PIONEERE-SERIES
ForSerialNos.
920,000&Higher
PartNo.4500-899Rev.B
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,or
grass-coveredlandasdenedinCPRC4126.
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
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2011ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
2
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved
Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
Exmarkpartsmanualsareavailableonlineat
http://www.exmark.com/manuals.htm
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................11
Specications.......................................................15
ModelNumbers............................................15
Systems.........................................................15
Dimensions...................................................16
TorqueRequirements....................................17
ProductOverview................................................18
Operation.............................................................18
Controls........................................................18
Pre-Start........................................................21
OperatingInstructions..................................21
Transporting.................................................25
Maintenance.........................................................27
RecommendedMaintenanceSchedule(s)...........27
PeriodicMaintenance.......................................28
CheckEngineOilLevel.................................28
CheckBatteryCharge....................................28
CheckMowerBlades.....................................29
CheckSafetyInterlockSystem.......................30
CheckRolloverProtectionsSystems(Roll
Bar)Knobs................................................31
CheckSeatBelt..............................................31
CheckforLooseHardware............................31
ServiceAirCleaner........................................31
ChangeEngineOil........................................31
CheckHydraulicOilLevel.............................31
CheckTirePressures.....................................32
CheckConditionOfBelts..............................32
LubricateGreaseFittings...............................32
CheckSparkPlugs.........................................32
ReplaceEmissionsAirIntakeFilter................32
ChangeHydraulicSystemFilterand
Fluid.........................................................33
CheckSparkArrester(ifequipped).................34
ThreadLockingAdhesives.............................34
Copper-BasedAnti-seize..............................34
DielectricGrease...........................................34
Adjustments.....................................................35
DeckLeveling...............................................35
AdjustingtheBladeSlope..............................35
PumpDriveBeltTension...............................36
DeckBeltTension.........................................36
AdjustingtheParkingBrake...........................36
MotionControlHandleAdjustment..............37
FullForwardTrackingAdjustment.................37
MotionControlLinkageAdjustment.............38
AdjustingtheSeatRideSuspension................39
ElectricClutchAdjustment............................39
Cleaning...........................................................40
CleanEngineandExhaustSystem
Area..........................................................40
RemoveEngineShroudsandCleanCooling
Fins...........................................................40
CleanHydroFanCoolingFins.......................40
CleanDebrisFromMachine..........................40
CleanGrassBuild-UpUnderDeck................40
WasteDisposal..............................................40
Troubleshooting...................................................42
Schematics...........................................................44
4
Safety
Safety
SafetyAlertSymbol
ThislawnmowermeetsorexceedstheB71.4
specicationsoftheAmericanNationalStandards
Instituteineffectatthetimeofproduction.
Exmarkdesignedandtestedthislawnmowertooffer
reasonablysafeservice;however,failuretocomply
withthefollowinginstructionsmayresultinpersonal
injury.
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
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.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator’s
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
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
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
5
Safety
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsonlevelground,
inanopenarea,whentheengineiscold.
Wipeupanygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletelyfull.
Fillthefueltanktothebottomoftheller
neck.Theemptyspaceinthetankallows
gasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengine
oremissionsystem.
•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyspark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoradd
fuelwhenengineisrunningorwhenthe
engineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.
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,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,to
coolbeforetouching.
•Removeaccumulateddebrisfrommufer
andenginearea.
•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts
withtherollbarintheraisedandlockedposition.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
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.
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.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
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.
•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(
Figure3).
Figure3
1.SafeZone-Usethemowerhereonslopeslessthan15
degrees
2.DangerZone-Useawalkbehindmowerand/orhand
trimmeronslopesgreaterthan15degrees,near
drop-offsandwater.
3.Water
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
UsingtheRolloverProtectionSystem
(ROPS)
ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.
WARNING
Thereisnorolloverprotectionwhentherollbar
isdown.Wheelsdroppingoveredges,ditches,
steepbanks,orwatercancauserollovers,which
mayresultinseriousinjury,deathordrowning.
•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.
•Lowertherollbaronlywhenabsolutely
necessary.
•DoNotwearseatbeltwhentherollbaris
down.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance
permits.
•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,andelectricalwires)before
drivingunderanyobjectsandDoNotcontact
them.
•Intheeventofarollover,taketheunittoan
AuthorizedServiceDealertohavetheROPS
inspected.
MaintenanceandStorage
•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
8
Safety
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
DANGER
Chargingorjumpstartingthebatterymay
produceexplosivegases.Batterygasescan
explodecausingseriousinjury.
•Keepsparks,ames,orcigarettesaway
frombattery.
•Ventilatewhenchargingorusingbattery
inanenclosedspace.
•Makesureventingpathofbatteryis
alwaysopenoncebatteryislledwith
acid.
•Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.
•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.
•DoNotswallowelectrolyte.
•Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagement
ofcomponents.Sparkscouldcausean
explosionormovingpartscouldaccidentally
engagecausingpersonalinjury.
Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
WARNING
Removingstandardoriginalequipmentparts
andaccessoriesmayalterthewarranty,traction,
andsafetyofthemachine.Failuretouseoriginal
Exmarkpartscouldcauseseriousinjuryor
death.Makingunauthorizedchangestothe
engine,fuelorventingsystem,mayviolateEPA
andCARBregulations.
Replaceallpartsincluding,butnotlimitedto,
tires,belts,blades,andfuelsystemcomponents
withoriginalExmarkparts.
9
Safety
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
•Ifequipped,makesureallhydraulicuid
hosesandlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretohydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,to
ndhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrollevers
inneutralandshuttingofftheenginebefore
performinganyworkonthehydraulicsystem.
10
Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1-303508
1-403005
1-633922
98-5954
103-2076
11
Safety
107-2102
109-3148
109-6014
116-1119
116-1121
1.Rotatethedriverelease
knobtoloosen,slidethe
knob,andtighten.
2.Pushthemachine.
116-1496
12
Safety
116-3303
116-4308
1.Latch2.Unlatch
116-4465
1.Fast
3.Choke-on
2.Slow4.Choke-off
PTOSwitchSymbols
1.PTO–disengage2.PTO–engage
13
Safety
109-6016
1.Readtheinstructionsbeforeservicingorperforming
maintenance
4.RefertotheOperator’smanualforgreaseinstructions
2.Timeinterval
5.CheckhydraulicoillevelandrefertotheOperator’s
manualorfurtherinstructions
3.Checkoillevel6.Checktirepressure
116-4430
1.Parkbrake—engage4.Neutral
2.Fast5.Reverse
3.Slow
14
Specications
Specications
ModelNumbers
SerialNos:920,000andHigher
PNE22KA482;PNE24KA522
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•EngineOilType:Exmark4–CyclePremium
EngineOil
•RPM:FullSpeed:3600±50RPM(PTOnot
engaged)Idle:1500±100RPM
FuelSystem
•Capacity:7.0gal.(26.5L)
•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher;containingnomorethan10%
methanolorethanol.
•FuelFilter:
Kawasaki:KawasakiP/N49019-7005
•FuelShut-OffValve:
AllUnits:1/4turnincrements(“ON”,“OFF”).
ElectricalSystem
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:15amps
•BatteryType:BCIGroupU1
•RecommendedMinimumBatteryCCA:260CCA
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:
Allunits:
–25ampmainfuse
–25ampchargingsystemfuse
–10ampPTOfuse
–15ampaccessoryfuse
SafetyInterlockSystem
•PTOmustbedisengaged,brakeengaged,and
motioncontrolleversout(neutrallock)tostart
engine.(Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.)
•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,ormotioncontrolleversare
movedinorenginewillstop.
•Enginewillstopifeithertheleft,theright,or
bothleversaremovedfromneutrallockposition
whilebrakeisengaged.
OperatorControls
•SteeringandMotionControl:
Note:Motioncontrolleversareadjustableto
threeheights.
–Separatelevers,oneachsideoftheconsole,
controlspeedanddirectionoftravelofthe
respectivedrivewheels.
–Steeringiscontrolledbyvaryingtheposition
oftheleversrelativetoeachother.
–Movingmotioncontrolleversoutward(in
slots)locksthedrivesysteminneutral.
•PTOEngagementSwitch:Engageselectricclutch
(todrivebelt)whichengagesmowerblades.
•ParkingBrakeLever:Engagesparkingbrake.
•DeckHeightAdjustmentLever:Setscutting
heighttodesiredposition.
•DeckLiftPedal:Footpedalthatliftsdeck.
•TransportLock:Latchingposition:Automatically
latchesatthetransportposition.
Seat
•Type:Standardseatwithfoampaddedseat
cushionwitharmrestsandintegralsafetyswitch.
Optionalseat:Seatwithhighback,extra
widefoampaddedseatcushionwithinternal
suspension,thickbolstering,two-tonecover,
15
Specications
armrests,integralsafetyswitch,andseatvibration
isolationsystem.
Optionalseataccessoriesforunitswithstandard
seats:
–Customridesuspensionsystemtoenhance
StandardSeat.Addsapproximately3inches
(7.6cm)toseatheight.
–Deluxesuspensionseatwithhighback,
(dampened,adjustablespringsuspension),
armrests,andintegralsafetyswitch.Adds
approximately1/2inch(1.3cm)toseatheight.
•Mounting:Adjustableforeandaftonseattracks.
•Armrests:Moldedip-uparmrests.
•SeatSafetySwitch:
Integratedseatswitch.Timedelayseatswitch
eliminatesroughgroundcut-outs.
HydrostaticGroundDriveSystem
•Twounitizedhydrostatictransmissions:
HydroGearZT2800
•HydraulicOilType:ExmarkPremiumHydroOil.
•HydraulicOilCapacity:77oz(2.3L)perside
•HydraulicFilter:P/N109-3321
•Speeds:
–0-7mph(11.3km/hr)forward.
–0-4mph(6.4km/hr)reverse.
•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
Tires&Wheels
DriveFrontCaster
Pneumatic(Air
lled)
Pneumatic(Air
lled)
Quantity
22
Tread
TurfMasterSmooth
Size20x8.00-1013x5.00-6
PlyRating
4
2
Pressure
13psi(90kPa)13psi(90kPa)
CuttingDeck
•CuttingWidth:
–48inchDeck:(121.9cm)
–52inchDeck:(132.1cm)
•Discharge:Side
•BladeSize:(3ea.)
–48inchDeck:16.25inches(41.3cm)
–52inchDeck:18.00inches(45.7cm)
•BladeSpindles:Solidsteelspindleswith.67inch
(17mm)I.D.bearings.
•DeckDrive:“B”Sectionbeltwithself-tensioning
idler.
•Electricclutch:125ft-lbMagStop
•Deck:Fulloatingdeckisattachedtoout-front
supportframe.Anti-scalprollersprovide
maximumturfprotection.Deckdesignallowsfor
bagging,mulchingorsidedischarge.
–48inchDeck:3anti-scalprollers
–52inchDeck:3anti-scalprollers
•DeckDepth:
–48inchDeck:4.0inches(10cm)
–52inchDeck:4.0inches(10cm)
•CuttingHeightAdjustment:
Footactivatedleverisusedtoadjustthecutting
heightfrom11/2inch(3.8cm)to5inches(12.7
cm)in1/4inch(6.4mm)increments.
•MulchingKit:Optional.
Dimensions
OverallWidth:
48inchDeck52inchDeck
WithoutDeck44.1inches
(112.0cm)
44.1inches
(112.0cm)
DeectorUp48.0inches
(121.9cm)
52.8inches
(134.1cm)
DeectorDown59.2inches
(150.4cm)
64.0inches
(162.6cm)
16
Specications
OverallLength:
48inchDeck52inchDeck
RollBar-Up77.8inches
(197.6cm)
77.8inches
(197.6cm)
RollBar-Down78.6inches
(199.6cm)
78.6inches
(199.6cm)
OverallHeight:
RollBar-UpRollBar-Down
70.0inches(177.8cm)46.8inches(118.9cm)
TreadWidth:(CentertoCenterof
Tires,Widthwise)
48inchDeck52inchDeck
DriveWheels35.8inches
(90.9cm)
35.8inches
(90.9cm)
CasterWheels33.5inches
(85.1cm)
33.5inches
(85.1cm)
WheelBase:(CenterofCasterTireto
CenterofDriveTire)
48inchDeck52inchDeck
48.7inches(123.7cm)48.7inches(123.7cm)
CurbWeight:
48inchDeck52inchDeck
KawasakiUnits
799lb
(362kg)
805lb
(365kg)
TorqueRequirements
BoltLocation
Torque
BladeDriveSheave
MountingNut
75-85ft-lb(102-115N-m)
BladeMountingBolt
(lubricatewithanti-seize)
50-60ft-lb(68-81N-m)
Anti-ScalpRollerNyloc
NutSee
Figure17
27-33ft-lb(37-45N-m)
EngineMountingBolts
(Kawasaki)
27-33ft-lb(37-45N-m)
WheelLugNuts
70-90ft-lb(95-122N-m)
BoltLocation
Torque
RolloverProtection
System(RollBar)1/2
inchMountingBolts
77-95ft-lb(104-129N-m)
ClutchRetainingBolt
(securedwiththreadlocker)
49-61ft-lb(66-83N-m)
17
Operation
ProductOverview
Figure4
1.RolloverProtection
System(ROPS)
5.Motioncontrollevers
2.Enginecontrols(right
console)
6.Parkingbrake
3.Seatbelt7.Heightofcutadjustment
4.Fuelcap
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
MotionControlLevers
Themotioncontrolleverslocatedoneachsideof
theconsolecontroltheforwardandreversemotion
ofthemachine.
Movingtheleversforwardorbackwardturns
thewheelonthesamesideforwardorreverse
respectively.Wheelspeedisproportionaltothe
amounttheleverismoved.
Movingtheleversoutwardfromthecenterposition
intotheT-slotlocksthemintheneutralposition
(
Figure5).
Figure5
1.Neutrallockposition
(handlesout)
4.Forward
2.Neutraloperateposition
(handlesin)
5.Neutral(operate)
3.Frontofunit
6.Reverse
ChokeControl
Locatedonrightconsole(blacklever)(seeFigure6).
Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
18
Operation
rear,tothedetent,willputthechokeinthe“OFF”
position.DoNotrunawarmenginewithchokein
the“ON”position.
Figure6
1.Throttlelever4.Bladecontrolswitch
(powertake-off)
2.Chokelever
5.Ignitionswitch
3.Hourmeter
ThrottleControl
Locatedonrightconsole(redlever)(seeFigure6).
Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.
BrakeLever
Locatedonleftsideofunit,justtothefrontofthe
LHmotioncontrollever.
Thebrakeleverengagesaparkingbrakeonthedrive
wheels.
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe
brake.
Theunitmustbetieddownandbrakeengagedwhen
transporting.
IgnitionSwitch
Locatedonrightconsole(seeFigure6).
Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”
and“START”.Insertkeyintoswitchandrotate
clockwisetothe“ON”position.Rotateclockwiseto
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).Allow
thekeytoreturntothe“on”positionimmediately
aftertheenginestarts.
Figure7
1.Off3.Start
2.On
Note:Brakemustbeengaged,motioncontrol
leversout(neutrallockposition)andPTOswitch
disengagedtostartengine.(Itisnotnecessaryforthe
operatortobeintheseattostarttheengine.)
HourMeter
Locatedonthecontrolpanel(seeFigure6and
Figure8).
Thehourmeterrecordsthenumberofhoursthat
theenginehasrun.
Figure8
1.LCDindicators3.Hour/Voltagedisplay
2.Lowvoltageindicator
light
FuelShut-OffValve
LocatedbythelowerLHROPStubemounting.
19
Operation
Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.
Alignvalvehandlewiththefuellinetoopen.Rotate
90°toclose.
DriveWheelReleaseValves
WARNING
Handsmaybecomeentangledintherotating
drivecomponentsbelowtheenginedeck,which
couldresultinseriousinjuryordeath.
Stopengine,removekey,allowallthemoving
partstostopbeforeaccessingthedrivewheel
releasevalves.
WARNING
Theengineandhydraulicdriveunitscanbecome
veryhot.Touchingahotengineorhydraulic
driveunitscancausesevereburns.
Allowtheengineandhydraulicdriveunitsto
coolcompletelybeforeaccessingthedrivewheel
releasevalves.
Locatedonthebackoftheunitizedhydraulicdrive
units,belowtheenginedeck.
Duringnormaloperatingconditions,thedrivewheel
releasevalvesarepositionedhorizontally.Ifthe
machinehastobepushedbyhand,thevalvesmust
beinthe“released”position(see
Figure9).
Duringnormaloperatingconditions,thedrivewheel
releasevalvesarepositionedhorizontally.Ifthe
machinehastobepushedbyhand,thevalvesmust
beinthe“released”position(seeFigure9).
Figure9
1.Frontofthemachine
2.Rotatebypassreleaseknobcounterclockwisetoloosen
3.Leverpositionforoperatingthemachine
4.Pullleverinthisdirectiontopushthemachine
5.Leverpositionforpushingthemachine
6.Rotatebypassreleaseknobclockwisetotighten
7.Releaselever
Toreleasethedrivesystem(seeitem1inFigure9),
loosentheknobbyturningcounterclockwise.Then
pullthereleaseleverontheundersideofmachine
towardsthebackofthemachineandretightenthe
knobtoholdthereleaseleverbackinthereleased
state.Repeatthisoneachsideofthemachine.
Releasetheparkingbrake.Themachineisnowable
tobepushedbyhand.
Toresetthedrivesystem(seeitem2in
Figure9),
loosentheknobbyturningcounterclockwise.Then
pushthereleaseleverontheundersideofmachine
towardsthefrontofthemachineandretightenthe
knobtoholdthereleaseleverintheoperatingstate.
Repeatthisoneachsideofthemachine.
DoNottowmachine.
PTOEngagementSwitch
Locatedonrightconsole(seeFigure6).
Switchmustbepulledout(up)toengagetheblades.
Switchispushedintodisengagetheblades.
20
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