Exmark 000 & Higher User manual

Category
Lawnmowers
Type
User manual

This manual is also suitable for

PIONEERS-SERIES
ForSerialNos.
312,000,000&Higher
PartNo.4501-000Rev.A
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,
orgrass-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.
©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,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
Exmarkpartsmanualsareavailableonlineat
http://www.exmark.com
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.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals......................11
Specications........................................................15
ModelNumbers.............................................15
Systems..........................................................15
Dimensions....................................................17
TorqueRequirements.....................................18
ProductOverview.................................................18
Operation..............................................................19
Controls.........................................................19
Pre-Start.........................................................21
OperatingInstructions...................................22
Transporting..................................................26
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..............................32
CheckTirePressures......................................32
CheckConditionOfBelts...............................32
LubricateGreaseFittings................................32
CheckSparkPlugs..........................................33
ChangeHydraulicSystemFilterand
Fluid..........................................................33
CheckSparkArrester(ifequipped)..................34
ThreadLockingAdhesives..............................35
Copper-BasedAnti-seize...............................35
DielectricGrease............................................35
Adjustments......................................................35
DeckLeveling................................................35
AdjustingtheBladeSlope...............................36
PumpDriveBeltTension................................37
DeckBeltTension..........................................37
AdjustingtheParkingBrake............................37
MotionControlHandleAdjustment...............38
FullForwardTrackingAdjustment..................38
MotionControlLinkageAdjustment..............39
AdjustingtheSeatRideSuspension.................40
ElectricClutchAdjustment.............................40
Cleaning............................................................42
CleanEngineandExhaustSystem
Area...........................................................42
RemoveEngineShroudsandClean
CoolingFins...............................................42
CleanHydroFanCoolingFins........................42
CleanDebrisFromMachine...........................42
CleanGrassBuild-UpUnderDeck.................42
WasteDisposal...............................................42
Troubleshooting....................................................44
Schematics............................................................46
4
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
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.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.
Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
CAUTION
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
5
Safety
Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
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.
Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
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.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
Avoidprolongedbreathingofvapors.
Keepfaceawayfromnozzleandgas
tank/containeropening.
Keepawayfromeyesandskin.
Neversiphonbymouth.
Checkthattheoperator'spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6
Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
Allowengineparts,especiallythemufer,to
coolbeforetouching.
Removeaccumulateddebrisfrommuferand
enginearea.
Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts
withtherollbarintheraisedandlockedposition.
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.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
DoNotoperatethemachinewithout
guards,shields,andsafetydevicesinplace
andworkingproperly.
Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.
Bealert,slowdownandusecautionwhen
makingturns.Lookbehindandtothesidebefore
changingdirections.
Stoptheblades,slowdown,andusecaution
whencrossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
DoNotoperatethemowerundertheinuence
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
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
8
Safety
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.
Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
DANGER
Chargingorjumpstartingthebatterymay
produceexplosivegases.Batterygasescan
explodecausingseriousinjury.
Keepsparks,ames,orcigarettesaway
frombattery.
Ventilatewhenchargingorusingbattery
inanenclosedspace.
Makesureventingpathofbatteryis
alwaysopenoncebatteryislledwith
acid.
Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.
Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.
DoNotswallowelectrolyte.
Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosion
ormovingpartscouldaccidentallyengage
causingpersonalinjury.
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
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.
10
Safety
SafetyandInstructionalDecals
Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
Replaceallworn,damaged,ormissingsafety
signs.
Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1-303508
1-403005
1-633922
98-5954
103-2076
11
Safety
107-2102
109-3148
109-6014
116-1119
116-1496
116-3303
12
Safety
116-4308
1.Latch2.Unlatch
116-4465
1.Fast
3.Choke-on
2.Slow4.Choke-off
116-6363
1.Rotatethedriverelease
knobtoloosen,slidethe
knob,andtighten.
2.Pushthemachine.
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.Parkbrakeengage4.Neutral
2.Fast5.Reverse
3.Slow
14
Specications
Specications
ModelNumbers
SerialNos:312,000,000andHigher
PNS600KA443;PNS651KA483;PNS680KC523;PNS740KC604
Systems
Engine
EngineSpecications:SeeyourEngineOwner’s
Manual
EngineOilType:Exmark4–CyclePremium
EngineOil
RPM:FullSpeed:
Kawasaki:3750±50RPM(PTOnotengaged)
Idle:1500±100RPM
Kohler:3700±50RPM(PTOnotengaged)Idle:
1500±100RPM
FuelSystem
Capacity:7.0gal.(26.5L)
FuelRecommendations:
Forbestresults,useonlyclean,fresh,unleaded
gasolinewithanoctaneratingof87orhigher
((R+M)/2ratingmethod).
Oxygenatedfuelwithupto10%ethanolor
15%MTBEbyvolumeisacceptable.
DoNotuseethanolblendsofgasoline(such
asE15orE85)withmorethan10%ethanol
byvolume.Performanceproblemsand/or
enginedamagemayresultwhichmaynotbe
coveredunderwarranty.
DoNotusegasolinecontainingmethanol.
DoNotstorefueleitherinthefueltankor
fuelcontainersoverthewinterunlessafuel
stabilizerisused.
DoNotaddoiltogasoline.
FuelFilter:
Kohler:KohlerP/N2405013
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
20ampchargingsystemfuse
10ampPTOfuse
15ampaccessoryfuse
SafetyInterlockSystem
LCDindicatorsappearforthePTO,parkbrake,
drivelevers,andoperatorpresenceinthemessage
displayontheRHcontrolpanel.
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.
15
Specications
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,
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:Moldedip-uparmrests.
SeatSafetySwitch:
Integratedseatswitch.Timedelayseatswitch
eliminatesroughgroundcut-outs.
HydrostaticGroundDriveSystem
Twounitizedhydrostatictransmissions:
Unitswith44,48,or52inchdecks:
HydroGearZT3100
Unitswith60inchdeck:
HydroGearZT3400
HydraulicOilType:ExmarkPremiumHydroOil.
HydraulicOilCapacity:77oz(2.3L)perside
HydraulicFilter:P/N109-3321
Speeds:
Forward:
Unitswith44,48,or52inchdecks:
0-8mph(12.9km/hr)forward.
Unitswith60inchdeck:
0-9mph(14.5km/hr)forward.
Reverse:
Unitswith44,48,or52inchdecks:
0-5mph(8.0km/hr)reverse.
Unitswith60inchdeck:
0-6mph(9.7km/hr)reverse.
Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
Tires&Wheels
Drive
Pneumatic(Airlled)
DeckSize
44,48,&5260
Quantity
22
Tread
TurfMasterK500SuperTurf
Size22x9.50-1223x10.50-12
PlyRating
44
Pressure
13psi(90kPa)13psi(90kPa)
FrontCaster
Pneumatic(Airlled)
DeckSize
AllUnits
Quantity
2
Tread
Smooth
Size13x5.00-6
PlyRating
4
Pressure
13psi(90kPa)
CuttingDeck
CuttingWidth:
44inchDeck:(111.8cm)
48inchDeck:(121.9cm)
52inchDeck:(132.1cm)
60inchDeck:(152.4cm)
Discharge:Side
BladeSize:
16
Specications
44inchDeck:22.25inches(56.5cm)(2ea.)
48inchDeck:16.25inches(41.3cm)(3ea.)
52inchDeck:18.00inches(45.7cm)(3ea.)
60inchDeck:20.50inches(52.1cm)(3ea.)
BladeSpindles:Solidsteelspindleswith.98inch
(25mm)I.D.bearings.
DeckDrive:“B”Sectionbeltwithself-tensioning
idler.
Electricclutch:
44,48,&52inchdecks:175ft-lbMagStop
60inchdeck:200ft-lbMagStopw/spotbrake
Deck:Fulloatingdeckisattachedtoout-front
supportframe.Anti-scalprollersprovide
maximumturfprotection.Deckdesignallowsfor
bagging,mulchingorsidedischarge.
44inchDeck:2anti-scalprollers
48inchDeck:3anti-scalprollers
52inchDeck:3anti-scalprollers
60inchDeck:4anti-scalprollers
DeckDepth:
44inchDeck:5.0inches(12.7cm)
48inchDeck:5.0inches(12.7cm)
52inchDeck:5.0inches(12.7cm)
60inchDeck:5.5inches(14.0cm)
CuttingHeightAdjustment:
Footactivatedleverisusedtoadjustthecutting
heightfrom11/2inch(3.8cm)to5inches(12.7
cm)in1/4inch(6.4mm)increments.
MulchingKit:Optional.
Dimensions
OverallWidth:
44inchDeck48inchDeck
WithoutDeck45.8inches
(116.3cm)
45.8inches
(116.3cm)
DeectorUp48.2inches
(122.4cm)
50.7inches
(128.8cm)
DeectorDown56.4inches
(143.3cm)
59.5inches
(151.1cm)
52inchDeck60inchDeck
WithoutDeck45.8inches
(116.3cm)
50.4inches
(128.0cm)
DeectorUp54.2inches
(137.7cm)
61.4inches
(156.0cm)
DeectorDown64.3inches
(163.3cm)
72.8inches
(185.0cm)
OverallLength:
44inchDeck48inchDeck
RollBar-Up78.8inches
(200.2cm)
77.8inches
(197.6cm)
RollBar-Down79.6inches
(202.2cm)
78.6inches
(199.6cm)
52inchDeck60inchDeck
RollBar-Up77.8inches
(197.6cm)
78.8inches
(200.2cm)
RollBar-Down78.6inches
(199.6cm)
79.9inches
(202.9cm)
OverallHeight:
RollBar-UpRollBar-Down
71.3inches(181.1cm)48inches(121.9cm)
TreadWidth:(CentertoCenterof
Tires,Widthwise)
44inchDeck48inchDeck
DriveWheels36.8inches
(93.5cm)
36.8inches
(93.5cm)
CasterWheels26.8inches
(68.1cm)
33.5inches
(85.1cm)
52inchDeck60inchDeck
DriveWheels36.8inches
(93.5cm)
39.7inches
(100.8cm)
CasterWheels33.5inches
(85.1cm)
38.3inches
(97.3cm)
17
ProductOverview
WheelBase:(CenterofCasterTireto
CenterofDriveTire)
44inch
Deck
48inch
Deck
52inch
Deck
60inch
Deck
49.7inches
(126.2cm)
48.7inches
(123.7cm)
48.7inches
(123.7cm)
49.7inches
(126.2cm)
CurbWeight:
44inch
Deck
48inch
Deck
52inch
Deck
60inch
Deck
Kawasaki
Units
822lb
(373kg)
862lb
(391kg)
873lb
(396kg)
948lb
(430kg)
TorqueRequirements
BoltLocation
Torque
BladeDriveSheave
MountingNut
130-160ft-lb(176-217
N-m)
BladeMountingBolt
(lubricatewithanti-seize)
50-60ft-lb(68-81N-m)
Anti-ScalpRollerNyloc
NutSeeFigure18
27-33ft-lb(37-45N-m)
Anti-ScalpRollerWhizlock
NutSeeFigure18
27-33ft-lb(37-45N-m)
EngineMountingBolts
27-33ft-lb(37-45N-m)
WheelLugNuts
70-90ft-lb(95-122N-m)
RolloverProtection
System(RollBar)1/2
inchMountingBolts
77-95ft-lb(104-129N-m)
ClutchRetainingBolt
(securedwiththreadlocker)
49-61ft-lb(66-83N-m)
ProductOverview
Figure4
1.RolloverProtection
System(ROPS)
5.Motioncontrollevers
2.EngineControls(right
console)
6.Parkingbrake
3.Seatbelt7.Heightofcutadjustment
4.Fuelcap
18
Operation
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
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).
19
Operation
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.
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.
Locatedontheleftandrightsidesunderneaththe
enginedeck.
Duringnormaloperatingconditions,thedrivewheel
releasevalvesarepositionedinfrontoftheslots.If
themachinehastobepushedbyhand,thevalves
mustbeinthe“released”position(see
Figure9).
20
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Exmark 000 & Higher User manual

Category
Lawnmowers
Type
User manual
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