V ANTAGE®S-SERIES
36INCHMODELS
ForSerialNos.
316,000,000&Higher
PartNo.4502-635Rev.A
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,
orgrass-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.
Labeledpowerratingsaresuppliedbytheengine
manufacturerinaccordancewithSAEtesting
andgross/netpowerratingstandards(J1940,
J1995,J1349).
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2015ExmarkMfg.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.
Important:Tomaximizesafety,performance,
andproperoperationofthismachine,itis
essentialthatalloperatorscarefullyreadand
fullyunderstandthecontentsoftheOperator’s
manualprovidedwiththeproduct.Safe
operationofExmarkequipmentisessential.
Failuretocomplywiththeoperatinginstructions
orreceivepropertrainingmayresultininjury.
Gotohttp://www.Exmark.comforadditional
safeoperationinformation,suchassafetytips,
trainingmaterials,andOperator’smanuals.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
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......................10
Specications........................................................14
Systems..........................................................14
Dimensions....................................................15
TorqueRequirements.....................................15
ProductOverview.................................................16
Operation..............................................................16
Controls.........................................................16
Pre-Start.........................................................19
OperatingInstructions...................................19
Transporting..................................................24
Maintenance..........................................................25
RecommendedMaintenanceSchedule(s)............25
PeriodicMaintenance........................................26
CheckEngineOilLevel..................................26
CheckBatteryCharge.....................................26
CheckMowerBlades......................................28
CheckSafetyInterlockSystem........................29
CheckforLooseHardware.............................29
ServiceAirCleaner.........................................29
ChangeEngineOil.........................................30
CheckHydraulicOilLevel..............................30
CheckTirePressures......................................30
CheckConditionOfBelts...............................30
LubricateGreaseFittings................................30
LubricateCasterWheelHubs.........................31
CheckSparkPlugs..........................................32
ChangeHydraulicSystemFilterand
Fluid..........................................................32
WheelHubNutTorqueSpecication..............34
CheckSparkArrester(ifequipped)..................34
ThreadLockingAdhesives..............................34
MobilHTSGrease(OrFood-Grade
Anti-seize)..................................................34
Copper-BasedAnti-seize................................34
DielectricGrease............................................34
Adjustments......................................................35
DeckLeveling................................................35
OverallHeightAdjustment.............................36
DeckLiftHandleForce..................................36
PumpDriveBeltTension................................36
MowerDeckDriveBeltTension.....................36
ParkBrakeAdjustment...................................36
ElectricClutchAdjustment.............................37
ForwardSpeedAdjustment............................38
MotionControlTrackingAdjustment.............39
AdjustRHMotionControlHandle
Position......................................................40
CasterPivotBearingsPre-Load
Adjustment................................................40
Cleaning............................................................41
CleanEngineandExhaustSystem
Area...........................................................41
RemoveEngineShroudsandClean
CoolingFins...............................................41
CleanDebrisFromMachine...........................41
CleanGrassBuild-UpUnderDeck.................42
WasteDisposal...............................................42
Troubleshooting....................................................43
Schematics............................................................46
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:Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.
WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.
CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readthismanual,itistheowner’sresponsibilityto
explainthismaterialtothem;otherlanguagesmay
beavailableonourwebsite.
•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,andhearingprotection.Do
Notoperatewhenbarefootorwhenwearingopen
sandals.Longhair,looseclothingorjewelrymay
gettangledinmovingparts.
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.Do
Notuseanozzlelockopendevice.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperatorpresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6
Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,to
coolbeforetouching.
•Removeaccumulateddebrisfrommuferand
enginearea.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,
DoNotoperatethemachine;seekshelter.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
•Neverraisedeckwithbladesrunning.
•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.
–Beforemakingheightadjustments.
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.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
7
Safety
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossofcontrol
and/orlossofoperator'sfootingcouldresultina
fallwithanarmorleggettingunderthemower
orenginedeckwhichmayresultinseriousinjury,
deathordrowning.
•Mowacrossslopes,neverupanddown.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan20degrees.
•Reducespeedanduseextremecautionon
slopes.
•Avoidsuddenturnsorrapidspeedchanges.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
MaintenanceandStorage
•Disengagedrives,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
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.
8
Safety
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
Removalormodicationoforiginalequipment,
partsand/oraccessoriesmayalterthewarranty,
controllability,andsafetyofthemachine.
Unauthorizedmodicationstotheoriginal
equipmentorfailuretouseoriginalExmark
partscouldleadtoseriousinjuryordeath.
Unauthorizedchangestothemachine,engine,
fuelorventingsystem,mayviolateapplicable
safetystandardssuchas:ANSI,OSHAand
NFPAand/orgovernmentregulationssuchas
EPAandCARB.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
•Ifequipped,makesureallhydraulicuid
hosesandlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretohydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,to
ndhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrollevers
inneutralandshuttingofftheenginebefore
performinganyworkonthehydraulicsystem.
WARNING
Fuelsystemcomponentsareunderhigh
pressure.Theuseofimpropercomponentscan
resultinsystemfailure,gasolineleakageand
possibleexplosion.
Useonlyapprovedfuellinesandfuelltersfor
highpressuresystems.
9
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.
106-5517
1.Warning—donottouchthehotsurface.
112-8760
1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
2.Cutting/dismembermentofhandorfoot—stayaway
frommovingparts.
115-4212
1.Hydraulicoillevel3.Warning—donottouch
thehotsurface.
2.ReadtheOperator's
Manual.
116-4270
10
Safety
116-4298
116-7912
1.Interval4.Neutral
2.PowerTake-off(PTO)5.Operatorpresence
control
3.Parkingbrake6.Battery
116-8283
1.Warning—readtheOperator'sManualforinstructions
ontorquingthebladebolt/nutto55-60ft-lb(75-81N-m).
116-8772
1.Accessory,15A
3.Charge,25A
2.PTO,10A
4.Main,30A
116-8775
1.ReadtheOperator’s
manual
2.Filltobottomofller
neck;warning—DoNot
overllthetank
121-6049
1.Thrownobject
hazard—keep
bystandersawayfrom
themachine.
3.Cutting/dismemberment
hazardofhandorfoot,
mowerblade—keep
handsawayfrommoving
parts.
2.Thrownobjecthazard,
mower—donotoperate
themowerwithguards
orshieldsremoved.
11
Safety
126-2130
1.Wheellugnuttorque95ft-lb(129N-m)(4x)
2.Wheelhubnuttorque200ft-lb(271N-m)
3.ReadandunderstandtheOperator’smanualbefore
performinganymaintenance,checktorqueafterrst
100hoursthenevery500hoursthereafter.
116-8819
1.Unlock
6.Greasebeltidlerevery500hours.
2.Forward-faster7.Greasefrontcasterpivotsandwheelbearingsevery500
hours.
3.Rearward-slower
8.Greaselinkagepivots(3)every200hours.
4.Lock
9.Checktirepressureevery50hours.
5.ReadtheOperator’sManualbeforeperformingany
maintenance.
10.Checkhydraulicoillevel(Onlyuserecommendedhydro
oil)every50hours.
12
Safety
116-8779
1.Parkingbrake-disengage
6.Continuousvariablesetting
2.Parkingbrake-engaged7.Throttle-slow
3.PTO-on8.Choke-on
4.PTO-off9.Choke-off
5.Throttle-fast
116-8780
1.Warning-ReadtheOperator’sManual.DoNotoperatethis
machineunlessyouaretrained.Wearhearingprotection.
4.Thrownobjecthazard-Pickupobjectsthatcouldbethrown
bymower.DoNotoperatewhenpeopleandpetsarein
thearea.Keepdeectorinplace.
2.Warning-Stayawayfrommovingparts;keepallguards
inplace.Stopengineandremovekeybeforeadjusting,
servicing,orcleaning.
5.Cutting/dismembermenthazard-DoNotoperateonslopes
greaterthan20degrees.DoNotmowwetslopes–use
extremecautionwhenoperatingonslopes;mowacross
slopesnotupanddown.
3.Warning-DisengagePTO,movedriveleversouttoneutral
lockposition,engageparkingbrake,andstopengine
beforeleavingtheoperator’sposition.
6.Crushing/dismembermenthazardofbystanders-donot
carrypassengers,lookforwardanddownwhenoperating
themachine,lookbehindanddownwhenreversing.
116-8781
1.Tractioncontrol5.Reverse
2.Fast
6.PTO
3.Slow7.Operator’spresenceswitch
4.Neutral
13
Specications
Specications
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•EngineOilType:Exmark4–CyclePremium
EngineOil
•RPM:FullSpeed:3600±100RPM(NoLoad)
FuelSystem
•Capacity:8.0gal.(30.2L)
•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:ReplaceableIn-line
•FuelShut-OffValve:1/4turn
ElectricalSystem(ElectricStart)
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:Kawasaki:15amps
•BatteryType:BCIGroupU1
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:
–30ampmainfuse
–25ampchargingsystemfuse
–10ampPTOfuse
–15ampaccessoryfuse
SafetyInterlockSystem
•LCDindicatorsappearfortheparkbrake,drive
levers,andoperatorpresenceinthemessage
displayonthefrontcontrolpanel.
Note:BecausethePTOmustbedisengaged
tostarttheengine,theLCDindicatorwillnot
illuminateatthistime.
•PTOmustbedisengagedandmotioncontrol
leversinneutraltostartengine.(Itisnot
necessaryfortheoperatortobeontheplatform
tostarttheengine.)
•Mowerbladeswillstopiftherightsidemotion
controlleverismovedorreleasedintothePTO
disengageposition.
•Enginewillstopifthemotioncontrolleversare
movedfromtheneutralpositionwiththepark
brakeengaged.
OperatorControls
SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand
neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.
Transmission
•TwoHydroGearvariabledisplacementhigh
efciencypumpsindependentlycoupledtotwo
highefciencyParker/Rosswheeldrivemotors.
•HydraulicOil:UseExmarkPremiumHydroOil.
•HydraulicOilCapacity:2.4qt.(2.2L)
•HydraulicFilterisreplaceablecartridgetype.
P/N109-4180:25microns,10psibypass
(Summeruseabove32°F(0°C))
P/N1-523541:40microns,18psibypass(Winter
usebelow32°F(0°C))
•Speeds:
–0-8.0mph(13km/hr)forward.
–0-4.0mph(6km/hr)reverse.
•Drivewheelsreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.
14
Specications
Tires&Wheels
Drive
FrontCaster
Pneumatic
(Air-Filled)
Semi-
Pneumatic
Quantity
22
TreadKendaK500
Smooth
Size18x8.50–811x4.00-5
PlyRating
4
Pressure
14psi
(97kPa)
CuttingDeck
•CuttingWidth:36inches(91.4cm)
•Discharge:Side
•BladeSize:(2ea.):18.00inches(45.7cm)
•BladeSpindles:Solidsteelspindleswith1.00inch
(25.4mm)I.D.bearings.
•DeckDrive:
–Electricclutchmountedonengineshaft.
–Bladesdrivenbyonebelt(w/self-tensioning
idlers).
•Deck:Fulloatingdeckisattachedtosupport
frame,removableforservice.Deckdesignallows
forbagging,mulchingorsidedischarge.
•DeckDepth:5.0inches(12.7cm)
•CuttingHeightAdjustment:
Adjustsfrom1inch(2.5cm)to5inches(12.7cm)
in1/4inch(6.4mm)increments
•MulchingKit:Optional
•Bagger:Optional
Dimensions
OverallWidth:
DeectorUp39.1inches(99.3cm)
DeectorDown48.0inches(121.9cm)
OverallLength:
PlatformUp61.5inches(156.2cm)
PlatformDown74.0inches(188.0cm)
OverallHeight:
51.5inches(130.8cm)
TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)
37.6inches(95.5cm)
CurbWeight:
800lb(363kg)
Note:Weightswillvaryslightlydependingonengine.
TorqueRequirements
BoltLocation
Torque
CutterHousingSpindle
Nut
130-160ft-lb
(176-217N-m)
BladeMountingBolt
(lubricatewithanti-seize)
50-60ft-lb(68-81N-m)
EngineDeck/Mower
DeckSupportMount
Bolts
30-35ft-lb(41-47N-m)
EngineMountingBolts
30-35ft-lb(41-47N-m)
WheelLugNuts
85-105ft-lb(115-142
N-m)
WheelHubNuts175-225ft-lb
(237-305N-m)
WheelMotorMounting
Bolts
67-83ft-lb(91-113N-m)
15
Operation
ProductOverview
Figure3
1.Platform
4.Motioncontrollevers
2.FuelCap5.EngineControls
3.Height-of-Cut
Adjustment
6.ParkBrakeLever
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
MotionControlLevers
Themotioncontrollevers,locatedoneachsideofthe
topconsole,controltheforwardandreversemotion
ofthemachine.
Movingtheleversforwardorbackwardturns
thewheelonthesamesideforwardorreverse
respectively.Wheelspeedisproportionaltothe
amounttheleverismoved.
Figure4
1.LHMotioncontrollever6.Neutral
2.RHMotioncontrollever7.Forward
3.RHMotioncontrol
leverinPTOdisengage
position
8.Frontreference/Speed
controlbar
4.Reverse
9.Frontofunit
5.Rearreferencebar
Whenthemotioncontrolleversareintheneutral
position,theLCDindicatorappearsinthemessage
displayonthefrontcontrolconsole(seeFigure5and
Figure7).
Whenthemotioncontrolleversareintheneutral
positionandtheRHmotioncontrolleverismoved
intothePTOdisengageposition,themowerblades
willdisengage.
16
Operation
ChokeControl
Locatedonthefrontcontrolconsolerightofthe
PTOengagementswitch.
Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
rear,tothedetent,willputthechokeinthe“OFF”
position.DoNotrunawarmenginewithchokein
the“ON”position.
Figure5
1.Choke
8.Fuelgauge
2.RHMotioncontrollever
9.PTOengagementswitch
3.LHMotioncontrollever10.Throttle
4.FrontReference/Speed
ControlBar
11.Decklifthandle
5.Parkbrakelever12.Fuelcap
6.Messagedisplay
13.Height-of-cutpin
7.Ignitionswitch
14.Platformlatch
ThrottleControl
LocatedontheRHsideofthefrontcontrolconsole
(redlever)(seeFigure5).
Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.
FrontReference/SpeedControlBar
Locatedinfrontofthemotioncontrollevers(see
Figure5).
Thefrontreference/speedcontrolbarcontrolsthe
maximumforwardspeedandisinnitelyvariable
fromapproximately4–8mph(6–13km/hr).
ParkBrakeLever
Locatedonleftsideofunit,justtothefrontofthe
LHmotioncontrollever(seeFigure5).
Thebrakeleverengagesaparkingbrakeonthedrive
wheels.
Note:TheLCDindicatorappearsinthemessage
displayonthefrontconsolewhentheparkbrakeis
engaged(seeFigure5andFigure7).
Toengagethebrake,pulltheleverrearward.
Torelease,pushtheleverforward.
Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.
Parkbrakemustbedisengagedbeforemovingmotion
controloutofneutralorenginewillkill.
IgnitionSwitch
LocatedontheLHsideofthefrontcontrolconsole
(seeFigure5).
Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”
and“START”.Insertkeyintoswitchandrotate
clockwisetothe“ON”position.Rotateclockwiseto
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).Allow
thekeytoreturntothe“ON”positionimmediately
aftertheenginestarts.
Figure6
1.Off3.Start
2.On
17
Operation
Note:Tostarttheengine,placetheLHmotion
controlleverinneutral,theRHmotioncontrol
inPTOdisengageposition,andthePTOswitch
disengaged.(Itisnotnecessaryfortheoperatorto
beontheplatform.)
HourMeter
LocatedontheLHsideofthefrontcontrolconsole
inthemessagedisplay(seeFigure5andFigure7).
Thehourmeterrecordsthenumberofhoursthat
theenginehasrun.
Figure7
1.LCDIndicators
2.Lowvoltageindicatorlight
3.Hour/Voltagedisplay
Thehourmeterisrecordingwhenthedecimalpoint
isashinginHour/Voltagedisplay.
Hoursaredisplayedwhenthekeyisofforwhenthe
machineisrunning.
Note:Iftheignitionkeyisturnedtothe“ON”
positionforafewsecondsbeforecrankingtheengine,
thebatteryvoltagewilldisplayintheareawherethe
hoursarenormallydisplayed.
Note:TheLCDindicatorsappearwheneach
controlmeetsthe“safetostart”mode.Becausethe
PTOmustbedisengagedtostarttheengine,the
LCDindicatorwillnotilluminateatthistime.
FuelShut-OffValve
LocatedontheRHsideofthecontroltowerbehind
thekneecushion.
Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.
Alignvalvehandlewiththefuellinetoopen.Rotate
90°toclose.
FuelGauge
Locatedonthetopleftsideofthetank(seeFigure5).
Thefuelgaugemonitorstheamountoffuelinthe
tank.
DriveWheelReleaseValves
Locatedontherightfrontcornerofthehydrostatic
pumps.
Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.
Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.
Turnclockwisetoresetthedrivesystem.DoNot
overtighten.DoNottowmachine.
PTOEngagementSwitch
Locatedonfrontcontrolpanel(seeFigure5).
Switchmustbepulledout(up)toengagetheblades.
Switchispushedintodisengagetheblades.
TheLCDindicatorwillappearwhenthePTOswitch
isengaged(seeFigure7).
LowVoltageIndicator
Locatedonthefrontcontrolpanelinthemessage
display(seeFigure5andFigure7).
Alowvoltagecondition(lessthan12.3volts)exists
whenthelowvoltageindicatorlightappearsonthe
messagedisplaywhiletheengineisrunning.
Iftheignitionkeyisturnedtothe“ON”positionfor
afewsecondsbeforecrankingtheengine,thebattery
voltagewilldisplayintheareawherethehoursare
normallydisplayed.
Note:Theindicatornormallyappearswhenthe
engineisoffandthekeyswitchisturnedtothe
“ON”position.
DeckLiftHandle
LocatedontheRHofthefrontcontrolpanel.
18
Operation
Pullthehandlerearwardtoraisethecuttingdeck.
Allowthehandletomoveforwardtolowerthe
cuttingdecktothecutheightthathasbeenset.
Pullthehandlerearwardandtotherighttolatch
thecuttingdeckintotheraisedtransportposition
(Figure6).
Pre-Start
Fillfueltankonlevelground.SeeFuel
RecommendationsintheSpecicationssectionfor
additionalgasolineinformation.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Fillthefueltanktothe
bottomofthellerneck.Theemptyspaceinthe
tankallowsgasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengineoremission
system.
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
OperatingInstructions
OpentheFuelShut-OffValve
Rotatethevalveandalignwiththefuellinetoopen.
StartingtheEngine
1.LeavetheLHmotioncontrolleverinneutraland
theRHleverinthePTOdisengageposition(see
Figure4).
2.Pulltheparkingbrakeleverrearwardtoengage
theparkingbrake.
3.Pushin(down)onthePTOswitchtothe
“disengage”position.
4.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
5.Onacoldengine,pushthechokeleverforward
intothe“ON”position.
Onawarmengine,leavethechokeinthe“OFF”
position.
6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.
Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.
7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.
PTOEngagement
DANGER
Therotatingbladesunderthemowerdeckare
dangerous.Bladecontactcancauseserious
injuryorkillyou.
DoNotputhandsorfeetunderthemoweror
mowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.
Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunlessthere
isagrasscollectionsystemormulchkitinplace
andworkingproperly.
ThePTOswitchengagesthecuttingblades.Besure
allpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO.
1.Setthrottleto“MIDWAY”position.
2.Releasetheparkingbrake.
3.Movetherightsidemotioncontrollevertothe
center,operateposition.
4.Continueholdingtherightsidemotioncontrol
leverinthecenter,operatepositionandpullup
onthebladecontrolswitch(PTO)andrelease.
Theclutchshouldengageandthemowerblades
beginrotating.
5.Placethethrottleinthe“FAST”positiontobegin
mowing.
19
Operation
DisengagingthePTO
1.Setthethrottlemidwaybetweenthe“SLOW”and
“FAST”positions.
2.PushdownonthePTOswitchtodisengagethe
blades.
Note:ThePTOwillbedisengagedbyreleasing
therightsidemotioncontrolleverandallowingit
tospringoutwardtothePTOdisengageposition.
ThePTOwillnotre-engagewhentheRHmotion
controlleverismovedoutofthePTOdisengage
positionwithoutpullinguponthePTOswitch.
TofullydisengagethePTO,continuetopushthe
switchdownward.
StoppingtheEngine
1.Bringtheunittoafullstop.
2.Movethemotioncontrolleverstotheneutral
position;movetheRHcontrolleverouttothe
PTOdisengageposition.
3.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
4.PushdownonthePTOswitchtodisengagethe
blades.
5.Engagetheparkingbrake.
6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.
7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.
8.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.
DrivingtheMachine
CAUTION
Machinecanspinveryrapidlybypositioningone
levertoomuchaheadoftheother.Operatormay
losecontrolofthemachine,whichmaycause
damagetothemachineorinjury.
•Usecautionwhenmakingturns.
•Slowthemachinedownbeforemakingsharp
turns.
Important:Tobeginmovement(forwardor
backward),thebrakelevermustbedisengaged
(pushedforward)beforethemotioncontrol
leverscanbemovedortheenginewillstop.
WhentheRHmotioncontrolleverispositioned
fullyoutward(apart),thedrivesystemisinthePTO
disengageposition(Figure8).
Note:The“N”LCDindicatorappearswhenthe
RHleverisinthePTOdisengageposition.
WhentheRHmotioncontrolleverismoveddirectly
inward(together)thedrivesystemisintheneutral
operateposition.
Figure8
1.LHMotioncontrollever6.Neutral
2.RHMotioncontrollever7.Forward
3.RHMotioncontrol
leverinPTOdisengage
position
8.Frontreference/Speed
controlbar
4.Reverse
9.Frontofunit
5.Rearreferencebar
DrivingForward
1.Makesurethemotioncontrolleversareinthe
neutralposition.
2.Releasetheparkingbrake.
3.Tomoveforwardinastraightline,moveboth
leversforwardwithequalpressure.
20
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