Page 2 - IMPORTANT
- i - WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system...
Page 4 - BEFORE OPERATING YOUR MOWER,
iii 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 instr...
Page 5 - TABLE OF CONTENTS
- iv - TABLE OF CONTENTS 1. SAFETY PAGE 1.1 Safety Alert Symbol ....................................................................................... 1 1.2 Training ......................................................................................................... 1 1.3 Preparation ............
Page 6 - SAFETY ALERT SYMBOL; YOUR SAFETY IS INVOLVED!; PREPARATION; CAUTION
- 1 - 1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL 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 ...
Page 7 - DO NOT
- 2 - 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. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, ...
Page 9 - NEVER
- 4 - 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, maintenan...
Page 10 - DANGER; Figure 1; SAFE ZONE FOR MOWING
- 5 - DANGER POTENTIAL HAZARD ♦ 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 ♦ Do not mow slo...
Page 11 - WARNING; EXTREME; midway
- 6 - WARNING POTENTIAL HAZARD ♦ There is no rollover protection when the roll bar is down. 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 ♦ Keep the roll bar in the rais...
Page 12 - MAINTENANCE AND STORAGE; Check all bolts frequently to maintain proper tightness.
- 7 - 1.4.17 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. 1.4.18 Be aware of the mower discharge and direct discharge away from others. 1.4.19 Do Not operate mower under the influence of alcoh...
Page 16 - Kohler; ELECTRICAL SYSTEM
- 11 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: 2.2 ENGINE: 2.2.1 Engine Specifications: See your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3750 RPM (No Load) Idle: 1500 RPM 2.3 FUEL SYSTEM 2.3.1 Capacity: 11 gal. (42 L.) 2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher 2.3.3 Fuel Fi...
Page 17 - HYDROSTATIC GROUND DRIVE SYSTEM
- 12 - Drive Front Caster Pneumatic (Air-Filled) Pneumatic (Air-Filled) Quantity 2 2 Tread Turf Mate Smooth Size 23 x 10.50-12 13 x 5.00-6 Ply Rating 4 4 Pressure 13 psi (90 kPa) 13 psi (90 kPa) • Custom ride suspension system to enhance Standard Seat. • Deluxe suspension seat with high back, low pr...
Page 18 - TORQUE REQUIREMENTS; ASSEMBLY INSTRUCTIONS
- 13 - 2.10 DIMENSIONS 2.10.1 Overall Width: without deck deflector up deflector down w/52” Deck 49.8 in. (126.5 cm) 53.4 in. (135.6 cm) 64.2 in. (163.1 cm) w/60” Deck 53.8 in. (136.7 cm) 61.4 in. (156.0 cm) 72.2 in. (183.4 cm) 2.10.2 Overall Length: w/52” Deck w/60” Deck Roll Bar - Up 78.2 in. (198...
Page 19 - LOOSELY
- 14 - CAUTION POTENTIAL HAZARD ♦ Raising the rear of the unit for assembly relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. HOW TO...
Page 20 - FIGURE 3; The machine is shipped with a filled lead acid battery.; Wash
- 15 - 3.2.5 Install the upper u-shaped section of the roll bar. (Reference Figure 3 for alignment and installation instructions below): 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 assemb...
Page 21 - cable and the red wire
- 16 - DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN HAPPEN ♦ Battery gasses 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. ♦ M...
Page 22 - INSTALL DRIVE WHEELS; a) Remove seat assembly from the crate.; INSTALL MOTION CONTROL LEVERS; outside; of the control arm shaft and secure with the bolts and; FIGURE
- 17 - 3.4 INSTALL DRIVE WHEELS . 3.4.1 Mount drive wheels with the valve stem to the outside of the unit. Secure using four (4) 1/2-20 wheel nuts (installed on studs in hubs) for each wheel. Torque to 95 ft-lbs (128 N x M). 3.5 CHECK TIRE PRESSURE. 3.5.1 Check tire pressure in drive tires. Proper i...
Page 23 - SERVICE HYDRAULIC OIL; OPERATION INSTRUCTIONS; FIGURE 6
- 18 - 3.8 POSITION DISCHARGE CHUTE. 3.8.1 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. 3.9 SERVICE ENGINE. Engine is shipped with oil; check oil level and if necessary and fill to t...
Page 24 - ROTATE
- 19 - 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 leve...
Page 25 - OPERATING INSTRUCTIONS
- 20 - 4.1.8 Ignition Switch: Located on the lower center of 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 th...
Page 26 - crank the engine continuously for more then ten (10); IMPORTANT: Operator must be in seat before the PTO can be engaged.
- 21 - 4.3.3 Starting Engine: 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.) On a cold engine, place the throttle midway between the “SLOW” and “FAST” positio...
Page 27 - TRANSPORTING
- 22 - 4.3.6 Stopping Engine: Bring unit to a full stop . Disengage the PTO, move motion control levers out to the neutral lock position and set parking brake . Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum of...
Page 28 - PERIODIC MAINTENANCE; Service Interval: Daily
- 23 - 4.4.2 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 th...
Page 29 - operate the engine with the oil level below the; Service Interval: Monthly
- 24 - d) 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 dipsti...
Page 30 - Service Interval: Daily
- 25 - a) Stop engine, wait for all moving parts to stop, and remove key. b) Clean all debris from rotating engine air intake screen and from around engine shrouding. c) Clean all debris from inside of pump drive belt compartment. d) Inspect rubber engine baffles for proper fit. Replace if necessary...
Page 33 - Use only Mobil 1
- 28 - e) 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. f) Start the engine and check for leaks. 5.1.12 Check hydraulic oil level: Service Interval: 40 hr. a) Stop engine and wait for all moving pa...
Page 34 - LUBRICATION CHART; Service Interval: Once Yearly; NOTE
- 29 - LUBRICATION CHART FITTING LOCATIONS INITIAL PUMPS NO. of PLACES SERVICE INTERVAL 1. Front Caster wheel hubs ∗ 0 2 ∗ yearly 2. Front Caster Pivots ∗ 0 2 ∗ yearly 3. Height Adj. Shaft Bearings 1 5 40 hours 4. Deck Drive Belt Idler Arm 1 1 Yearly 5. Brake Brackets 1 2 200 hours 6. Mule Drive Bel...
Page 37 - ADJUSTMENTS; FIGURE 9
- 32 - 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 ta...
Page 38 - For Maximum Deck Flotation,; Do; ANTI-SCALP ROLLER ADJUSTMENT; one of the front
- 33 - d) Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter. See decal on the side of deck lift plate. e) Move lever out of transport (or 4.5” (11.4 cm) cutting height) position and down onto height adjustment pin to mow at selected height. f) ...
Page 39 - Pump Drive Belt Tension.
- 34 - j) 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” (19 mm) block. Secure front swivel using locking nut in front of swivel. Repeat for right side. k) Recheck that...
Page 40 - MULE DRIVE BELT ADJUSTMENT; no adjustment is; BELT GUIDE POSITIONING
- 35 - FIGURE 12 MULE DRIVE BELT ADJUSTMENT 5.2.5 Deck Belt Tension. a) The deck belt is tensioned by a self-tensioning idler, no adjustment is necessary . 5.2.6 Adjust Seat Switch a) If necessary, adjust the seat actuator rod length to where the machine will shut off when the operator raises off th...
Page 41 - BRAKE ADJUSTMENT; Adjust Throttle Lever Tension.; THROTTLE TENSION; Electric Clutch Adjustment:
- 36 - b) Measure the length of the spring. Measurement should be 2.75” (7.0 cm) between washers (see Figure 14). c) If adjustment is necessary, tighten the nut directly below the yoke and loosen the bottom nut (bottom one of the two tightened together) below the spring. Turn the nut directly below ...
Page 42 - REVERSE INDICATOR ADJUSTMENT
- 37 - 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 adj...
Page 43 - MOTION CONTROL ADJUSTMENT; Brake must be engaged and motion control levers out to
- 38 - a) This adjustment must be made with the drive wheels turning. First raise the frame and block up so that drive wheels can rotate freely. b) Remove the electrical connection from the seat safety switch, located directly to the left of the seat switch assembly beside the hydraulic oil reservoi...
Page 44 - CASTER ADJUSTMENT
- 39 - 5.2.14 Caster pivot bearings pre-load adjustment. a) 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, make sure the spring washers are reinstalled as shown in Figure 18. 5.2.15 Se...
Page 46 - ENGINE TROUBLESHOOTING TABLE
- 41 - ENGINE TROUBLESHOOTING TABLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LINE DIRTY AIR FILTER FAULTY SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN INSUFFICIENT BATTERY CHARGE Will not start X X X X X X X Hard starting X X X X X X X Stops suddenly X X X ...
Page 47 - ELECTRICAL DIAGRAM
Page 48 - HYDRAULIC DIAGRAM
Page 50 - SERVICE RECORD; Date
- 45 - SERVICE RECORD Date Description of Work Done Service Done By
Page 52 - RIDING ACCESSORIES; INDUSTRIAL PARK BOX 808; Check us out on the Web:
® MFG. CO. INC. 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...
