Exmark Phazer 977, Phazer 820 User Manual

PHAZER
ForSerialNos. 820,977&Higher
PartNo.4500-488Rev.C
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:IMPORTANTTheengineinthis productisnotequippedwithasparkarrester mufer.ItisaviolationofCaliforniaPublic ResourceCode(CPRC)Section4442touse oroperatethisengineonanyforest-covered, brush-covered,orgrass-coveredlandasdened inCPRC4126.Otherstatesorfederalareasmay havesimilarlaws.
Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.
ThissparkignitionsystemcomplieswithCanadian ICES-002Cesystèmed’allumageparètincellede vèhiculeestconformeàlanormeNMB-002du Canada
TheenclosedEngineOwner’sManualis suppliedforinformationregardingTheU.S. EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit. ShouldthisengineOwner’sManualbecome damagedorillegible,replaceimmediately. Replacementsmaybeorderedthroughthe enginemanufacturer.
Exmarkreservestherighttomakechangesor addimprovementstoitsproductsatanytime withoutincurringanyobligationtomakesuch changestoproductsmanufacturedpreviously. Exmark,oritsdistributorsanddealers,accept noresponsibilityforvariationswhichmaybe evidentintheactualspecicationsofitsproducts andthestatementsanddescriptionscontained inthispublication.
©2010ExmarkMfg.Co.,Inc. IndustrialParkBox808 Beatrice,NE68310
Contactusatwww.Exmark.com.
2
PrintedintheUSA
AllRightsReserved
Introduction
CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.
Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.
BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety instructions,youwillprolongthelifeofyourmower, maintainitsmaximumefciency ,andpromotesafe operation.
Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
AllExmarkequipmentdealersanddistributorsare keptinformedofthelatestmethodsofservicing andareequippedtoprovidepromptandefcient serviceintheeldorattheirservicestations.They carryamplestockofservicepartsorcansecurethem promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready .
Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................10
Specications.......................................................13
ModelNumbers............................................13
Systems.........................................................13
Dimensions...................................................14
TorqueRequirements....................................15
ProductOverview................................................15
Operation.............................................................16
Controls........................................................16
Pre-Start........................................................17
OperatingInstructions..................................18
Transporting.................................................20
Maintenance.........................................................22
RecommendedMaintenanceSchedule(s)...........22
PeriodicMaintenance.......................................23
CheckEngineOilLevel.................................23
CheckBatteryCharge....................................23
CheckMowerBlades.....................................24
CheckSafetyInterlockSystem.......................25
CheckforLooseHardware............................25
ServiceAirCleaner........................................26
ChangeEngineOil........................................26
CheckHydraulicOilLevel.............................26
CheckTirePressures.....................................26
CheckConditionOfBelts..............................26
LubricateGreaseFittings...............................27
LubricateCasterWheelHubs........................27
CheckSparkPlugs.........................................28
ChangeHydraulicSystemFilter.....................28
ThreadLockingAdhesives.............................29
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................29
DielectricGrease...........................................29
Adjustments.....................................................30
DeckLeveling...............................................30
PumpDriveBeltTension...............................30
DeckDriveBeltTension................................30
ElectricClutchAdjustment............................30
MotionControlLinkageAdjustment.............30
AdjustThrottleLeverTension.......................31
Cleaning...........................................................31
CleanEngineAirCoolingSystem...................31
RemoveEngineShroudsandCleanCooling
Fins...........................................................31
CleanGrassBuild-UpUnderDeck................31
WasteDisposal..............................................32
Troubleshooting...................................................33
Schematics...........................................................35
4
Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.
Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.
Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator’s
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.
Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.
Preparation
Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.
Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.
CAUTION
Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)can notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.
Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.
Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.
Wearhearingprotectionwhenoperatingthis machine.
Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.
5
Safety
DANGER
Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.
Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.
Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.
DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineor emissionsystem(ifequipped).
Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.
Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.
Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.
Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.
DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.
Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.
Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.
Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.
Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.
DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.
WARNING
Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.
Avoidprolongedbreathingofvapors.
Keepfaceawayfromnozzleandgas tank/containeropening.
Keepawayfromeyesandskin.
Neversiphonbymouth.
Checkthattheoperator’spresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly.DoNotoperateunlessthey arefunctioningproperly.
6
Safety
Operation
WARNING
Operatingengineparts,especiallythemufer, becomeextremelyhot.Severeburnscanoccur oncontactanddebris,suchasleaves,grass, brush,etc.cancatchre.
Allowengineparts,especiallythemufer,to coolbeforetouching.
Removeaccumulateddebrisfrommufer andenginearea.
Installandmaintaininworkingordera sparkarresterbeforeusingequipment onforest-covered,grass-covered,or brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.
DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.
Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.
Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.
Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.
Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.
DoNotchangetheenginegovernorsettingor overspeedtheengine.
–Beforeclearingblockages.
–Wheneveryouleavethemower.
Stopengine,waitforallmovingpartstostop,and engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
WARNING
Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.
DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.
Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.
NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.
Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.
Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.
Beawareofthemowerdischargepathanddirect dischargeawayfromothers.
DoNotoperatethemowerundertheinuence ofalcoholordrugs.
Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.
Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
Stopengine,waitforallmovingpartstostop, removekeyandengageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).
SlopeOperation
UseExtremecautionwhenmowingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.
7
Safety
DANGER
Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.Wheelsdroppingover edges,ditches,steepbanks,orwatercancause rollovers,whichmayresultinseriousinjury, deathordrowning.
DoNotmowslopeswhengrassiswet.
DoNotmowneardrop-offsornearwater.
DoNotmowslopesgreaterthan15degrees.
Reducespeedanduseextremecautionon slopes.
Avoidsuddenturnsorrapidspeedchanges.
Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.
Useawalkbehindmowerand/orahandtrimmer neardrop-offs,ditches,steepbanksorwater. (Figure3).
Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.
Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.
Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.
Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.
MaintenanceandStorage
Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.
Keepengine,enginearea,andpumpdrivebelt compartmentfreefromaccumulationofgrass, leaves,excessivegreaseoroil,andotherdebris whichcanaccumulateintheseareas.These materialscanbecomecombustibleandmayresult inare.
Figure3
1.Water
2.DangerZone-Useawalkbehindmowerand/orhand trimmeronslopesgreaterthan15degrees,near drop-offs,andwater.
3.SafeZone-Usethemowerhereonslopeslessthan15 degrees
Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.
Watchforditches,holes,rocks,dipsandrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.
Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.
LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.
Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.
Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.
Usejackstandstosupportcomponentswhen required.
Carefullyreleasepressurefromcomponentswith storedenergy.
Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.
Usecarewhencheckingblades.Wraptheblade(s) orweargloves,andusecautionwhenservicing them.Onlyreplacedamagedblades.Never straightenorweldthem.
Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.
8
Safety
Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugcharger beforeconnectingordisconnectingfrombattery. Wearprotectiveclothinganduseinsulatedtools.
DANGER
Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.
Keepsparks,ames,orcigarettesaway frombattery.
Ventilatewhenchargingorusingbattery inanenclosedspace.
Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.
Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.
Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.
DoNotswallowelectrolyte.
Intheeventofanaccident,ushwith waterandcalladoctorimmediately.
CAUTION
WARNING
Removingstandardoriginalequipmentparts, orusingnon-Exmarkreplacementpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.
Replaceallpartsincluding,butnotlimitedto tires,belts,andbladeswithoriginalExmark parts.
WARNING
Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.
Ifequipped,makesureallhydraulicuid hosesandlinesareingoodconditionandall hydraulicconnectionsandttingsaretight beforeapplyingpressuretohydraulicsystem.
Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
Usecardboardorpaper,notyourhands,to ndhydraulicleaks.
Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.
Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagement ofcomponents.Sparkscouldcausean explosionormovingpartscouldaccidentally engagecausingpersonalinjury
Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.
Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.
Checkallboltsfrequentlytomaintainproper tightness.
Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.
9
Safety
SafetyandInstructionalDecals
Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.
Replaceallworn,damaged,ormissingsafety signs.
Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.
Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.
Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.
Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.
Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.
93-8069
1-303508
1-403005
1-513747
1.Hotsurface/burnhazard—stayasafedistancefromthe hotsurface.
98-5954
103-1077
1-513748
1.Fast3.Neutral
2.Slow
10
109-2356
4.Reverse
Safety
109-2463
109-2992
109-2465
116-0950
109-2467
109-2490
HourMessageDisplay
1.HourMeter4.Neutral
2.PTO5.Operator’spresence
3.ParkingBrake6.Battery
109-2862
switch
11
Safety
116-1400
12
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