Exmark Viking Hydro 920000 User Manual

Page 1
VIKING
ForSerialNos. 920,000&Higher
PartNo.4500-693Rev.A
HYDRO
Page 2
WARNING
CALIFORNIA
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered,or grass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilar laws.
Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.
Thissparkignitionsystemcomplieswiththe CanadianstandardICES-002.Cesystèmed’allumage parètincelledevèhiculeestconformeàlanorme NMB-002duCanada.
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
Page 3
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
Page 4
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................10
Specications.......................................................13
ModelNumbers............................................13
Systems.........................................................13
Dimensions...................................................14
TorqueRequirements....................................14
ProductOverview................................................15
Operation.............................................................15
Controls........................................................15
Pre-Start........................................................17
OperatingInstructions..................................17
Transporting.................................................19
Maintenance.........................................................20
RecommendedMaintenanceSchedule(s)...........20
PeriodicMaintenance.......................................21
CheckEngineOilLevel.................................21
CheckMowerBlades.....................................21
CheckSafetyInterlockSystem.......................22
CheckforLooseHardware............................22
ServiceAirCleaner........................................23
ChangeEngineOil........................................23
CheckHydraulicOilLevel.............................23
CheckTirePressures.....................................23
CheckConditionOfBelts..............................23
LubricateGreaseFittings...............................24
CheckSparkPlugs.........................................24
ChangeHydraulicSystemFilter.....................24
ReplaceEmissionsAirIntakeFilter................26
WheelHub-SlottedNutTorque
Specication..............................................26
ThreadLockingAdhesives.............................27
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................27
Copper-BasedAnti-seize..............................27
DielectricGrease...........................................27
Adjustments.....................................................28
AdjustingtheCuttingHeight.........................28
AdjustingtheAxlePosition............................29
AdjustingtheNumberofSpacersbelow
CasterSupportHub...................................30
AdjustingtheCuttingHeightwithBlade
Spacers......................................................30
PTOEngagementLinkage
Adjustment...............................................31
PTOSafetySwitchAdjustment......................31
EnginetoMowerDeckBelt
Adjustment...............................................31
BladeBrakeAdjustment................................32
BeltGuideAdjustment..................................33
PumpDriveBeltTension...............................33
HydroDriveLinkageAdjustment..................33
TrackingAdjustment.....................................36
HydroPumpSpringTensionSetting..............36
ParkBrakeAdjustment..................................36
Cleaning...........................................................37
CleanEngineAirCoolingSystem...................37
RemoveEngineShroudsandCleanCooling
Fins...........................................................37
CleanGrassBuild-UpUnderDeck................37
WasteDisposal..............................................37
Troubleshooting...................................................38
Schematics...........................................................40
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Page 5
Safety
Safety
SafetyAlertSymbol
ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.
Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.
ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.
Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.
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.
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.
Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)can
Preparation
Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.
Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.
CAUTION
Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.
Wearhearingprotectionwhenoperatingthis machine.
Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.
5
Page 6
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 infuelleakageordamagetotheengine oremissionsystem.
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.
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Page 7
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.
Neverraisedeckwithbladesrunning.
Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.
Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.
DoNotchangetheenginegovernorsettingor overspeedtheengine.
Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
Stopengine,waitforallmovingpartstostop,and engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.
WARNING
Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.
DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.
Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.
DONOToperatethemowerwhenpeople, especiallychildren,orpetsareinthearea.
Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.
Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.
Beawareofthemowerdischargepathanddirect dischargeawayfromothers.
DoNotoperatethemowerundertheinuence ofalcoholordrugs.
Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.
Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.
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Page 8
Safety
DANGER
Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Lossofcontrol and/orlossofoperator’sfootingcouldresultina fallwithanarmorleggettingunderthemower orenginedeckwhichmayresultinserious injury,deathordrowning .
Mowacrossslopes,neverupanddown.
DoNotmowslopeswhengrassiswet.
DoNotmowneardrop-offsornearwater.
DoNotmowslopesgreaterthan20degrees.
Reducespeedanduseextremecautionon slopes.
Avoidsuddenturnsorrapidspeedchanges.
Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.
Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.
Watchforditches,holes,rocks,dipsandrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.
Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.
Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.
Keepengineandengineareafreefrom accumulationofgrass,leaves,excessivegrease oroil,andotherdebriswhichcanaccumulate intheseareas.Thesematerialscanbecome combustibleandmayresultinare.
Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.
Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.
Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.
Usejackstandstosupportcomponentswhen required.
Carefullyreleasepressurefromcomponentswith storedenergy.
Usecarewhencheckingblades.Wraptheblade(s) orweargloves,andusecautionwhenservicing them.Onlyreplacedamagedblades.Never straightenorweldthem.
Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.
Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.
Checkallboltsfrequentlytomaintainproper tightness.
Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.
Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.
Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.
Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.
MaintenanceandStorage
Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.
WARNING
Removingstandardoriginalequipmentparts, orusingnon-Exmarkreplacementpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.
Replaceallpartsincluding,butnotlimitedto, tires,belts,andbladeswithoriginalExmark parts.
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Page 9
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.
Safety
9
Page 10
Safety
SafetyandInstructionalDecals
Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.
Replaceallworn,damaged,ormissingsafety signs.
Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.
Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.
1-303508
Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.
Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.
Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.
1-403005
1-303517
1-323427
36inchDeckUnitsOnly
1-403143
1-413214
98-5954
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Page 11
Safety
103-1798
103-2076
103-2103
103-2196
103–2242
11
Page 12
Safety
116-0404
103–2243
103-4935
103-5626
48inchDeckUnitsOnly
117–2718
12
Page 13
Specications
ModelNumbers
SerialNos:920,000andHigher
VH16KA362;VH16KA483;VH16KA362CA;VH16KA483CA
Specications
Systems
Engine
EngineSpecications:SeeyourEngineOwner’s Manual
EngineOilType:Exmark4–CyclePremium EngineOil
RPM:FullSpeed:3600(NoLoad)
Idle:1550RPM
FuelSystem
Capacity:5.0gal.(18.9L)
TypeofFuel:Regularunleadedgasoline,87 octaneorhigher;containingnomorethan10% methanolorethanol.
FuelFilter:ReplaceableIn-line
FuelShut-OffValve:1/4turnincrements
SafetyInterlockSystem:
Transmission
TwoHydroGearvariabledisplacementpiston pumpsindependentlycoupledtotwohigh efciencyParkerwheeldrivemotors.
HydraulicOil:UseExmarkPremiumHydroOil.
HydraulicOilCapacity:2.4qt.(2.2L)
HydraulicFilterisreplaceablecartridgetype.
P/N109–4180:25microns,10psibypass (Summeruseabove32°F(0°C))
P/N1–523541:40microns,18psibypass(Winter usebelow32°F(0°C))
Speeds:
–0-6.2mph(10.0km/hr)forward.
–0-2.2mph(3.5km/hr)reverse.
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive motorswith1inch(25.4mm)taperedshaft.
OperatormusthaveOPC(OperatorPresence Control)leversheldincontactwithhandle grips,speedcontrolleverinneutral,andPTO disengagedtostartengine.ReleaseofOPClevers willcausetheenginetostopifspeedcontrollever isnotinneutraland/orPTOisengaged.
Parkbrakemustbedisengagedtomovespeed controloutofneutralorenginewillkill.
Steering/BrakeControls
Fingertipdrivecontrolleversprovideindependent speedcontrol,brakingandneutraltoeachdrive wheelformovingforwardorreverse,stoppingand powerturning.
Tires&Wheels
DriveFrontCaster
Pneumatic
(Air-Filled)
Quantity
Tread
Size16x6.50–89x3.50-4
PlyRating
Pressure
13
22
TurfMasterSmooth
4
14psi (97kPa)
Semi­Pneumatic
Page 14
Specications
CuttingDeck
CuttingWidth:
–36inchDeck:35.38inches(89.9cm)
–48inchDeck:47.25inches(120.0cm)
Discharge:Side
BladeSize:
–36inchDeck:18.00inches(45.7cm)—
Quantity:2
–48inchDeck:16.25inches(41.3cm)—
Quantity:3
DeckDrive:Manualengagementofbeltwith over-centerlock.Bladebelttensionisadjustable viaturnbuckle.
BladeBrake:WhenthePTOengagementcontrol ismovedtothedisengagedpositionafriction brakepadstopstherotationoftheblades.
DeckMounting:Bolteddirectlytoenginedeck.
DeckDepth:
–36inchDeck:5.0inches(12.7cm)
–48inchDeck:5.0inches(12.7cm)
CuttingHeightAdjustment:
Adjustsfrom1inch(2.5cm)to41/4inches(10.8 cm)in1/4inch(6.4mm)incrementsbyvarious adjustmentsofcasterspacers,bladespacers,and axleheight.
Dimensions
TreadWidth:(OutsidetoOutsideof Tires,Widthwise)
36inchDeck48inchDeck
35.6inches (90.4cm)
40.4inches (102.6cm)
CurbWeight:
36inchDeck48inchDeck
573lb(260kg)633lb(287kg)
TorqueRequirements
BoltLocation
Blade/CutterHousing SpindleBolt
CasterBracketMounts
MowerDeck/Engine DeckMount
EngineMountingBolts
WheelLugNuts
WheelHubSlottedNut (StyleA)
WheelHubSlottedNut (StyleB)
WheelMotorMounting Bolts
Torque
75-80ft-lb(102-109N-m)
30-35ft-lb(41-48N-m)
30-35ft-lb(41-48N-m)
17-23ft-lb(23-31N-m)
90-95ft-lb(122-129N-m)
140-155ft-lb (190-210N-m)
minimum100ft-lb (136N-m)
30-35ft-lb(41-48N-m)
OverallWidth:
36inchDeck48inchDeck
DeectorUp36.4inches
(92.5cm)
DeectorDown47.0inches
(119.4cm)
48.1inches (122.2cm)
57.9inches (147.1cm)
OverallLength:
36inchDeck48inchDeck
77.3inches(196.3cm)72.3inches(183.6cm)
OverallHeight:
36inchDeck48inchDeck
43.2inches(109.7cm)43.2inches(109.7cm)
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Page 15
Operation
ProductOverview
Figure3
1.ECSHandles3.FuelCap
2.Controls4.BladeSpacers
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
OperatorPresenceControl(OPC) Levers
Locatedontheupperhandleassemblydirectlyabove thehandlegrips.
Whentheseleversaredepressed,theOPCsystem sensesthattheoperatorisinthenormaloperator’s position.Whentheleversarereleased,theOPC systemsensesthattheoperatorhasmovedfromthe normaloperatingpositionandwillkilltheengineif eitherthespeedcontrolleverisnotintheneutral positionorthePTOisengaged(see
Figure4).
Figure4
1.OPCLever
2.Rotateneutrallocklatch downwardforneutral lockposition
3.NeutralLockLatch
4.DriveLeverinneutral position
DriveLevers
Locatedoneachsideoftheupperhandleassembly aheadofandbelowthehandlegrips.
Theseleversindividuallycontrolthespeedand directionofeachdrivewheel.Whenthespeedcontrol leverismovedoutoftheneutralpositionandthe neutrallocklatchesaremovedintothedriveposition,
15
Page 16
Operation
asshowninFigure4,andthedriveleversarereleased, thedrivewheelsareengagedintheforwarddirection.
Squeezingthelefthandand/orrighthandlever causesthelefthandand/orrighthanddrivewheel respectivelytoslowdown,stop,orreverse,depending onhowfareachdriveleveris“squeezed”.Squeezing thedriveleversbeyondtheneutralpositioncauses thedrivewheelstoengageinthereversedirection regardlessofthepositionoftheneutrallocklatches andthespeedcontrollever.
NeutralLockLatch
Locatedattheendofthehandles.
Thepurposeoftheselatchesistoallowtheoperator tolockthedriveleversina"neutral"positionwhere neitherofthedrivewheelsareengagedineithera forwardorreversedirection(see
Figure4).
ParkBrakeLever
Locatedontherightsideoftheunitabovethe hydraulictank.
Thebrakeleverengagestheparkbrakeonthedrive wheels.
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe brake.
Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeing engaged.Theunitmustbetieddownandbrake engagedwhentransporting.
speedandmovingittotherearwilldecreaseengine speed.Movingthethrottleforwardintothedetent isfullposition.
SpeedControlLever
Locatedinmiddleofcontrolconsole.
Thespeedcontrollevercontrolsthemaximum forwardspeedandisinnitelyvariablefromneutral 0–6.2mph(10.0km/hr).
Parkbrakemustbedisengagedtomovespeedcontrol outofneutralorenginewillkill.
“Off-Run”Switch
Locatedonthecontrolconsole.
Turnthekeytothe“Run”positiontoallowthe enginetobestarted.Turnthekeytothe“Off” positiontoshutengineoff.
FuelShut-OffValve
Locatedinthefuellinemidwaybetweenthetank andengine.
Thefuelshut-offvalveisusedtoshutoffthe owoffuelwhenparkinginsideabuilding,during transportationtoandfromthejobsites,andwhen themachinewillnotbeusedforafewdays.
Rotatevalve1/4turnclockwisetoshutfueloff. Rotatevalve1/4turncounterclockwisetoturnfuel on.
Parkbrakemustbedisengagedtomovespeedcontrol outofneutralorenginewillkill.
ChokeControl
Locatedonthefrontleftcornerofthefueltank support.
Chokeisusedtoaidinstartingacoldengine.The chokecontrolispulledouttobeinthe“ON”position andpushedintobeinthe“OFF”position.DoNot runawarmenginewithchokeinthe“ON”position.
ThrottleControl
Locatedontheonthecontrolconsolerightside.
Thethrottleisusedtocontrolenginespeed.Moving thethrottlecontrolforwardwillincreaseengine
DriveWheelReleaseValves
Locatedonthetoprearcornerofthehydrostatic pumps.
Drivewheelreleasevalvesareusedtoreleasethe hydro-staticdrivesystemtoallowthemachinetobe movedbyhandwithouttheenginerunning.
Witha5/8wrench,turnbothvalvesoneturn counterclockwisetoreleasethedrivesystem.
Turnclockwisetoresetthedrivesystem.DoNot
overtighten.
TrackingAdjustmentKnob
Locatedontheright-handsideoftherearofthefuel tanksupport.
16
Page 17
Operation
Theknobcanbeadjustedsothatmachinewill “track”straightaheadwiththedriveleversreleased.
PTOEngagementControl
Locatedonleftsideofcontrolconsole.
Toengagetheblades,theknobmustbepulled towardtheoperatoruntiltheturnbuckle(attached tothebladeengagementidler)locksover-center.T o disengagetheblades,pushtheknobdownuntilthe assistarmcontactsthepinonthedeck.
ParkbrakemustbedisengagedbeforePTOis engagedorenginewillkill.
ColdStartKit
Locatedontherighthandsideofenginedeck,below andslightlyaheadofthehydrocontrolshield.
Thecoldstartkitisusedtoeasethestartingofthe unitincoldweatherorwhentheunithasnotbeen operatedforaperiodoftime.Thecoldstartkit movestheidlerpulleyawayfromthepumpbelt, releasingthetensiononthebeltwhichallowsthe enginetoturnoverwithlessresistance(seeStarting theEnginesectioninOperation).
Pre-Start
Fillfueltankonlevelground.Forbestresultsuse onlyclean,freshregulargradeunleadedgasolinewith anoctaneratingof87orhigher.
Important:Neverusemethanol,gasoline containingmethanol,gasoholcontainingmore than10%ethanol,premiumgasoline,orwhite gasbecausethefuelsystemcouldbedamaged.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Fillthefueltanktothe
bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system.
Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.
OperatingInstructions
OpentheFuelShut-OffValve
Rotatethevalve1/4turncounterclockwisetoturn fuelon.
StartingtheEngine
Note:OperatormusthavePTOdisengagedand
speedcontrolleverinneutralpositionwhenstarting theengine.
Lockdriveleversinneutralandengageparkbrake
Note:Acoldweatherstartingkithasbeenaddedfor easeofstartingineithercoldweatherorwhenthe unithasnotbeenrunforaperiodoftime.
Tousecoldstartkit:
1.Pullsplitringstraightoutthesideoftheunit, andhooktheringoverthelowerfronthydro controlshieldbolt.
2.Startengine.Refertothefollowingguidelines forfurtherstartingsuggestions.
Toengagepumpdrive(disengagecoldstartkit):
1.Pullchainstraightoutfromthesideofthe unituntilthesplitringcanberemovedfrom thebolt.
2.Slowlyreleasetensiononchain.
1.Pulloutthechokecontrol.Placethethrottle controlmidwaybetweenthe“Slow”and“Fast” positions.Turnthekeyswitchtothe“Run” position.
2.Pullrecoilropetostartengine.Afterengine warmsup,graduallypushinthechokecontrol. DoNotrunwarmenginewiththechokeinthe “ON”position.
Note:Kawasakienginesgenerallyneedtobe “choked”evenwhenwarm.
EngagingthePTO
DANGER
Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.
RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.
DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.
17
Page 18
Operation
DANGER
Anuncovereddischargeopeningwillallow objectstobethrowninanoperator’sor bystander’sdirection.Also,contactwiththe bladecouldoccur.Thrownobjectsorblade contactcancauseseriousinjuryordeath.
Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.
ThePTOswitchengagesthecuttingblades.Besure thatallpersonsareclearofmowerdeckanddischarge areabeforeengagingthePTO.
1.Setthrottleto“MIDW AY”position.
2.PullthePTOengagementknobuptoengage blades.
3.Placethethrottleinthe“FAST”positiontobegin mowing.
Note:ParkbrakemustbedisengagedbeforePTOis engagedorenginewillkill.
DisengagingthePTO
1.Setthrottleto“MIDW AY”position.
2.PushdownonthePTOengagementknobto disengagetheblades.
StoppingtheEngine
transporting,orwhentheunitisparkedinside abuilding.
DrivingtheMachine
DriveLever/NeutralLockLatchOperation
Tolockthedriveleversin“neutrallock”,squeezethe driveleverstothe“neutral”position(DoNotsqueeze thedriveleversallthewaybackasthiswillcausethe drivewheelstogointofullreversedirection).See Figure5position1.Placethumbsontheinnerlobe oftheneutrallocklatchesandrotatethemunder thedriveleversintothe“neutrallock”position.See Figure5position2.Releasethedrivelevers.
CAUTION
Iftheneutrallocklatchesarenotcompletely engagedthedriveleverscouldunexpectedlyslip intotheforwarddriveposition.Ifthedrivelevers slipintothedrivepositiontheunitcouldlurch forwardandcauseinjuryorpropertydamage.
Besurethedriveleversarepasttherollerand securelyseatedatthebottomoftheneutrallock latches.
Toplacethedriveleversinthe“forward”position, slightlysqueezethedriveleverswhileplacingthumbs ontheouterthumblobeoftheneutrallocklatches (ortheindexngeronthefrontlobe)androtatethem fromunderthedrivelevers.Slowlyandcarefully releasethedrivelevers.See
Figure5position3.
1.Bringtheunittoafullstop.
2.Lockdriveleversinneutral.
3.DisengagethePTO.
4.Movespeedcontrollevertoneutral.
5.Engagetheparkingbrake.
6.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.
7.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.
8.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.
9.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when
Toplacethedriveleversinthe“reverse”position, squeezethedriveleverspasttheneutralposition.See Figure5position4.
18
Page 19
1.DriveLeverinneutral position
2.DriveLeverlockedin neutralposition
DrivingForward
Figure5
3.DriveLeverinforward position
4.DriveLeverinreverse position
Operation
DrivinginReverse
Tomoverearwardinastraightline,squeezedrive leversintothereverseposition.
Toturnleftorright,squeezetherighthanddrivelever toturnleftandthelefthanddrivelevertoturnright.
Tomakea“zeroturn”,squeezeeitherthelefthand ortherighthanddriveleverbackintothereverse positionwhiletheoppositedriveleverisinaforward positionatanequalbutoppositespeed.
Note:Forsmoothoperationofthismachine,avoid quick,jerkymovementsofthedrivelevers.Movethe driveleverssmoothlyanddeliberately.
Tostop,squeezedriveleversbacktothe“neutral” position.Movetheneutrallocklatchesintothe “neutrallock”positionandreleasedrivelevers.Move thespeedcontrollevertotheneutralposition.
1.Releasetheparkingbrake.
2.Withdriveleverslockedin“neutral”,shiftspeed controllevertodesiredforwardspeed.
3.Slowlysqueezeandholdbothdriveleversin theneutralpositionandrotatebothneutrallock latchesfromtheneutrallockpositiontothe forwardposition.
Note:DoNotsqueezebothdriveleversallthe wayback.Thiswillcausethedrivewheelsto engageinthereversedirection.
4.Tomoveforwardinastraightline,smoothly releasebothdriveleverstoengagedrivewheels.
Toturnleftorright,squeezetherighthanddrive levertoturnrightandthelefthanddrivelever toturnleft.
Tomakea“zeroturn”,squeezeeithertheleft handortherighthanddriveleverbackintothe reversepositionwhiletheoppositedriveleverisin aforwardpositionatanequalbutoppositespeed.
Note:Forsmoothoperationofthismachine, avoidquick,jerkymovementsofthedrivelevers. Movethedriveleverssmoothlyanddeliberately .
Tostop,squeezedriveleversbacktothe“neutral” position.Movetheneutrallocklatchesintothe “neutrallock”positionandreleasedrivelevers. Movethespeedcontrollevertotheneutral position.
Transporting
TransportingaUnit
WARNING
Loadingthemowerontoatrailerwithoutstrong enoughorproperlysupportedrampscouldbe dangerous.Therampscouldcollapsecausing theunittofall,whichcouldcauseinjury.
Useproperrampsthataresecuredtothe truckortrailer.
Keepfeetandlegsoutfromundertheunit whenloadingandunloading.
Ifnecessary,useassistancewhenloading.
Besurethefuelshut-offvalveisclosed.
Useaheavydutytrailertotransportthemachine. Engageneutrallocklatchesandparkbrake,then blockwheels.
Securelyfastenthemachinetothetrailerwithstraps, chains,cables,orropes.
DoNotrelysolelyontheparkingbraketoholdthe machineonthetrailer.
Besurethatthetrailerhasallnecessarylightingand markingasrequiredbylawanduseasafetychain.
19
Page 20
Maintenance
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
WARNING
Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.
Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst5hours
Aftertherst100hours
Aftertherst250hours
Beforeeachuseordaily
MaintenanceProcedure
•Changetheengineoil.
•Checkwheelhub-slottedtorquespecication.
•Changethehydrauliclter.
•Checktheengineoillevel.
•Checkthemowerblades.
•Checkthesafetyinterlocksystem.
•Checkforloosehardware.
•Greasethecasterwheelbearings.
•Greasecasterpivots.
•Cleanengineaircoolingsystem(SeeEngineOwner’ sManual)
•Cleanthegrassbuild-upfromunderthedeck.
WARNING
Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.
Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.
Every25hours
Every40hours
Every100hours
Every160hours
Every200hours
Every500hours
•Servicethefoamelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’smanualforadditionalinformation.)
•Checkthehydraulicoillevel.
•Checkthetirepressures.
•Checktheconditionofthebelts.
•Greasethepumpdriveidlerpivot.
•Greasethepumpcontrolbearings.
•Greasethemowerdeckidlerpivot
•Servicethepaperelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’smanualforadditionalinformation.)
•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)
•Removeengineshroudsandcleancoolingns.
•Checkthesparkplugs.
•Replacethepaperelement.
•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)
•Replacetheemissionsairintakelter.
•Checkwheelhub-slottedtorquespecication.
Monthly
•GreasethePTOengagementbellcrank.
20
Page 21
PeriodicMaintenance
CheckEngineOilLevel
ServiceInterval:Beforeeachuseordaily
1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.
2.Checkwithenginecold.
3.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.DoNotscrewinto place.Removethedipstickandreadtheoillevel.
4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner’smanualforanacceptablealternative.Do Notoverll.
Maintenance
Figure6
1.Springdiscwasher(conetowardsbolthead)
2.Bladebolttorqueto75-80ft-lb(102-109N-m).
Important:DoNotoperatetheenginewiththe oillevelbelowthe“LOW”(or“ADD”)markon thedipstick,oroverthe“FULL”mark.
CheckMowerBlades
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Liftdeckandsecureinraisedpositionasstated intheCleanGrassBuild-UpUnderDeck procedure.
3.Inspectbladesandsharpenorreplaceasrequired.
4.Re-installtheblades(iftheywereremoved)and torquebladeboltsto75-80ft-lb(102-109N-m). Besurethespringdiscwasherconeisinstalled towardthebolthead(see
Figure6).
ReplacingtheDischarge Deector
ServiceInterval:Asrequired
DANGER
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.
1.Toremoveadamagedorworndischarge deector,liftthelegofthespringwiththeloop outofthenotchinthedischargedeectorand slidetherodoutofthedischargedeector brackets,anddischargedeector.
2.Toinstallnewdischargedeector,orientthe springontherodasshowninFigure7.Slidethe rodthroughthefrontdischargedeectorbracket, dischargedeector,andreardeectorbracket.
21
Page 22
Maintenance
Figure7
1.Rod4.Mowerdeck
2.Spring5.Dischargedeector
3.Dischargedeector
3.Hookthebentendoftherodaroundthefront dischargedeectorbrackettoretainitfrom slidingout.Placethelegofthespringwiththe loopinthenotchinthedischargedeectorto holdthedischargedeectorinthedownposition
Figure7).
(see
Important:Thedischargedeectormustbe springloadedinthedownposition.Liftthe deectoruptotestthatitsnapstothefull downposition.
bracket
6.Assembledview
CheckSafetyInterlock System
ServiceInterval:Beforeeachuseordaily
1.Foryoursafety,yourExmarkmowerisequipped withOperatorPresenceControls,referredtoas (OPC).WheneitherthePTOisengaged,or thespeedcontrolleverisnotinneutralandthe operatorremovesbothhandsfromthehandles, themowerenginemuststop.
2.TodetermineiftheOPCisinoperatingcondition, clearareaofbystanders.Runtheengineat one-thirdthrottle,thenwiththedriveleversand neutrallocklatchesinthe“neutrallock”position, movethespeedcontrolleveroutofneutraland releasetheOPClevers–theenginemuststop.
3.Again,runtheengineatone-thirdthrottle,move thespeedcontrollevertoneutral,engagethe PTOandreleasetheOPClevers–theengine muststop.
Note:Parkbrakemustbedisengagedbeforethe speedcontrolleverismovedoutofneutralor PTOisengagedorenginewillkill.
Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK
SERVICEDEALER.
Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.
CheckforLooseHardware
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.
22
Page 23
Maintenance
ServiceAirCleaner
ServiceInterval:Every25hours—Service
thefoamelement.(May needmoreoftenunder severeconditions.See theEngineOwner’s manualforadditional information.)
Every100hours—Service thepaperelement.(May needmoreoftenunder severeconditions.Seethe EngineOwner’smanual foradditionalinformation.)
Every200hours/Yearly (whichevercomes rst)—Replacethepaper element.
1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.
2.SeetheEngineOwner’sManualformaintenance instructions.
ChangeEngineOil
ServiceInterval:Aftertherst5hours
Every100hours(May needmoreoftenunder severeconditions.)
5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.
6.UseoilrecommendedintheCheckEngineOil Levelsection.DoNotoverll.Starttheengine andcheckforleaks.Stopengineandrecheckoil level.
CheckHydraulicOilLevel
ServiceInterval:Every40hours
1.Stopengineandwaitforallmovingpartstostop, andremovekey.Engageparkingbrake.
2.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.UseExmark PremiumHydroOil.Replacehydraulicreservoir capandtightenuntilsnug.DoNotovertighten.
Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.
CheckTirePressures
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Drainoilwhileengineiswarmfromoperation.
3.Theoildrainhoseassemblyislocatedontheleft sideoftheengine.
Placepanundermachinetocatchoil.Removeoil drainplug.Allowoiltodrainandreplaceoildrain plug.Torqueplugto20-24ft-lb(27-33N-m).
4.ReplacetheoillterpertheEngineOwner’s Manual.Cleanaroundoillterandunscrewlter toremove.Beforethenewlterisinstalled, applyathincoatingofExmark4–CyclePremium EngineOilonthesurfaceoftherubberseal. Turnlterclockwiseuntilrubbersealcontacts thelteradapter,thentightenlteranadditional 2/3to3/4turn.
ServiceInterval:Every40hours
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Checktirepressureindrivetires.
3.Inatedrivetiresto12–14psi(83–97kPa).
4.Inatetirestopressuresstatedabove.Measure thecircumferenceofeachdrivetire.Adjusttire pressureswithintheaboverangetotrytomake tirecircumferencesmatchascloselyaspossible.
5.Semi-pneumaticcastertiresDoNotneedtobe inated.
CheckConditionOfBelts
ServiceInterval:Every40hours
23
Page 24
Maintenance
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Removethemowerdeckbeltshieldtocheck mowerbladedrivebeltcondition.
3.Lookunderenginedecktocheckthepumpdrive beltcondition.
4.Checkallidlerarmstobesuretheypivotfreely . Disassemble,cleanandgreasepivotbushingsif necessary.
LubricateGreaseFittings
Note:Seechartforserviceintervals.
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.LubricatettingswithNGLIgrade#2 multi-purposegungrease.
Refertothefollowingchartforttinglocations andlubricationschedule.
LubricationChart
Fitting
Locations
1.CasterWheel Bearings
2.CasterPivots
3.PTO Engagement Bellcrank
4.PumpDrive IdlerPivot
5.Pump Control Bearings
6.MowerDeck IdlerPivots
Initial
Pumps
122
22
11
21
22
21
Numberof
Places
Service
Interval
Daily
Daily
Monthly
40hours
40hours
40hours
Number4IdlerPivot(PumpDrive)Located
underenginedeck
Number4and6(IdlerPivots)Disassembleandgrease
onceamonthundera“NoLoad”condition.
3.Lubricatepivotpointswithaspraypenetrating lubricantasshownintheSprayLubricantChart.
SprayLubricantChart
PivotPoint
1.PTOEngagement UpperBellcrank
NumberofPlaces
1
ServiceInterval
40hours
CheckSparkPlugs
ServiceInterval:Every160hours
Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’ s Manual.
ChangeFuelFilter
ServiceInterval:Asrequired
Afuellterisinstalledinthefuellinebetweenthe fueltankandtheengine.Replacewhennecessary.
ChangeHydraulicSystem Filter
ServiceInterval:Aftertherst250hours
Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearlyif usingMobil115W50)
24
Page 25
Maintenance
Note:UseonlyExmarkPartNo.109-4180for
Summeruseabove32°F(0°C)orP/N1-523541for Winterusebelow32°F(0°C)(RefertoTransmission sectioninSpecicationsforlterspecications).
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.
3.Unscrewltertoremoveandallowoiltodrain fromreservoir.
Important:Beforereinstallingnewlter, llitwithExmarkPremiumHydroOiland applyathincoatofoilonthesurfaceofthe rubberseal.
Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.
4.FillreservoirasstatedinCheckHydraulicOil
Level.
ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:
CAUTION
Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.
DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.
7.Ifeitherdrivewheeldoesnotrotate,oneorboth ofthechargepumps(locatedonthetopofthe mainpumpasshownin their“prime”.RefertoHydraulicSystemAir Purgesection.
Note:DoNotchangehydraulicsystemoil(except forwhatcanbedrainedwhenchanginglter),unless itisfelttheoilhasbeencontaminatedorbeen extremelyhot.
Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.
Figure8)mayhavelost
HydroOil
ExmarkPremiumHydro Oil(Preferred)
Mobil115W50
5.Loosenlter1/2turnandallowasmallamount ofoiltoleakfromtheoillter(thisallowsairto bepurgedfromtheoillterandsupplyhosefrom thehydraulicreservoir).Turnlterclockwise untilrubbersealcontactsthelteradapter.Then tightenthelteranadditional2/3to3/4turn.
6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .
ChangeInterval
500Hours
250Hours
HydraulicSystemAirPurge
ServiceInterval:Asrequired
Airmustbepurgedfromthehydraulicsystem whenanyhydrauliccomponents,includingoil lter,areremovedoranyofthehydrauliclinesare disconnected.
Thecriticalareaforpurgingairfromthehydraulic systemisbetweentheoilreservoirandeach chargepumplocatedonthetopofeachvariable displacementpump( thehydraulicsystemwillbepurgedthroughnormal operationoncethechargepumpis“primed”.
Figure8).Airinotherpartsof
25
Page 26
Maintenance
Figure8
1.Chargepumpcap2.Loosen11/2turnsonly
asteadyowofoiltoowoutfromunderthe housing.Retightenthecapscrews.Dothisfor bothpumps.
Note:Hydraulicreservoircanbepressurizedup to5psitospeedthisprocess.
6.Ifeitherdrivewheelstilldoesnotrotate,stop andrepeatsteps pump.Ifwheelsrotateslowly,thesystemmay primeafteradditionalrunning.Checkoillevel asstatedinChecktheHydraulicOilLevel section.
7.Allowunittorunseveralminutesafterthecharge pumpsare“primed”withdrivesysteminthefull speedposition.CheckoillevelasstatedinCheck theHydraulicOilLevelsection.
8.Checkhydrodrivelinkageadjustmentasstatedin HydroDriveLinkageAdjustmentsectionin Adjustments.
4and5abovefortherespective
ReplaceEmissionsAirIntake
1.Stopengineandwaitforallmovingpartstostop. Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsoffthe ground.
2.CheckoillevelasstatedinCheckHydraulicOil Levelsection.
3.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol levertothemiddlespeedpositionandplacethe driveleversinthe“drive”position.
Ifeitherdrivewheeldoesnotrotate,itispossible toassistthepurgingofthechargepumpby carefullyrotatingthetireintheforwardposition.
Note:Itisnecessarytolightlytouchthecharge pumpcapwithyourhandtocheckthepump temperature.Ifthecapistoohottotouch,turn offengine.Thepumpsmaybedamagedifthe pumpbecomestoohot.
Ifeitherdrivewheelstilldoesnotrotatecontinue withstep
4.
Filter
ServiceInterval:Every500hours
1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.
2.Removethelterfromtheventhose.
3.Insertanewlterintotheendoftheventhose.
WheelHub-SlottedNut TorqueSpecication
ServiceInterval:Aftertherst100hours
Every500hoursthereafter
Figure9todeterminewhichslottednuthasbeen
See installedontheunit.
4.Thoroughlycleantheareaaroundeachofthe chargepumphousings.
5.To“prime”chargepump,loosentwohexsocket headcapscrews(showninFigure8)11/2turns only.Makesureengineisnotrunning.Lift thechargepumphousingupwardandwaitfor
Figure9
1.StyleA(blacknish)3.StyleB(yellowzinc)
2..03inch(.76mm)4..24inch(6mm)
StyleA(blacknish):
26
Page 27
Maintenance
Torquetheslottednutto140-155ft-lb(190-210 N-m).
Note:DoNotuseanti-seizeonwheelhub.
StyleB(yellowzinc):
1.Removeanddiscardthecotterpin.
2.Torquetheslottednutto100ft-lb(136N-m).
3.Checkdistancefrombottomofslotinnutto insideedgeofhole.Twothreads(0.1inch)or lessshouldbeshowing.
Figure10
1.0.1inchmax2.Nomorethantwo threads(0.1inchmax) shouldbeshowinghere.
Sheaveretainingboltinendofenginecrankshaft.
Fueltankbulkheadttingthreads
Adhesivessuchas“LoctiteRC/609orRC/680”or “Fel-ProPro-LockRetainingIorRetainingII”are usedonthefollowing:
OPCleverhubsandcross-shaft.
Note:Caremustbeusednottobondthe bearing,nexttoeachOPChub,tothecross-shaft whichcouldcausebindingoftheOPCleversand erraticoperation.
Fueltankstuds,wherestudsareinsertedintotank.
MobilHTSGrease(Or Food-GradeAnti-seize)
MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:
Betweenthecutterhousingspindleandbearings.
Betweenthecutterhousingspindleandsheave.
Undertopcutterhousingbearingguard.
4.Ifmorethantwothreads(0.1inch)are showingremovenutandinstallwasher(P/N 1-523157)betweenhubandnut.
5.Torquetheslottednutto100ft-lb(136N-m).
6.Thentightennutuntilthenextsetofslotsline upwiththecrossholeinshaft.DoNotloosen nuttoaligntheslot.Ifrequired,tightento thenextsetofslots.
7.Installnewcotterpin(P/N1-806800).
Note:DoNotuseanti-seizeonwheelhub.
ThreadLockingAdhesives
Threadlockingadhesivessuchas“Loctite242” or“Fel-Pro,Pro-LockNutType”areusedonthe followingfasteners:
Pumpsheavesetscrews.
Squareheadsetscrewsonhydropumpcontrol arms.
Copper-BasedAnti-seize
Copper-basedanti-seizeisusedinthefollowing locations:
Betweenthebladedriveandpumpdrivesheavesand enginecrankshaft.
DielectricGrease
Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.
OPCleversetscrews.
Shoulderboltsinendsofspeedcontrolcrank.
27
Page 28
Maintenance
Adjustments
Note:DisengagePTO,shutoffengine,waitfor allmovingpartstostop,engageparkingbrake,and removekeybeforeservicing,cleaning,ormakingany adjustmentstotheunit.
AdjustingtheCuttingHeight
Thecuttingheightofthemowerdeckisadjusted from1inchto41/4inches(2.54cmto11.4cm)in 1/4inch(.64cm)incrementsbyadjustingtheaxle position,numberofspacersbelowthecasterhub, andnumberofspacersbetweenbladeandspindle.
RefertotheCuttingHeightAdjustmenttableand selectacuttingheightrangeinthelefthandcolumn whichcorrespondstotherangeofcuttingheights youwillmostoftenbeusing.Adjustmentswithinthis rangecanthenbemadebyadjustingthenumberof bladespacersbetweenthebladeandthebottomof thespindle(thisisamucheasieradjustmenttomake
thanadjustingaxlepositionandnumberofspacers belowcastersupporthub).
Notethat:
Forthebestcutanddischarge,placeaminimum oftwospacersbetweenthebladeandthespindle.
Forhighestqualitycut,placeallfourspacers betweenthebladeandthespindle.
Ifmulchingkitisinstalled,thehighestqualitycut canbeobtainedwith3spacersbetweentheblade andthespindle(minimumis1foragoodcut).
Whenmulchingleavesitisbesttohavefewer spacersbetweenbladeandspindle.
Refertothetableandselectdesiredcuttingheight range.RefertoAdjustingtheAxlePosition,
AdjustingtheNumberofSpacersbelowCaster SupportHub,andAdjustingtheCutting HeightwithBladeSpacersandsectionstomake
adjustmentsmakeadjustmenttoobtainspecic cuttingheight.
CuttingHeightAdjustmentT able(1inchto41/4inches(2.5cm-10.8cm))
Cutting
Height
Range
1–2inches
(2.5–5.0cm)A00
11/8–
21/8inches
(2.9–5.4cm)A01
13/8–
23/8inches
(3.5–6.0cm)A10
13/8–
23/8inches
(3.5–6.0cm)B01
15/8–
25/8inches
(4.1–6.7cm)B10
13/4–
23/4inches
(4.4–7.0cm)B11
2–3inches
(5.0–7.6cm)B20
17/8–
27/8inches
(4.8–7.3cm)C11
Axle
Position
(Figure11)
NumberOfSpacers
BelowCaster
SupportHub
1/2 inch
(1.2cm)
3/16
(.48cm)
Numberof1/4inch(.64cm)BladeSpacersBelowSpindle
4
inch
1inch
(2.5cm)
11/8inch
(2.9cm)
13/8inch
(3.5cm)
13/8inch
(3.5cm)
15/8inch
(4.1cm)
13/4inch
(4.4cm)
2inch
(5.0cm)
17/8inch
(4.8cm)
11/4inch
(3.2cm)
13/8inch
(3.5cm)
15/8inch
(4.1cm)
15/8inch
(4.1cm)
17/8inch
(4.8cm)
2inch (5.0cm)
21/4inch
(5.7cm)
21/8inch
(5.4cm)
32
11/2inch
(3.5cm)
15/8inch
(4.1cm)
17/8inch
(4.8cm)
17/8inch
(4.8cm)
21/8inch
(5.4cm)
21/4inch
(5.7cm)
21/2inch
(6.4cm)
23/8inch
(6.0cm)
10
13/4inch
(4.4cm)
17/8inch
(4.8cm)
21/8inch
(5.4cm)
21/8inch
(5.4cm)
23/8inch
(6.0cm)
21/2inch
(6.4cm)
23/4inch
(7.0cm)
25/8inch
(6.7cm)
2inch
(5.0cm)
21/8inch
(5.4cm)
23/8inch
(6.0cm)
23/8inch
(6.0cm)
25/8inch
(6.7cm)
23/4inch
(7.0cm)
3inch
(7.6cm)
27/8inch
(7.3cm)
28
Page 29
CuttingHeightAdjustmentTable(1inchto41/4inches(2.5cm-10.8cm))(cont'd.)
Maintenance
Cutting
Height
Range
21/8–
31/8inches
(5.4–7.9cm)C20
21/4–
31/4inches
(5.7–8.3cm)C21
21/2–
31/2inches
(6.4–8.9cm)C30
23/8–
33/8inches
(6.0–8.6cm)D21
21/2– 31/2inches (6.4–8.9cm)D30
23/4–
33/4inches
(7.0–9.5cm)D31
3–4inches
(7.6–10.1cm)D40
27/8–
37/8inches
(7.3–9.8cm)E31
31/8–
41/8inches (7.9–10.5cm)E40
31/4–
41/4inches (8.3–10.8cm)E41
Axle
Position
(Figure11)
NumberOfSpacers
BelowCaster
SupportHub
1/2 inch
(1.2cm)
(.48cm)
Numberof1/4inch(.64cm)BladeSpacersBelowSpindle
3/16
inch
4
21/8inch
(5.4cm)
21/4inch
(5.7cm)
21/2inch
(6.4cm)
23/8inch
(6.0cm)
21/2inch
(6.4cm)
23/4inch
(7.0cm)
3inch
(7.6cm)
27/8inch
(7.3cm)
31/8inch
(7.9cm)
31/4inch
(8.3cm)
32
23/8inch
(6.0cm)
21/2inch
(6.4cm)
23/4inch
(7.0cm)
25/8inch
(6.7cm)
23/4inch
(7.0cm)
3inch
(7.6cm)
31/4inch
(8.3cm)
31/8inch
(7.9cm)
33/8inch
(8.6cm)
31/2inch
(8.9cm)
25/8inch
(6.7cm)
23/4inch
(7.0cm)
3inch (7.6cm)
27/8inch
(7.3cm)
3inch (7.6cm)
31/4inch
(8.3cm)
31/2inch
(8.9cm)
33/8inch
(8.6cm)
35/8inch
(9.2cm)
33/4inch
(9.5cm)
10
27/8inch
(7.3cm)
3inch
(7.6cm)
31/4inch
(8.3cm)
31/8inch
(7.9cm)
31/4inch
(8.3cm)
31/2inch
(8.9cm)
33/4inch
(9.5cm)
35/8inch
(9.2cm)
37/8inch
(9.8cm)
4inch
(10.1cm)
31/8inch
(7.9cm)
31/4inch
(8.3cm)
31/2inch
(8.9cm)
33/8inch
(8.6cm)
31/2inch
(8.9cm)
33/4inch
(9.5cm)
4inch
(10.1cm)
37/8inch
(9.8cm)
41/8inch
(10.5cm)
41/4inch
(10.8cm)
Important:AlwaysadjusttheNumberofSpacersbelowCasterHubtocorrespondtotheAxle Positionasshownintabletoobtainproper“rake”(bladesshouldalwaysbeleveltotheground ortippedslightlydownatthefront).
AdjustingtheAxlePosition
Desiredcuttingheightrangecanbeobtainedby adjustingtherearaxleandplacingcasterspacers aboveorbelowthecasterarm(seeFigure11and Figure12alongwiththeCuttingHeightAdjustment Chart).
Toadjustrearaxle:
1.Stopthemachineandmovethedriveleversto theneutrallockposition.
2.DisengagethePTO.
3.Raisetherearofthemachineupontojackstands andremovethedrivewheels.
4.Loosenbutdonotremovethetoptwobolts oneachhydraulicmotormountingbracket(see Figure11).
5.Removethebottomsetsofhardwareforeach bracket.
6.Repositionthemountingbrackettothedesired heightandreinstallthebottomhardware.
7.Tightenallhardwareandremountdrivewheels.
29
Page 30
Maintenance
8.Removejack.
9.Adjustwheeldriveandbrakelinkagesas required(seeBrakeandWheelDriveLinkage Adjustmentsection).
Figure11
1.PositionA4.PositionD
2.PositionB5.PositionE
3.PositionC
6.AxlePivotBolt-loosen butDoNotremove
Figure12
1.Four1/2inch(127mm) spacers
2.QuickPin4.Castersupport
3.3/16inch(4.8mm) spacer
7.Adjustthenumberof1/2inchspacersbetween bottomofhubandcasteryoketoobtainthe desiredcuttingheightfromtheCuttingHeight AdjustmentTableintheAdjustingtheCutting Heightsection.
8.Installremainingspacersontopofhub.
9.Install“quickpin”.
10.Repeatforothercaster.
Note:Theaxlepositionsarein1/2inch(1.3cm) incrementsandthelargecasterspacersare1/2 inch(1.3cm)thick.Therefore,byadjustingthe samenumberof1/2inch(1.3cm)casterspacersas axleholepositionsthebladeswillretainthesame front-to-backtip(rake).
AdjustingtheNumber ofSpacersbelowCaster SupportHub
1.Stopthemachineandmovethedriveleversto theneutrallockposition.
2.DisengagethePTO.
3.Placethedriveleversinthe“parkbrake”position.
4.Pushdownonhandlestoliftfrontcastersoffthe ground.
5.Supportwithjackstands.
6.Remove“quickpin”fromonecasterandremove casterfromhub(seeFigure12).
AdjustingtheCuttingHeight withBladeSpacers
1.Stopthemachineandmovethedriveleverstothe neutrallockedposition.
2.DisengagethePTO.
3.Engagetheparkbrake.
4.Stoptheengine,removethekeyandwaitforall movingpartstostop.
5.Bladesmaybeadjustedforcuttingheightbyusing thefour1/4inch(.64cm)spacersfoundonthe bladespindlebolts(factorysettingistwoabove andtwobelow).Thisallowsa1inch(2.5cm) rangein1/4inch(.64cm)incrementsofcutting heightinanyaxleposition.Thesamenumber ofbladespacersmustbeusedonallbladesto achievealevelcut(twoaboveandtwobelow,one aboveandthreebelow,etc.).
6.Raisefrontofdeckandsupportwithjackstands.
7.Holdbladeboltonbottomandloosenspindle nutontop.
8.Adjustnumberofspacersbetweenbottomof spindleandbladeasindicatedintheCutting
30
Page 31
HeightAdjustmentTableandnotesinthe AdjustingtheCuttingHeightsection.
9.Installunusedspacersbetweentopofspindleand spindlenut.
10.Torqueboltto75–80ft-lb(102–109N-m)(see Figure13).
Maintenance
Figure14
1.ThebellcrankjustclearsthegussetwiththePTO engaged
2.PTOSafetySwitch(locatedbeneaththeenginedeck)
3.Bellcrank
Figure13
1.Springdiscwasher (conetowardsbolthead)
2.Bladebolttorqueto 75–80ft-lb(102–109 N-m)
PTOEngagementLinkage Adjustment
LocatedbetweenthePTOengagementbellcrankand PTOengagementassistarmbeneaththefront,left handcorneroftheenginedeck.
1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
2.WithPTOengaged(leverpulledup,adjustthe linkagelengthtowherethelowerendofthe bellcrankjustclearstheaxlesupportgusset(see Figure14).Makesuretheassistarmisagainstthe rearassistarmstoponthedeck(seeFigure15). Pushtheleverdowntothedisengagedposition. Theassistarmshouldcontactthefrontassistarm stoponthedeck.Ifitdoesnotcontact,readjust sothatthebellcrankisclosertothegusset.
PTOSafetySwitch Adjustment
1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
2.WithPTOdisengagedandassistarmagainstthe frontassistarmstop,adjustthebladesafetyswitch mountingbracket(ifneeded)untilthebellcrank depressestheplungerby1/4inch(.64cm).
3.BesurethebellcrankDoesNottouchtheswitch bodyordamagetotheswitchcouldoccur.
4.Retightenswitchmountingbracket.
EnginetoMowerDeckBelt Adjustment
1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
2.EngagePTO.
3.Checkbeltguidesunderrearengineandfront mowerdecktoseethattheyareproperlyset(see BeltGuideAdjustmentsectionforinstructions).
4.Beltmustbetightenoughsoitdoesnot slipduringheavyloadswhilecuttinggrass. Over-tensioningwillreducebeltandspindle bearinglife.Toadjustbelttension,loosenthe 5/16inchwhizlocknutonturnbuckleandrotate theturnbuckle;rotateturnbuckletowardrearof
31
Page 32
Maintenance
mowertotighten,andtowardfrontofmowerto loosenbelttension(seeFigure15).
For48inchDecks:Ifthereisnoadjustmentleft intheturnbuckleandthebeltisstillloose,therear idlerpulleycanberepositionedinthefronthole
Figure15).Thebeltguidelocatednexttothe
(see pulleymustalsoberepositionedinthefronthole whenthepulleyismoved.Theturnbucklewill needtobereadjusted.
Checkbelttensionafterthersthourofoperation andatleasttwiceduringtherst24hoursof operation.Adjustasnecessary.
Note:Afterreadjustingthebelttensioncheck thebeltguideadjustmentasstatedinthe
BeltGuideAdjustmentandBladeBrake Adjustmentsections.
Figure16
36inchMowerDeck
Figure15
48inchDeckShownforReferenceOnly
1.PulleylocationforVikingHydro
2.Beltguidemustbemovedtothefrontpositionifthe pulleyismoved(48inchdeckonly)
3.Pulleycanbemovedtothefrontpositiontotightenthe beltwhenthereisnoadjustmentleftintheturnbuckle (48inchdeckonly)
4.Turnbuckle
5.5/16inch(.79cm)minimumengagement
6.5/16inchwhizlocknut
7.RearAssistArmStop
8.AssistArm
9.FrontAssistArmStop
10.Point“A”
5.Properbelttensionwillrequireabout10lb(4.5 kg)sidepullonbelt,halfwaybetweenpulleys(see Figure15,item10–PointA)todeectbelt1/2 inch(1.3cm).
MowerDeckBeltRoutings:
Figure17
48inchMowerDeck
BladeBrakeAdjustment
1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
2.DisengagePTO.
3.Makesurethebladebrakepadrestsagainst thesheave.Adjustthespringmountingbolts toproperlyalignthepadonthesheave(see Figure18).
32
Page 33
Figure18
ShownwithBladesDisengaged
1.BladeBrakeRod
2.SpringMountingBolts
3.1/8inchto3/16inch (.32–.47cm)
4.Checkthedistancebetweenthespacerandthe nutattheendofthebladebrakerod.The distanceshouldbebetween1/8inch(.32cm)and 3/16inch(.47cm)(see
Figure18).
5.EngagethePTOandchecktomakesurethe bladebrakepadclearsthesheave.
Maintenance
Figure20
48inchBeltGuideLocation
(Viewedfromunderneaththeenginedeck)
1.13/8inch(3.5cm)3.Endofslot
2.1/4inch(.64cm) clearance
PumpDriveBeltTension
Self-tensioning-Noadjustmentnecessary.
BeltGuideAdjustment
1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
2.EngagethePTO.
3.Checkbeltguideundertheenginedeckforproper adjustment(seeFigure19andFigure20).Adjust asnecessary.
Figure19
36inchBeltGuideLocation
(Viewedfromunderneaththeenginedeck)
HydroDriveLinkage Adjustment
AdjustSpeedControlLinkageandNeutral SafetySwitch:
1.Stopengineandwaitforallmovingpartsto
stop.Engageparkingbrake.Removekeyor sparkplugwire(s).
2.Movethespeedcontrollever(locatedon
theconsole)tothefullforwardpositionand checktheorientationofthetabsontheends ofthespeedcontrolcrank(see Thesetabsshouldbepointingstraightdown atthe6o’clockpositionorslightlyforward. Adjustthethreadedyokeatthebottomofthe speedcontrollinkage(see tabsarepositionedcorrectly.
Figure21)untilthe
Figure21).
1.11/4inch(3.1cm)3.Endofslot
2.1/4inch(.64cm) clearance
33
Page 34
Maintenance
Figure21
ViewedfromLeftSideofUnit
1.NeutralSafetySwitch3.5/16inch(7.9mm)
2.ActuatingTabinneutral position
3.Pullthespeedcontrolleverbacktoneutral. Checkthattheneutralsafetyswitchactuating tabhasdepressedtheplungeroftheswitch sothatthereisabout5/16inch(7.9mm) betweenthetabandtheswitch(see Ifnecessary,movetheswitchforeandaft.
AdjustNeutralControlLinkages:
1.Raisetherearofthemachineupontojack standshighenoughtoraisethedrivewheels offoftheground.
2.Starttheengineandmovethethrottleahead tothefullthrottleposition.Placetheneutral locklatchesinthe“forward”positionas shownin
Figure4.Releasetheparkbrake andmovethespeedcontrollevertothe “mid-speed”position.
Note:TheOPCleversmustbehelddown andtheparkbrakemustbedisengaged wheneverthespeedcontrolleverismoved outofneutralortheenginewillkill.
3.Squeezetherespectivedriveleveruntilan increasedresistanceisfelt,thisiswhere neutralshouldbe.
Ifthewheelturnswhileholdingthedrive leverinneutral,theneutralcontrollinkages needtobeadjusted.Ifthewheelstopsthen gotostep
7.
Figure21).
Figure22
ViewedfromLeftSideofUnit
1.NeutralControlLinkage5.SpeedControlLinkage
2.HydroControlLinkage
3.DriveLeverLinkage7.Loosennut
4.SpeedControlCrank
6.Adjusthere-rotateat approximately1/4 turnincrementsand re-check.
8.Yoke
4.Loosenthenutagainsttheneutralcontrol linkageyokeasshowninFigure22.
5.Adjusttheneutralcontrollinkageuntil therespectivedrivewheelstopswhenthe leverispulledagainsttheneutralspring (neutralposition).Turntheadjustingbolt approximately1/4turnclockwiseifthe wheelisturninginreverseorturnthebolt approximately1/4turncounterclockwiseif thewheelisturningforward.Releasethe drivelevertotheforwarddrivepositionand squeezebackintotheneutralposition.Check toseeifthewheelstops.Ifnot,repeatthe aboveadjustmentprocedure.
6.Makethisadjustmentonbothsides.
7.Afteradjustmentsaremadeandthewheels stopwhenthedriveleversareintheneutral position,tightenthenutsagainsttheyokes.
AdjustHydroControlLinkages:
1.Placethespeedcontrolleverinthe“neutral” position.Thisadjustmentisagainmadewith rearofmachineonjackstandsandengine runningatfullthrottle.OPCleverswillhave tobehelddownandtheparkbrakemustbe
34
Page 35
Maintenance
disengagedwheneverspeedcontrolleversare movedoutoftheneutralposition.
Note:Theneutrallocklatchesshouldbe “unlocked”andintheforwardposition.
2.Loosenthefrontnutonlefthydrocontrol linkageasshownin
Figure22.Turntherear controllinkageadjustingnutcounterclockwise untilwheelrotatesforward.Turntherearnut ofleftcontrollinkageclockwise1/4ofaturn atatime,stoppingtomovethespeedcontrol forwardandbacktoneutral,untilleftwheel stopsrotatingforward.
Turntherearnutanadditional1/2turnand tightenthefrontnutmakingsurenottoput abindonthelinkage.Makesureatpartof linkageisperpendiculartopinpartofswivel
Figure23).
(see
toneutral.Recheckthedrivewheelrotation toseeiffurtheradjustmentisnecessary.
4.Thespringthatkeepstensionontheknob shouldnormallynotneedadjustment. However,ifadjustmentisneeded,adjustto wherelengthofspringisabout1inch(2.5cm) betweenthewashers.Adjustspringlengthby turningnutatfrontofspring.
DriveLeverLinkageAdjustment:
1.Withrearofmachinestillonjackstandsand enginerunningatfullthrottle,disengage theparkbrakeandmovethespeedcontrol levertothemidwayposition.Movethe respectivedriveleverupwarduntilitreaches theneutralpositionandengageneutrallock latches(
Figure24).Ifthetirerotatesineither direction,thelengthofthedriveleverlinkwill needtobeadjusted.
Figure23
1.LeftHydroControlLink (leftsideshown)
2.Frontnut5.Linkageinincorrect
3.Rearnut
4.Linkageisperpendicular topin(correctposition)
position
6.Endviewofswivel
Afteradjustingthelefthydrocontrollinkage, movethespeedcontrollevertothemid-speed positionandthenbacktotheneutralposition. Rechecktheleftdrivewheelrotationtoseeif furtheradjustmentisnecessary-besurethe speedcontrolleverisintheneutralposition.
Important:Ifinconsistentneutraloccurs, checktobesurebothspringsareproperly tightenedonthespeedcontrolleverunder theconsole–especiallytherearpivot spring.
Repeataboveadjustmentsifnecessary.
3.Placethespeedcontrolleverinneutral.Adjust therightsidelinkagebyturningthequicktrack knobcounterclockwiseuntilthetirebeginsto rotateforward.Begintoretightentheknob clockwiseabout1/4turnatatime,stopping tomovethespeedcontrolforwardandback
Figure24
2.Adjustthelinkagelengthbylooseningthejam nutsatbothendsofthelinkageandrotating thelinkageintheballjoints.Lengthenthe linkageifthetireisturninginreverseand shortenthelinkageifthetireiscreeping forward.Tightenthejamnutsatbothends. Releaseandre-engagetheneutrallocklatch checkingthatthetirestops.Continuethis processuntilthetireisatadeadstop.
3.Makethisadjustmentforbothsides.
4.Stopengineandwaitforallmovingparts tostop.Raiserearofmachine,removejack stands,andcarefullylowermachinetothe ground.
35
Page 36
Maintenance
TrackingAdjustment
1.Stopengineandwaitforallmovingpartstostop.
2.Checkthedrivetirepressuresandtire circumferencesasstatedinChecktheTire PressuressectioninMaintenance.
3.Runtheunitandobservethetrackingonalevel, smooth,hardsurfacesuchasconcreteorasphalt.
4.Iftheunittrackstoonesideortheother,turnthe quicktrackknob.Turntheknobrightto“steer” right,turntheknobleftto“steer”left.
HydroPumpSpringTension Setting
1.Formediumorheavydutydriveconditionssuch asoperationwithasulkyonsteepslopes,ahigher springforcemayberequiredonthehydropump controlarmstopreventthedrivesystemfrom stalling.
2.Foraheavierdrivesetting,relocatethespring anchorlinkstoeitherthe“medium”or“heavy duty”positionsasshownin anchorlinksareattachedtotheupperrearcorner ofthehydrodriveshieldsontheleftandright handsidesofthemachine.
Figure25.Thespring
ParkBrakeAdjustment
1.Stopengineandwaitforallmovingpartstostop.
2.Disengagetheparkbrake.
3.Removethehairpininthelowerparkbrake linkage.Turnthelinkageintheyokeuntilthereis 3/16inch(.48cm)to1/4inch(.64cm)clearance betweentheparkbraketirebarsandthetireswith theparkbrakedisengaged.Re-installthehairpin.
Note:Inthe“medium”or“heavyduty” positions,thedriveleverforcesattheupper handlewillalsobeincreased.
Figure25
1.Heavyduty
2.Mediumduty4.Retainingbolt
3.Standard
36
Page 37
Maintenance
Cleaning
CleanEngineAirCooling System
ServiceInterval:Beforeeachuseordaily
1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
2.Cleanalldebrisfromengineairintakescreenand fromaroundengineshrouding.
RemoveEngineShroudsand CleanCoolingFins
ServiceInterval:Every100hours
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Removecoolingshroudsfromengineandclean coolingns.Alsocleandust,dirt,andoilfrom externalsurfacesofenginewhichcancause impropercooling.
recyclingcenteroraccordingtoyourstateandlocal regulations.
3.Makesurecoolingshroudsareproperly reinstalled.Operatingtheenginewithout coolingshroudswillcauseenginedamagedueto overheating.
CleanGrassBuild-UpUnder Deck
ServiceInterval:Beforeeachuseordaily
1.DisengagePTO.
2.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).
3.Raisedeckandsupportunitusingjackstandsor equivalentsupport.
4.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.
WasteDisposal
MotorOilDisposal
Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied
37
Page 38
Troubleshooting
Troubleshooting
Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating
conditionpriortomoweruse.
Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.
Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.
Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.
ProblemPossibleCauseCorrectiveAction
Enginewillnotstart,startshard,orfailsto keeprunning.
Enginelosespower
1.Fueltankisempty .1.Fillthefueltank.
2.Fuelshutoffvalveisclosed.
3.Thethrottleandchokearenotinthe correctposition.
4.Dirtinfuellter.4.Replacethefuellter.
5.Dirt,water,orstalefuelisinthefuel system.
6.Aircleanerisdirty .
7.Electricalconnectionsarecorroded,loose orfaulty.
8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.
9.Faultysparkplug.
10.Sparkplugwireisnotconnected.
11.PTOisengaged.
12.Speedcontrolleverisnotinneutral position.
13.OPCleversarereleased.
1.Engineloadisexcessive1.Reducethegroundspeed.
2.Aircleanerisdirty .
3.Oillevelinthecrankcaseislow.
4.Coolingnsandairpassagesforthe engineareplugged.
5.Ventholeinthefuelcapisplugged.
6.Dirtinfuellter.6.Replacethefuellter.
7.Dirt,water,orstalefuelisinthefuel system.
2.Openthefuelshutoffvalve.
3.Besurethethrottlecontrolismidway betweenthe“SLOW”and“F AST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.
5.ContactanAuthorizedServiceDealer.
6.Cleanorreplacetheaircleanerelement.
7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.
9.Clean,adjustorreplacesparkplug.
10.Checkthesparkplugwireconnection.
11.DisengagethePTO.
12.Ensuretheshifterleverisintheneutral position.
13.DepressOPClevers.
2.Cleanorreplacetheaircleanerelement.
3.Addoiltothecrankcase.
4.Removetheobstructionsfromthecooling nsandairpassages.
5.Cleanorreplacethefuelcap.
7.ContactanAuthorizedServiceDealer.
Engineoverheats
Mowerpullsleftorright(withleversfully forward).
1.Engineloadisexcessive1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow.
3.Coolingnsandairpassagesforthe engineareplugged.
1.Trackingneedsadjustment.1.Adjustthetrackingbyturningknobonthe
2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.
2.Addoiltothecrankcase.
3.Removetheobstructionsfromthecooling nsandairpassages.
righthydrocontrollinkageinthedirection thatthemowerneedstobeadjustedto. Turntheknobin1/4turnincrements untilthemowertrackscorrectly .
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Troubleshooting
ProblemPossibleCauseCorrectiveAction
Machinedoesnotdrive.
Unevencuttingheight.
Abnormalvibration
Bladesdonotrotate.
1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.
2.Driveorpumpbeltisworn,looseor broken.
3.Driveorpumpbeltisoffapulley.3.Changethebelt.
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.
3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand
4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.
5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.
6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.
7.Tipsofadjacentbladesareatanuneven cuttingheight.Bladestipsshouldbeeven within3/16inchwhichisapproximately onebladethickness.
1.Cuttingblade(s)is/arebentorunbalanced.
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Looseenginepulley ,idlerpulley ,orblade pulley.
5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.
6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.
7.Beltisdamaged.7.Installnewbelt.
1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.
2.Deckbeltisoffpulley .2.Installdeckpulleyandchecktheidler
2.Changethebelt.
2.Installnewcuttingblade(s).
front-to-rear.
7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley .
pulley,idlerarmandspringforcorrect positionandfunction.
Bladesdonotstopwhendisengaged.
1.Bladebrakeisnotadjustedproperly .1.Adjustbladebrake.
2.Beltguideisnotproperlyset2.Adjustbeltguidetoproperposition.
3.PTOengagementisnotproperlyset.3.CheckthePTOengagementposition.
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Schematics
GREEN
BLACK
RED
RED
BLACK
GREEN
YELLOW
BLUE
ORANGE
BROWN
A
B
C
D
E
F
CONNECTORS ARE VIEWED FROM WIRE END N.C. = NORMALLY CLOSED N.O. = NORMALLY OPEN
FROM SAFETY
INTERLOCK MODULE
TRANSMISSION
SWITCH
N.O.
PTO
SWITCH
N.O.
OPC
SWITCH
N.O.
KEY
SWITCH
ENGINE
PARK BRAKE
SWITCH
N.O.
G006968
Schematics
WiringDiagram
40
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Schematics
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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 1 Year Prorated
• Engine *
* 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
This 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.
If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:
Exmark Customer Service Department  The Exmark Warranty Company  2101 Ashland Avenue  Beatrice, NE 68310  402-223-6375 or  service@exmark.com
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 warranty.
• 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.
Exmark Commercial Turf Equipment
2 Year Limited Warranty
G4500-589_C
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Notes:
43
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Notes:
44
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ServiceRecord
Date:
DescriptionofWorkDone:ServiceDoneBy:
45
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46
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G011841
Figure26
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan20degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
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MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
MICRO-MULCH SYSTEM
TURF STRIPER
STANDON
CUSTOM RIDE SEAT SUSPENSION SYSTEM
FULL SUSPENSION SEAT
DECK LIFT ASSIST KIT
HITCH KIT
LIGHT KIT
12
V POWER PORT
MICRO-MULCH SYSTEM
OPERATOR CONTROLLED DISCHARGE
ROLL OVER PROTECTION SYSTEM (ROPS)
SUN SHADE
TRASH CONTAINER
TURF STRIPER
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OU T-F RONT RIDING AC CESSORIES A ND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
DUAL-TAIL WHEEL
FLOOR PAN EXTENDER
HITCH KIT
LIGHT KIT
MICRO-MULCH SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
SNOW BLADE
SNOWBLOWER
SUN SHADE
TRASH CONTAINER
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
WEATHER CAB
PlaceModelNo.andSerialNo.
LabelHere(IncludedintheLiterature
Pack)orFillinBelow
ModelNo.EngineSerialNo.(E/No)
SerialNo.
©2010ExmarkMfg.Co.,Inc. IndustrialParkBox808 Beatrice,NE68310 AllRightsReserved
DatePurchased
EngineModelNo.andSpec.No.
PartNo.4500-693Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA
www.exmark.com
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