be accessed from the right side of the unit and are located as shown in Figure 9 The engine has a socket head bolt for the drain plug COOLANT DRAIN PLUG LOCATED HERE SOCKET HEAD BOLT VIEW FROM RIGHT SIDE OF UNIT FIGURE 9 COOLANT PLUG LOCATION Re install drain plug and hoses and tighten drain cock Fill radiator with a 50 50 mix of water an
84. ty gives you specific legal rights and you may also have other rights which vary from state to state NOTES 51 NOTES 52 SERVICE RECORD Description of Work Done Service Done By 53 ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC ve MTHM TEA pod ye ne a FOLD ALONG APPROPRIATE LINE EXAMPLE COMPARE S 7 SLOPE WITH FOLDED 54 SEE EXMARK S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER Check us out on the Web www exmark com A WARNING A WARNING The engine exhaust from this product CALIFORNIA contains chemicals known to the State Proposition 65 of California to cause cancer birth Diesel engine exhaust and some of its constituents defects or other reproductive harm are known to the State of California to cause cancer birth defects and other reproductive harm 2004 EXMARK MFG CO INC PART NO 103 7372 Rev B INDUSTRIAL PARK BOX BEATRICE NE 68310 ALL RIGHTS RESERVED 808 402 223 6300 FAX 402 223 5489 ank MFG CO INC PRINTED IN U S A
85. ulic jacks could be dangerous WHAT CAN HAPPEN e The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD e DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support a b This adjustment must be made with the drive wheels turning First raise the frame and block up so that drive wheels can rotate freely Disconnect the electrical connection from the seat wire harness from the main harness The electrical connection is below the seat hold up rod just above the left wheel drive pump Temporarily install a jumper wire across the terminals in the connector of the main wiring harness Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature Return the drive levers to the neutral position Tilt seat forward Loosen lock nut from the ball joints at the pump end of the RH pump control linkage See Figure 19 42 LOOSEN HERE RIGHTHAND THREAD Gjim TURN HERE TO ADJUST TURN LH TRACKING ADJUSTMENT KNOB Gora RIGHT HAND SIDE OF UNIT LEFT HAND SIDE OF UNIT DO NOT LOOSEN ANY 5 2 14 NUTS ON LH SIDE NOTE The nuts to the front of the unit on RH rod has left hand threads k Caster pivot bearings pre load adj
86. ustment a FIGURE 19 MOTION CONTROL ADJUSTMENT Start engine Brake must be engaged and motion control levers out to start engine Operator does not have to be in the seat Run engine at full throttle and release brake The reverse indicator spring must be correct before the following adjustments can be made See Section 5 2 12 NOTE The motion control lever needs to be in neutral while making any necessary adjustments The left rod assembly controls the left wheel and the right rod assembly controls the right wheel Bring the RH motion control lever into the neutral position Adjust RH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse See Figure 19 Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to bring the levers back to neutral The wheel must stop turning or slightly creep in reverse When adjustment is complete re tighten lock nuts to the ball joints at rear of the RH pump control linkage See Figure 19 Bring the LH motion control lever into the neutral position Adjust the LH pump control rod length by rotating the tracking adjustment knob in the appropriate direction until the wheels slightly creep in reverse Move the motion control lever to the reverse position and while applying slight pressure to the lever allow the reverse indicator spring to
87. varies with the temperature of the oil The HOT level shows the level of oil when it is a 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 4 OPERATION INSTRUCTIONS 4 1 CONTROLS 4 1 1 4 1 2 Familiarize yourself with all controls before operating the mower Motion Control Levers Located on each side of the console The left lever controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor The right lever controls the flow of hydraulic oil from the right hydrostatic pump to the right drive wheel motor 18 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 kill 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 See Figure 7 FRONT OF FORWARD NIT HANDLES IN NEUTRAL NEUTRAL NEUTRAL LOCK HANDLES OUT REVERSE RIGHT SIDE NEUTRAL LOCK ST FIGURE 7 MOTION CONTROL POSITIONS By moving both levers a
88. when in the neutral position See Figure 6 loosen the hardware and make the appropriate adjustment by sliding tilting the lever s forward or backward until properly aligned and tighten hardware LEVERS IN Gi MOTION ALIGNMENT CONTROL LEVER A MOUNT PLATE TO THE REAR amp OUTSIDE OF ARM SHAFT FIGURE 5 FIGURE 6 CONTROL ARM SHAFT LEVER ALIGNMENT b Ifthe 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 bend them outward Move them back to the drive position and check for clearance repeat if necessary 3 7 POSITION DISCHARGE CHUTE 3 7 1 Loosen two 2 5 16 nyloc nuts attaching discharge chute Lower the discharge chute into position Retighten nyloc nuts until chute is snug but can pivot freely 3 8 SERVICE ENGINE Engine is shipped with oil check oil level and if necessary and fill to the appropriate level with oil as specified in Engine Owner s Manual 3 9 SERVICE ENGINE COOLANT Machine is shipped filled with engine coolant size A WARNING POTENTIAL HAZARD e Engine coolant is hot and pressurized 4 Radiator and surrounding parts are hot WHAT CAN HAPPEN Spray or steam from hot pressurized liquid in the engine cooling system or touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely befor

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