Exmark 820 Lawn Mower User Manual
Contents
1. m HOLIMS LVIS ENS HOLMS H91012 014 13S NI HOLVu3dO 35012 SI HOLIMS 191015 walaW 9 n a 1 5 TWNIWYSL 1891 NOILIN9I Auanvs 1 055399 SNOLO3NNOO VNIWH3L HO LIMS NOLLINSI SVNIWH3L S HTVNIWHSL V aviam s i utg 1891 viltute NOY BAVA LINDUID 35 Schematics Electrical Logic Schematic SLIHM M TM 13101IA7 A sia NVL L y HO 3 N3399 LH917 49 a AD a 2 o N33H9 ND gt 5 m ania 5 E NMOHS d 9 5 al z H HHBH 5 5 0 vor ed unoH REN AM 5 x Aa 2 B E J gere p Bod o 5 e 1 Ne m E 8 H v u 4 M GrinaN 1uV1S 1 i s lavis b vMS Sy 19015 1 ZMS H LIMS 014 n z ov AD vas ja SS LMS b oms d h Sa1naow 1n32. Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check under engine deck to check pump drive belt 3 Remove left and right belt shields on deck and lift up floor pan to inspect deck drive belt 4 For belt adjustment see the Pump Drive Belt and Deck Belt Tension Adjustment sections Maintenance Lubricate Grease Fitti ngs pump with grease until it oozes out around top beating Remove grease zerk and thread plug back Note See chart for service intervals in Place cap back on 1 Stop engine wait for all moving parts to stop and key E king brake Lubricate Caster Wheel Hubs 2 Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Service Interval Yearly Refer to the following chart for fitting locations 1 Stop engine wait for all moving parts to stop and and lubrication schedule remove key Engage parking brake Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval 1 Belt 1 2 25 Houts Idlers 2 Deck 1 4 40 Hours Pivots 2 Yearly 6006115 Figure 12 1 Seal guard 2 Spacer nut with wrench flats 0 2 Yearly 2 Remove caster wheel from caster forks 1 1 16
3. Engage parking brake Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck section Inspect blades and sharpen or replace as required Install blade bolt and spring disc washer Be sure the spring disc washer cone is installed towards the bolt head Place a block of wood between front or rear baffles and the blade then torque the blade bolts to 115 120 ft Ib 156 163 N m Figure 11 Maintenance G007554 Figure 11 1 Do Not use wrench here for blade installation Maintain 140 145 ft lb 190 197 N m 2 Use 1 inch wrench here to hold spindle for blade replacement 3 Cone towards bolt head 4 Torque to 115 120 ft lb 156 163 N m WARNING Incorrect installation of the blade or components used to retain the blade can be dangerous Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death Always install the original Exmark blades spring disc washers and blade bolts as shown Check Safety Interlock System Service Interval Before each use or daily Note To prevent engine cut outs on tough terrain the seat kill switch has a 1 2 second delay 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be i
4. Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and ate equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 G007549 Figure 1 Model and serial number location Model No Serial No Contents tes teg E ERR Lan 3 Mov 5 Safety Alert si 5 Safe Operating PEACUCOS 5 Safety and Instructional Decals 10 EN deno 13 Model orat p d tnt 13 A EA re 13 tc d 14 Torque Requirements ed tds ates 15 Product Overview esed cade L5 Operat ess Dude eus n TN OP PEU E RASA 16 aa 16 Pre Statta 17 Oper
5. is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire or explosion from gasoline can burn you others and cause property damage the fuel tank outdoors on level ground in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer Do Not fill the fuel tank completely full Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system if equipped Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the reach of children fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot 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 Do Not operate without entire exhaust system in place and in proper working conditio
6. known to the State of California to cause cancer and reproductive harm Wash hands after handling 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 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Maximum Charger Settings 16 volts 7 amps Voltage Reading 12 6 100 greater 12 4 12 6 75 100 16 volts 7 30 Minutes amps 12 2 12 44 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 509 o 14 4 volts 4 2 Hours amps 11 7 12 0 0 2590 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours ot amps More Recommended Jump Starting Procedure Service Interval As required 1 Check the weak battery for terminal corrosion white green or blu
7. mower to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights ot counter weights to improve stability Use extreme cate with grass catchers or attachments These can change the stability of the machine and cause loss of control Maintenance and Storage Disengage dtives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait fot all movement to stop before adjusting cleaning or repairing Keep engine engine area and pump drive belt compartment free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and Do Not store neat flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect th
8. new filter apply a thin coat of Exmark Premium Hydro oil on the surface of the rubber seal Turn the filters clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 1 2 to 3 4 turn Remove the vent plug on each transmission and fill through expansion reservoir when oil comes out of vent reinstall plug Torque plugs to 180 in lbs 20 N m Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filter is installed between the fuel tanks and the engine Replace when necessaty Replacement Filters Kawasaki Kawasaki P N 49019 7001 Figure 13 Left Side Shown 1 Left rear tire 2 Oil filter 3 Vent plug 28 Maintenance Add oil until it reaches the FULL COLD line on the expansion reservoit Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours 7 Raise the tear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely CAUTION Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may no
9. the mowet After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping the grass catcher WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts NEVER carry passengers DO NOT operate the mower when people especially children or pets are in the area Be alert slow down and use caution when making tutns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck e Use care when approaching blind corners shrubs trees ot other objects that may obscure vision Slop
10. 0 Hours 3 Remove seal guards from the wheel hub 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread See step 3 for special lubrication instructions on locking adhesive has been applied to lock the the front caster pivots and the Lubricate Caster spacer nuts to the axle Remove the axle with Wheel Hubs section for special lubrication the other spacer nut still assembled to it from instructions on the front casters wheel hubs the wheel assembly 5 2 3 4 5 Pry out seals and inspect bearings for wear or damage and replace if necessaty 6 Pack the bearings with a NGLI grade 1 multi purpose grease 7 Insert one bearing one new seal into the wheel Note Seals Exmark P N 103 0063 must be replaced 8 If the axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do Not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 3 Lubricate front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and 27 Maintenance 10 11 12 13 14 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing With the ope
11. 14 Motion control levers 3 3 8 16 x 1 inch screw 2 Spring disc washer 2 If the ends of the levers hit against each other while in the drive position levers rotated in as far as possible make adjustments by moving the levers outwards to the neutral lock position and carefully bending them outward Move them back to the drive position and check for clearance Repeat if necessary If the machine turns right or left when handles are pushed forward together adjust the stop on the side opposite the direction of turn see Figure 15 Move the stop back until the unit drives straight Readjust handles if necessary Maintenance 1 Adjust stop Adjust Throttle Lever Tension T Bom Stop engine wait for all moving parts to stop and remove key Engage parking brake Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt which is located under the console Figure 16 6007566 3454 Figure 16 Hex bolt Spring disc washers Tab washer Friction washer 5 Lever 6 Bracket 7T Hexlocknut Cleaning Clean Engine Air Cooling System Service Interval Before each use or daily May be required more often in dry or dirty conditions CAUTION Excessive debris can cause the engine and hydraulic system to overheat which can create a fire hazard Clean all debris from around the engine and hydraulic pumps daily 1 S
12. 300 Cf Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
13. IDNUDW Be NI lt ain Part No 4500 488 Rev For Serial Nos 820 977 amp Higher WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Important IMPORTANT The engine in this product is not equipped with a spark arrester muffler It is a violation of California Public Resource Code CPRC Section 4442 to use ot operate this engine on any forest covered brush covered or grass covered land as defined in CPRC 4126 Other states or federal areas may have similar laws To acquire a spatk arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturet Exmatk 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
14. N NOLLINDI b SMS T uvas AUREUS ve 2 Sida 1uvis NO SNOLLO3NNOO ON 440 SNOILV201 1 HOLIMS NOLLIND p JI i 1 IMS 36 Exmark Commercial Turf Equipment 2 Year Limited Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark commercial turf equipment sold in the U S or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery Year Prorated Engine 2 years The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor Items and Conditions Not Covered Th
15. Schematics Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure 2 1s used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 Safety alert symbol The safety alert symbol appeats above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read the Operator s Manual and other training material If the operatot s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and s
16. TERY 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 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 156 163 N m SEE OPERATOR S MANUAL 103 1077 103 1077 1 513747 ACAUTION DO NOT OPERATE WITHOUT GUARD IN PLACE 1 513748 1 513748 o D e 9 9 109 2356 Fast 3 Neutral 2 Slow 4 Reverse 10 Safety 45 40 35 30 25 20 15 Deck Transport Lock 5 0 Pin Storage 109 2463 E 109 2463 34 BELT ROUTING 44 BELT ROUTING BELT BELT 103 9366 109 2236 109 2465 109 2465 DRIVE WHEEL RELEASE A CAUTION QU MUFFLER AND ZG ya um SHIELDS MAY MS EXCEED 150 F 109 2467 109 2467 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 opera
17. afety signs e All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate ot service the equipment Local regulations may restrict the age of the operator Only adults and mature teenagers should operate a mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Manual and recognizes the risks involved is sufficiently mature to use caution and 3 1s of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks The owner user can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation Evaluate the terrain to determine what accessoties and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Inspect the area where the equipment
18. ating Inste retlonis s scu ocn evo ed 18 MANS POPU aa 20 MM 22 Recommended Maintenance Schedule s 22 Periodic Maintenance eoo ee eg e ETE 23 Check Engine Oil asus 23 Cheek Battery 23 Check Mower Blades 24 Check Safety Interlock System 25 Check tor Loose Hardware eee nete 25 Service Ait Cleaner eere atate eins 26 Change Engine a asse dese 26 Check Hydraulic Oil Level i tide 26 Check Tire Pressures Pet eite sons 26 Check Condition Of Belts tete treinta 26 Lubricate Grease 27 Lubricate Caster Wheel Hubs iot 27 Check Spark 28 Change Hydraulic System Filtet 28 Thread Locking Adhesives etn te 29 Mobil HTS Grease Or Food Grade Jet eoe in 29 29 Adj stments doas deo ode a ng aed 30 Wee Leveling outs edi aei dais 30 Pump Drive Belt irit 30 Deck Drive Belt veo meer 30 Electric Clutch Adjustment ree 30 Motion Control Linkage Adjustment 30 Adjust Throttle Lever Tension 31 Clanin o cr eet daro Un e DNO EDEN UN UNE 31 Clean Engine Air Cooling System 31 Remove Engine Shrouds and Clean Cooling doeet ded 31 Waste Disposal ii esas uann osie nn DEG DIS DO OH PIDE i AR gn
19. ch 3 8 cm height position Place two 1 1 8 inch 2 9 cm thick blocks under the rear edge of the cutting deck skirt one on each side of the cutting deck 6 Place a 1 inch 2 5 cm block under the center front edge but not under the anti scalp roller brackets 7 Loosen the four bottom chain bolts in slots until the deck is supported by the blocks Take the slack out of the chains and retighten the hardware 8 Recheck that blocks fit just snugly under the deck skirt and that the tension on all the chains is approximately equal Make sure all chain attachment bolts are tight 9 Reposition anti scalp rollers if installed and tighten securely Note When above adjustments have been made the front of the deck will be slightly lower than the reat of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary Deck Drive Belt Tension Self tensioning No adjustment necessary Electric Clutch Adjustment No adjustment necessaty 30 Motion Control Linkage Adjustment Note There are two levet height options available Place the levers in the top two holes to increase height of the levers or in the bottom two holes to decrease the height of the levers 1 Align the levers front rear position With the levers in the neutral position loosen the hardware and adjust the levers sliding and or tilting the lever s forward or backward until properly aligned and tighten hardware Figure 14 Figure
20. e negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s or wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Safety Charge batteties in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Charging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery e Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid e Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately CAUTION If the ignition is in the ON position there is potential for spa
21. e snow it must be cleaned off prior to jump starting Clean and tighten connections as necessary CAUTION Corrosion loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist 23 Maintenance 2 Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries Note The following instructions are adapted from the SAE J1494 Rev Dec 2001 Battery Booster Cables Surface Vehicle Recommended Practice SAE Society of Automotive Engineers WARNING Batteries contain acid and produce explosive gases Shield the eyes and face from the batteries at all times Do Not lean o
22. e Operation Use Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes Safety DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes See inside the back cover to determine the approximate slope angle of the area to be mowed Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figure 3 6007037 Figure 3 Water Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water Safe Zone Use the mower here on slopes less than 15 degrees Remove ot mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwards Be aware that operating on wet grass across steep slopes or downhill may cause the
23. e s is are bent Mower deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Cutting blade s is are bent or unbalanced Blade mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Belt is damaged Drive belt is worn loose or broken Drive belt is off pulley Deck belt is worn loose or broken Deck belt is off pulley Broken or missing idler spring PTO clutch does not engage 34 Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust tire pressure in the drive tires Adjust the motion control stops Close the drive wheel release Change the belt Change the belt Replace the spring Add hydraulic fluid to reservoir or let it cool down Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to rear Clean the underside of the mower Adjust tire pressure in the drive tires Contact an Authorized Service Dealet Replace blades spindles and or check for damage to mower deck Install new cutting blade s Tighten the blade mounting bolt Tighten the engine mounting b
24. ended ENGAGE CALIFORNIA SPARK ARRESTER WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrester may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements e mr44ozr4 116 1400 116 1400 Avoid blades unless engine and blades are stopped To avoid serious injury or death Pick up objects that could be thrown by the blades Do NOT mow when children or others are in the area Do NOT carry passengers Look behind and to the side before Before leaving the operator s position Disengage PTO Move drive levers out to neutral lock position Engage park brake Stop engine 12 Specifications Specifications Model Numbers Serial Nos 820 977 and Higher PHZ19K A343 PHZ19KA343CA Systems Engine Engine Specifications See your Engine Owner s Manual RPM Full Speed 3750 100 RPM No Load Idle 1400 RPM Fuel System e Capacity 7 7 gal 29 1 Type of Fuel Regular unleaded gasoline 87 octane or higher containing no more than 10 methanol or ethanol Fuel Filter In line Kawasaki P N 49019 7001 Fuel Shut Off Valve 1 4 turn increments 5 Electrical System Charging System Flywheel Alternator Charging Capacity 13 amps Battery Type BCI Group U1 Battery Voltage 12 Volt e Polarity Negative Gr
25. etween the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Adjust the seat switch Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate Engine load is excessive Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Tire pressure in drive tires not correct Motion control stops need adjustment Drive wheel release is not closed Drive or pump belt is worn loose or broken Drive or pump belt is off a pulley Broken or missing idler spring Hydraulic fluid level is low or too hot Blade s not sharp Cutting blad
26. ge will display in the area where the hours are normally displayed Note The LCD indicators appear when each control meets the safe to start mode e g the indicator turns on when the operator is in the seat Note This switch is not a low oil sensot and will not alert the operator if the engine oil is low Fuel Shut Off Valve The valve is located in the fuel line midway between the fuel tank and the engine behind the seat The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Rotate the valve 1 4 turn clockwise to shut off fuel Rotate the valve 1 4 turn counterclockwise to turn on fuel Drive Wheel Release Levers Located at the rear of the mainframe Drive wheel telease levers are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Pull each lever rearward and outward to lock Pull each lever inward and push forward to reset Do Not tow machine PTO Engagement Switch Located right of center on the console left side of ignition switch 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 The LCD indicator will appear when the PTO switch is disengaged see Figure 6 Low Voltage Indicator Located on the center console in the message d
27. hey are functioning properly Safety Operation WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect e Operate only in daylight or good artificial light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Stop engine wait fot all moving parts to stop remove key and engage parking brake Before checking cleaning ot working on
28. il to drain then close valve by pushing inward and rotating 1 4 turn clockwise Remove and retain the hose for future use 4 Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn 5 Clean around oil fill cap and remove cap Fill to specified capacity and replace cap 6 Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks Stop engine and recheck oil level Check Hydraulic Oil Level Service Interval Every 40 hours 1 Stop engine and wait for all moving parts to stop Engage parking brake Allow engine to cool Clean area around hydraulic expansion reservoir Oil level should be at the FULL COLD line on expansion reservoir If not add oil Use only Exmark Premium Hydro oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Do Not overfill Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check tire pressure in drive tires Inflate drive tires to 13 psi 90 kPa Semi pneumatic caster tires do not need to be inflated Note Do Not add any type of tire liner or foam fill material to the tires
29. ing Width 54 5 inches 87 6 cm Tread Width Center to Center of Discharge Side Tires Widthwise Blade Size 2 ea 17 50 inches 44 5 cm 26 5 inches 67 3 cm Blade Spindles Solid steel spindles with 1 inch Caster Wheels 29 0 inches 73 7 cm 25 4 mm LD bearings Deck Drive Wheel Base Center of Caster Tire to Electric clutch mounted on vertical engine Center of Drive Tire shaft 45 0 inches 114 3 cm Blades are driven by one belt w self tensioning idler direct from Curb Weight the engine a Deck 570 Ib 258 5 kg Full floating deck is attached to out front support frame Two optional anti scalp rollers Deck design allows for bagging mulching or side discharge 14 Product Overview Torque Requirements Product Overview Cutter Housing Spindle 140 145 ft Ib Nut 190 197 N m Blade Mounting Bolt 115 120 ft Ib 156 163 N m Anti Scalp Roller Nyloc 40 45 ft lb 54 61 N m Nut Engine Mounting Bolts 25 30 ft lb 34 41 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Clutch Retaining Bolt 55 60 ft lb 75 81 N m secured with threadlocker Figure 4 1 Fuel Cap 4 Parking Brake Lever 2 Motion Control Lever 5 Height of Cut Foot Lever 3 Controls 15 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Motion Control Levers The motion control levers located on each side of the cons
30. is warranty does not cover the following Pickup and delivery charges to and from any authorized Exmark Service Dealer Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 37 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Se
31. isplay see Figure 6 A low voltage condition less than 12 3 volts exists when the low voltage indicator light appears on the message display while the engine is running If the ignition key is turned to the ON position for a few seconds before cranking the engine the battery voltage will display in the area where the hours are normally displayed Note The indicator normally appears when the engine is off and the key switch is turned to the ON position Pre Start Fill fuel tank on level ground For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Important Never use methanol gasoline containing methanol gasohol containing more than 10 ethanol premium gasoline or white gas because the fuel system could be damaged Do Not add oil to gasoline Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system if equipped 17 Operation Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Open the Fuel Shut Off Valve Rotate the valve 1 4 turn counterclockwise to turn on fuel Starting the Engine 1 Move the
32. ite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners Clutch retaining bolt in the end of engine crankshaft e Caster wheel spacer nuts e Cutter housing spindle nut Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining IT are used on the following Fuel tank studs where studs are inserted into tank Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations Between the cutter housing spindle and bearings Between the cutter housing spindle and sheave Under top cutter housing bearing guard Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 29 Maintenance Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit Deck Leveling 1 Position mower on a flat sutface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check tite pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Semi pneumatic caster tires Do Not need to be inflated 4 Setanti scalp rollers to top holes if installed or remove them completely for this adjustment 5 Lowet the deck to the 1 1 2 in
33. l suspension and armrests Mounting Hinged to tilt up for access to battery and other components Held in tilted position with lanyard Adjustable fore and aft seat track e Armrests Standard foam padded flip up armrests e Seat Safety Switch Incorporated into the Safety Interlock System Time delay seat switch eliminates rough ground cut outs 13 Specifications Hydrostatic Ground Drive System Hydrostatic Drive Two Hydro Gear ZT2800 Integrated drive systems Deck Depth 5 0 inches 12 7 cm Cutting Height Adjustment Foot operated deck lift lever is used to adjust the Hydraulic Oil Type Use Exmark Premium Hydro cutting height from 1 inch 2 5 cm to 5 inches Oil 12 7 cm in 1 4 inch 6 4 mm increments Speeds The cutting height adjustment handle has a mare transport position and all adjustments can be 0 7 2 mph 11 6 km hr forward made while the operator remains seated 0 4 0 mph 6 4 km hr reverse 5 Drive wheel releases allow machine to be moved when engine is not running and brake is off left and right sides of engine D i mens i ons Tires amp Wheels Overall Width Drive Front Caster Pneumatic Semi Pneumatic Air Filled Without Deck 34 5 inches 87 6 cm Deflector Up 35 0 inches 89 0 cm Overall Length 18 x 7 00 8 11 x 400 5 70 0 inches 177 8 cm pee Overall Height 39 0 inches 99 1 cm Cutting Deck Cutt
34. manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2010 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact yout authorized Exmatk equipment dealer or distributor Exmark parts manuals are available online at http www exmark com manuals htm All
35. motion control levers out to the neutral lock position Pull up and back on the parking brake lever to engage the parking brake Push in on the PTO switch to the STOP position Note It is not necessary for the operator to be in the seat to start the engine Place the throttle midway between the SLOW and EAST positions On a cold engine push the choke lever forward into the ON position On a warm engine leave the choke in the OFF position Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the ON position gradually return choke to the OFF position as the engine warms up Engaging the PTO DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged 4 DANGER An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflecto
36. n DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground e If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless t
37. n end of the wheel facing up fill the atea inside the wheel atound the axle full of NGLI grade 1 multi purpose grease Insert the second beating and new seal into the wheel Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outwatd Torque the nut to 75 80 in lb 8 9 N m loosen then re torque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut Reinstall the seal guards over the wheel hub and insert wheel into caster fork Reinstall caster bolt Change Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Locate the two filters under the transmissions Remove filter guards 3 Carefully clean area around filters It is important that no dirt or contamination enter hydraulic system and tighten nut fully Unscrew filters to remove and allow oil to drain Important To prevent seal and bearing damage from drive system check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Important Before reinstalling
38. n onto the height adjustment pin to mow at selected height To transport move lever back up to transport or 5 inch 12 7 cm cutting height position Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain 20 Operation CAUTION This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not drive a unit on a public street or roadway WARNING Loading a unit on a trailer or truck increases the possibility of backward tip over Backward tip over could cause serious injury or death Use extreme caution when operating a unit on a ramp e Use only a single full width ramp Do Not use individual ramps for each side of the unit Ifindividual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ram
39. n the seat to start the engine Try to statt 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 2 Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Run engine at one third throttle with brake disengaged move levers in and raise off seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Again run engine at one third throttle brake engaged and move left motion control lever in engine must initiate shutdown Repeat again moving the right lever in then moving both levers in engine must initiate shutdown whether operator is on seat
40. nd sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 21 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position WARNING While maintenance or adjustments are being made someone could start the engine WARNING The engine can become very hot Touching a hot engine can cause severe burns Accidental starting of the engine could seriously injure you or other bystanders Allow the engine to cool completely before service or making repairs around the engine area Remove the key from the ignition switch engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s Recommended Maintenance Schedule s Maintenance Service 2 Maintenance Procedure Interval After the first 5 hours Change the engine oil After the first 250 hours Change the hydraulic filter heck the engine oil level heck the mower blades heck the safety interlock system heck for loose hardware ean the engine air cooling system ean the grass build up from under the deck Every 25 hours Grease the belt idlers Check the hydraulic oil level Check the tire pressures Every 40 hours x y Check the condition of the belts Grease the deck pivots Service the air cleaner May need more often
41. ntrol of the machine which may cause damage to the machine or injury e Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop When levers are centered in the T slot the drive system is in the neutral position With levers moved out in the T slot the drive system is in the neutral lock position Figure 7 Note The N LCD indicator appears when both levers ate in the neutral lock position 7 G006147 Figure 7 1 Handles Out Neutral 5 Neutral Lock 2 Handles In Neutral 6 Reverse 3 Front of Unit 7 Neutral Lock 4 Forward Driving Forward 1 Release the parking brake 2 Move the motion control levers inward to the center to the neutral unlocked position To move forward in a straight line apply equal forward pressure to both levers To turn left or right pull the motion control lever back toward neutral in the direction desired The machine will move faster the farther the motion control levers are moved away from neutral To stop pull the motion control levers back to the neutral position 19 Operation 2 5 4 Figure 8 1 Handles Out Neutral 4 Forward Lock 2 Handles In Neutral 5 Reverse 3 Front of Unit Driving in Reve
42. ole control the forward and reverse motion of the machine The levers control the flow of hydraulic oll from the hydrostatic pump to the drive wheel motor for each side Moving the levers forward or backward turns the wheel on the same side forward or in reverse Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position into the T slot locks them in the neutral position Figure 7 When the motion control levers are in the neutral position the LCD indicator appears in the message display on the center console see Figure 6 G006147 Figure 5 1 Handles Out Neutral 5 Neutral Lock 2 Handles In Neutral 6 Reverse 3 Front of Unit 7 Neutral Lock 4 Forward Choke Control Located on the center of the console The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear will put the choke in the OFF position Do Not run a warm engine with choke in the ON position Throttle Control Located on the center of the console to the left side of the choke The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Brake Lever Located on left side of the console The brake lever engages a parking brake on the drive wheels N
43. olts Tighten the appropriate pulley Contact an Authorized Service Dealer Contact an Authorized Service Dealer Install new belt Check the belt tension Check belt for damage replace if necessary Install drive belt and check adjusting shafts and belt guides for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Replace the spring Contact an Authorized Service Dealer Schematics Schematics Electrical Diagram 05 ais 1uvis 19915 GIoN310s 1uvis HOLIMS vit ej t z z tov NOILISOd 4907 NI 5 1 1041409 035079 S3HOLIMS 1081NO2 HOLIMS HOLIMS HILMO EE fa 21 He 1304 CT MOTIBA N3349 13101 39Nvu0 13101 ama 7 Y 9 1959 2 S LT oF o momo o omm aNd BY HOLIMS NOLLINSI
44. opied for personal use 1 The maximum slope you can safely operate the machine on is 15 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 39 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Engine Serial No E No Serial No 2010 Exmark Mfg Co Inc Part No 4500 488 Rev C Industrial Park Box 808 402 223 6
45. 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 for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating 25 Maintenance Service Air Cleaner Service Interval Every 50 hours Service the air cleaner May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 See Engine Owner s Manual for cleaning instructions Change Engine Oil Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Drain oil while engine is warm from operation 3 The oil drain is located on right hand side of engine Place pan under machine to catch oil Fit hose in literature pack over oil drain valve Rotate valve 1 4 turn counterclockwise and gently pull outward to open valve Allow o
46. ote The LCD indicator appears in the message display on the RH console when the park brake is engaged see Figure 6 Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake The unit must be tied down and brake engaged when transporting Ignition Switch Located right of center on the console The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Note Brake must be engaged motion control levers out neutral lock position and PTO switch OFF to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located right of center on the console below ignition switch 16 Operation The hour meter records the number of hours that the engine has run 50 6011142 Figure 6 1 LCD Indicators 2 Low voltage indicator light 3 Hour Voltage display The hour meter is recording when the decimal point is flashing in Hour Voltage display Hours are displayed when the key is off or when the machine is running Note If the ignition key is turned to the ON position for a few seconds before cranking the engine the battery volta
47. ound e Fuses 30 amp main fuse 25 amp charging system fuse 10 amp clutch fuse Safety Interlock System LCD indicators appear for the PTO park brake drive levers and operator presence in the message display on the center console e PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levets are adjustable to two heights Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the position of the levers relative to each other Moving motion control levers outward in slots locks the drive system in neutral PTO Engagement Switch Engages electric clutch to drive belt which engages mower blades e Parking Brake Lever Engages parking brake Deck Height Adjustment Lever Sets cutting height to desired position Deck Lift Assist Lever Foot pedal that assists in raising the deck Seat Type Standard seat with high back foam padded interna
48. p and trailer or truck 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 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 sutface for the frame members to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck Do Not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer ot 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 ot truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp a
49. r raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle to the MIDWAY position 2 Pull the PTO switch outward to the ROTATE position 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle to the MIDWAY position 2 Push the PTO switch in to the STOP position to disengage the blades Stopping the Engine 1 Bring the unit to a full stop 2 Disengage the PTO 3 Move the motion control levers out to the neutral lock position 4 Engage the parking brake Place the throttle midway between the SLOW and FAST positions 18 Operation 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose co
50. rks and engagement of components Sparks could cause an explosion ot moving parts could accidentally engage causing personal injury Be sure ignition switch is in the OFF position before charging the battery Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard WARNING Removing standard original equipment parts or using non Exmark replacement parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Replace all parts including but not limited to tires belts and blades with original Exmark parts WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks ot nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic sy
51. rse 1 Move the motion control levets inwatd to the center to the neutral unlocked position 2 To move rearward in a straight line applying equal pressure pull both motion control levers rearward To turn left or right release pressure on the motion control lever toward the direction desired 3 To stop push the motion control levers to the neutral position Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 inch to 5 inches 2 5 cm to 12 7 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position Disengage the PTO 3 Raise the deck height lever to the transport position also the 5 inch 12 7 cm cutting height position Figure 9 The deck can be raised by pushing down on the foot operated deck lift assist lever located at the front right corner of the floor pan Note When changing the cutting height positions always come to a complete stop and disengage the PTO d OOOOOOOO G007555 Figure 9 Transport position and 5 inch 12 7 cm cutting height position Insert the height adjustment pin into the hole corresponding to the desired cutting height and install the hairpin cotter pin See the decal on the side of the deck lift plate for cut heights Move the deck height lever out of the transport position or 5 inch 12 7 cm cutting height and dow
52. rvice Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warrant
53. ses power PTO is engaged Parking brake is not engaged Drive levers are not in neutral lock position Battery does not have a full charge Electrical connections are corroded loose ot faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Air cleaner is dirty Seat switch is not properly adjusted Electrical connections are corroded loose ot faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Engine load is excessive Ait cleaner is dirty Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt watet or stale fuel is in the fuel system 33 Disengage the PTO Set the parking brake Ensure the drive levers are in the neutral lock position Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Fill the fuel tank Open the fuel shutoff valve Be sure the throttle control is midway b
54. stem by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system Safety Safety and Instructional Decals e Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged ot missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components e Ifan attachment accessory has been installed make sure current safety signs are visible WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any ait bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower Het 93 8069 93 8069 Hot surface burn hazard stay a safe distance from the hot surface KEEP HANDS and FEET AWAY A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 1 403005 WARNING BAT
55. t be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Start engine and move throttle control ahead to 1 2 throttle position Disengage parking brake A With the bypass valve open and the engine running slowly move the directional control in both forward and reverse 5 or 6 times With the bypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times It may be necessary to repeat steps A and B until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged Note Do Not change hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Fuel Tank Mounting Hardware Specifications Service Interval As required When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels Thread Locking Adhesives Thread locking adhesives such as Loct
56. te on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes 109 2490 109 2490 AWARNING ez ROTATING MECHANICAL DEVICES CAN CAUSE SERIOUS INJURY DO NOT operate without seat in place 109 2862 109 2862 BELT ROUTING BELT 1029377 N 109 2992 109 2992 SERVICE AID Every 8 hours 1 Check engine Every 25 hours 2 Grease belt idlers Every 40 hours 3 Check hydraul Only use recommended hydro oil 4 Check tire pressure 13 psi 5 Grease deck pivots Yearly 6 Grease front caster pivots 7 Grease front caster wheel bearings See operator s manual for additional details 116 0950 3 Hour Message Display Hour Meter 4 Neutral PTO 5 Operator s presence switch Parking Brake 6 Battery 11 Safety A WARNING To avoid serious injury or death RELEASE Read and understand the operator s manual before N using this machine Do NOT operate unless trained to safely use this machine Do NOT operate under the influence of alcohol or drugs Do NOT operate without shields guards and safety devices in place and working Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system Stop engine and remove key before adjusting servicing or cleaning machine and attachments Hearing protection is recomm
57. top engine wait for all moving parts to stop and remove key Engage parking brake Clean all debris from rotating engine air intake screen and from around engine shrouding Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 80 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling 3 Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 31 Maintenance 2 Raise deck to the transport maximum cutting height position Lift the front of unit and support unit using jack stands or equivalent support 3 Clean out any grass build up from underside of deck and in discharge chute Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations Battery Disposal DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it
58. touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte n the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the gatbage Management and disposal practices must be within relevant federal state ot 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 battety to any certified battery reseller 32 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running Engine lo
59. under severe conditions See the Engine Before each use or daily Ferro hours Owner s Manual for additional information Every 80 hours Remove engine shrouds and clean cooling fins Every 100 hours Change the engine oil May need more often under severe conditions Grease the brake handle pivot se Check the spark plugs Every 500 hours Change the hydraulic filter Every 250 hours yearly if using Mobil 1 15W50 Grease the front caster wheel bearings Grease front caster pivots Lubricate the caster wheel hubs 22 Maintenance Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving patts to stop Make sure unit is on a level surface Check with engine cold Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick Screw into place Remove the dipstick and read the oil level If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval Monthly WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals
60. ver the batteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems ate off and at the same rated system voltage These instructions are for negative ground systems only Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 10 NOaRWN gt G012785 Figure 10 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block Connect the other end of the positive cable to the positive terminal of the booster battery Connect the black negative cable to the other terminal negative of the booster battery MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK Start the vehicle and remove the cables in the reverse order of connection the engine block black connection is the first to disconnect Check Mower Blades Service Interval Before each use or daily Important Mower blades are sharp Wrap the blade or wear gloves and use extra caution when servicing them 1 24 Stop engine wait for all moving parts to stop and remove key
61. y Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are limited to the duration of the express warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 589 B NEW PREMIUM HYDRO OIL BENEFITS Designed amp manufactured with superior anti wear protection Superior thermal stability Consistent hydro performance Superior shear resistance under heavy loads Field tested amp proven performance Twice the shear stability of SPECIALLY FORMULATED amp competing oils MANUFACTURED FOR SUPERIOR P CR CORMANCE IN ALL EXMARK Enhanced control performance DRAULIC DRIVE SYSTEMS Specially formulated for any 1 US Quart 946 ML 32 FL oz Exmark hydraulic system NOW AVAILABLE FOR PURCHASE Part No 109 9828 38 G011841 Figure 17 This page may be c
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