Exmark 000 & Higher User manual

Brand: Exmark

Model: 000 & Higher

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.

IndustrialParkBox808

Beatrice,NE68310

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.

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

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.

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.

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.

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.

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.

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.

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

Safety

107-2102

109-3148

109-6014

116-1119

116-1496

116-3303

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

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

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.

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

Tread

TurfMasterK500SuperTurf

Size22x9.50-1223x10.50-12

PlyRating

Pressure

13psi(90kPa)13psi(90kPa)

FrontCaster

Pneumatic(Airlled)

DeckSize

AllUnits

Quantity

Tread

Smooth

Size13x5.00-6

PlyRating

Pressure

13psi(90kPa)

CuttingDeck

•CuttingWidth:

–44inchDeck:(111.8cm)

–48inchDeck:(121.9cm)

–52inchDeck:(132.1cm)

–60inchDeck:(152.4cm)

•Discharge:Side

•BladeSize:

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)

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

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).

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).

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Model: 000 & Higher

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