Exmark Lawn Tractor manual

For Serial Nos. 540,000 & Higher Part No. 103-9170[...]

- i - WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working[...]

- ii - EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not ha ve the Ex mark part in stock, Exmark w ill get the parts to the dealer the next business day or the part will be FREE* Guaranteed! ! How the Program Works 1. If dealer does not have part in stock for a "dow n" unit at the tim[...]

iii CONGRAT ULATIONS on t he purchase of your Ex m ark Mower. This product has been caref ully designed and manufact ured to give y ou a maximum amount of dependability and years of tr ouble- f ree operat ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ust ment, and saf ety instructi ons for your E xma[...]

- iv - TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety A lert Symb ol ....................................................................................... 1 1.2 Traini ng ......................................................................................................... 1 1.3 Prepar ation .............................................[...]

- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he m achine t o identif y import ant safet y messag es which must be followed to avoid accidents. Th is symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion which alerts you to [...]

- 2 - 1.3.4 Thoroug hly inspect t he ar ea where the equipment is t o be used and r em ove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage t he equipment or cause per sonal inj ur y to the operator or bystander s. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly po[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved cont[...]

- 4 - 1.4 OPERA TION Although hazard control and acci dent prevent i on are partially dependent upon t he design and configurat i on of t he equi pment, these fact ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of t he personnel involved in the operation, t ransport , maintenance, and st orage of t he equi pm[...]

- 5 - DA NGER POTENT IAL HAZARD ♦ Mow ing on wet g r ass or st eep slopes can cause sliding and loss of cont r ol. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Do not mow slopes when grass is wet. ♦ Do [...]

- 6 - WA RNING POTENT IAL HAZARD ♦ There is no r ollover prot ection when the roll bar is down. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Keep the roll bar in t he r aised and locked position and use s[...]

- 7 - 1.4.17 Do Not mow with the discharge def lector raised, r em oved or alt er ed unless t her e is a grass collect ion system or mulch kit in place and working properly. 1.4.18 Be aware of the mower discharg e and direct discharg e away from ot her s. 1.4.19 Do Not operate m ower under t he inf luence of alcohol or dr ugs. 1.4.20 Use extra care[...]

- 8 - WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penet rate skin and cause injur y. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surgically removed within a few hours by a doctor fam iliar with this f orm of injury or g angrene may result . HOW TO AVO ID THE HAZARD ♦ Make sure all hydra[...]

- 9 - PART NO. 1- 633313 LOCATI ON: RH Side on Top Front of Mower Deck PART NO. 1- 403005 LOCATIO N: Left and Right Corners of Mower Deck PART NO. 1- 633462 LOCATI ON: Rubber Heat Shield Flap behind Seat PART NO. 1- 303508 LOCATIO N: RH Side on Top Rear of Mower Deck PART NO. 1- 513742 LOCATI ON: Top of Mower Deck Belt Shields, Left and Right Sides[...]

- 10 - PART NO. 1- 643222 LOCATIO N: Left of Center on Mower Deck , Under Floor Pan PART NO. 103- 5368 LOCATI ON: LH Side of Cutting Height Adjustm ent Plate PART NO. 103- 0368 LOCATI ON: Rubber Heat Shield Flap behind Seat PART NO. 1- 643339 LOCATI ON: Top of Right Engine Baffle PART NO. 1- 633922 LOCATIO N: Front Center on T op of Mower Deck PART[...]

- 11 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: 2.2 ENGIN E: 2.2.1 Engine Specifications: See your Eng ine Owner’s Manual 2.2.2 RPM: Full Speed: 3750 RPM (No Load) Idle: 1500 RPM 2.3 FU EL SYSTEM 2.3.1 Capacity: 11 gal. ( 42 L. ) 2.3.2 Type of Fuel: Reg ular unleaded gasoline, 87 octane or higher 2.3.3 Fuel Filter: I n - line 15 Micron Kohler P/N 24[...]

- 12 - Drive Front Caster Pneumatic (Air - Filled) Pneumatic (Air - Filled) Quantity 2 2 Tread Turf Mate Smooth Size 23 x 10.50-12 13 x 5.00-6 Ply Rating 4 4 Pressure 13 psi (90 kPa) 13 psi (90 kPa) • Custom r ide suspension system t o enhance St andar d Seat . • Deluxe suspension seat with high back , low prof ile foam- in- place cushion (damp[...]

- 13 - 2.10 DIMENS IONS 2.10.1 Overall W idth: withou t deck deflector u p deflector down w/52” Deck 49.8 in. ( 126.5 cm) 53.4 in. (135.6 cm ) 64.2 in. (163.1 cm) w/60” Deck 53.8 in. ( 136.7 cm) 61.4 in. (156.0 cm ) 72.2 in. (183.4 cm) 2.10.2 Overall Lengt h: w/52” Deck w/60” Deck Roll Bar - Up 78.2 in. (198.7 cm ) 78.2 in. (198.7 cm ) Roll[...]

- 14 - CA UTION POTENT IAL HAZARD ♦ Raising the r ear of the unit f or assembly relying solely on mechanical or hydraulic jack s could be dangerous. W HAT CAN HAPPEN ♦ The mechanical or hydraulic j ack s may not be enough support or m ay malf unction allowing the unit t o fall, which could cause injury. HOW TO AVO ID THE HAZARD ♦ DO NOT r e l[...]

- 15 - 3.2.5 Install the upper u- shaped sect ion of the r oll bar . (Reference Fig ure 3 f or alignment and inst allat ion instructions below): a) Locate t he lat ch pin assem blies (pin and hairpin connected with a lanyard). b) Inst all a 1/ 2- 13 x 3 1/4 capscr ew in the washer on the lanyard of each pin assembly. Not e: Make sur e t he bent t a[...]

- 16 - DA NGER POTENT IAL HAZARD ♦ Charging t he bat tery may produce explosive gasses W HAT CAN HAPPEN ♦ Battery gasses can explode causing ser ious inj ur y. HOW TO AVO ID THE HAZARD ♦ Keep sparks, f lames, or cig arettes away from bat t ery. ♦ Ventilate when charging or using batter y in an enclosed space. ♦ Make sure venting path of b[...]

- 17 - 3.4 INSTA LL DRIVE WHEELS . 3. 4. 1 Mount drive wheels w ith t he valve stem to t he out side of the unit . Secure using four ( 4) 1/ 2- 20 wheel nuts (inst alled on st uds in hubs) f or each wheel. Torq ue to 95 ft - lbs (128 N x M) . 3.5 CHECK TIRE P RESSURE. 3. 5. 1 Check t ir e pr essur e in dr ive tires. Proper inf lation pressure f or [...]

- 18 - 3.8 POSITION DISCHARGE CHUTE. 3.8.1 Loosen two (2) 5/ 16” nyloc nuts at t aching discharge chute. Lower the discharge chute into position. Ret ighten nyloc nuts until chut e is snug but can pivot fr eely. 3.9 SERVICE ENGINE. Engine is shipped with oil; check oil level and if necessary and fill to t he appropriate level with oil as specifie[...]

- 19 - To turn right while moving f or ward, m ove the ri ght l ever back toward neutral to slow the right dr ive wheel. To make a zero turn to the le ft , pull the left lever back beyond neutral while holding the r ig ht lever slight ly ahead of neutral. To make a zero turn to the right , pull the right lever back beyond neutral while holding the [...]

- 20 - 4.1.8 Ignit ion Switch : Located on t he lower center of console. The ignit ion switch is used to start and stop t he eng ine. The switch has three positions “OFF” , “ON” and “ST ART”. I nser t key into switch and rotat e clockwise to the “O N” position. Rotat e clock wise to the next position to eng ag e the starte r (key mu[...]

- 21 - 4.3.3 Starting Eng ine : Brake must be engaged, moti on cont rol l evers out (neutral lock posi t i on) and PTO swit ch “O FF” t o st art engi ne. (It is not necessar y f or t he operator to be in the seat to st ar t the engine.) On a cold engine, place the throttle midway between the “SLOW ” and “FAST ” positions and pull choke [...]

- 22 - 4.3.6 Stopping Engine : Brin g unit to a fu ll stop . Disengage the PT O , move motion control levers out to the neutral lock position and set parki ng brake . Befor e st opping the engine, place t he t h r ot t le control midw ay betw een the “ slow” and “f ast ” posit ions. Allow the engine to run a m inim um of 15 seconds; then st[...]

- 23 - 4.4.2 Loading a Unit : Use extrem e caut ion when loading unit s on t r ailers or truck s. One f ull width ramp t hat is wide enough to extend beyond the rear tires is recommended inst ead of individual ramps for each side of the unit . T he lower rear section of the tract or f rame extends back bet ween the rear wheels and serves as a stop [...]

- 24 - d) I f the oil level is low, wipe off t he ar ea ar ound the oil fill cap, remove cap and fill t o t he “FULL” mark on the dipstick . Use oil as specif ied in Engine Owner’s Manual. DO NOT overfill. IMPORT A NT : DO NOT operate the engine with the o il level belo w the “LOW” (or “A DD”) mark on t he di pst i ck, or over the “[...]

- 25 - a) Stop engine, wait f or all m oving par ts to stop, and r emove key. b) Clean all debris from r ot ating eng ine air int ak e screen and f r om around engine shrouding . c) Clean all debr is f rom inside of pump drive belt compar t ment. d) Inspect rubber eng ine baf fles f or proper f it. Replace if necessary. 5.1.4 Clean grass build-up u[...]

- 26 - FIGURE 7 BLA DE BOLT INSTA LLAT I O N IMPO RTANT : DO NOT use components other t han the original blade, blade bushing, spr ing disc washer, and blade bolt supplied with the unit. Failure to use all original com ponent s and assem bled as shown will increase the risk of a blade bolt becoming loose or weak af ter str iking a f oreign object .[...]

- 27 - Run engine at one- t hir d thrott le, engage PTO and rai se of f of seat (but do not get of f of machine) eng ine must stop aft er 1/2 second has elapsed. Run engine at one- t hir d throttle, with brak e disengaged, move levers in and raise of f seat (but do not get of f of machine) engine must st op af ter 1/2 second has elapsed. Again, r u[...]

- 28 - e) Clean around oil fill cap and r e m ove cap. Fill t o specif ied capacity and replace cap. Use oil recomm ended in eng ine owner’s manual. DO NO T overf ill. f) St ar t the engine and check f or leaks. 5.1.12 Check hydraulic oil level : Service Interval: 40 hr. a) Stop engine and wait f o r all m oving par ts to stop. b) Unhook seat lat[...]

- 29 - LUBRICA TION CHA RT FI TTING LOCAT IONS INITIAL PUMPS NO. of PLACES SERVICE INTERVAL 1. Front Caster wheel hubs ∗ 0 2 ∗ yearly 2. Front Caster Pivots ∗ 0 2 ∗ yearly 3. Height Adj. Shaft Bear ings 1 5 40 hours 4. Deck Drive Belt Idler Arm 1 1 Yearly 5. Brak e Brackets 1 2 200 hours 6. Mule Drive Belt Idler Arm 1 1 Yearly 7. Pum p Driv[...]

- 30 - h) If the axle assembly has had both spacer nuts r em oved (or br ok en loose), apply a thread locking adhesive to (1) spacer nut and t hr ead ont o t he axle with the wrench flats f acing outward. Do not thr ead spacer nut all of the way onto the end of the axle. Leave approximately 1/8” (3 mm ) f rom t he out er surf ace of the spacer nu[...]

- 31 - b) Remove cooling shrouds f rom engine and clean cooling fins. Also clean dust , dirt, and oil f rom external sur f aces of eng ine, which can cause improper cooling. c) Make sure cooling shrouds ar e r einst alled. Operating t he eng ine without cooling shrouds will cause engine damag e due to overheating. 5.1.22 Check spark plugs : Service[...]

- 32 - d) T o r q ue the slotted nut t o 125 f t. lbs ( 169 N- M). e) T hen t ighten nut unt il t he next set of slots line up with the cross hole in shaf t. f) Replace cotter pin. NOTE: Do not use antisieze on wheel hub. 5.1.26 Fuel T ank – mount ing hardware specification. W hen installing the nuts on the f uel tank st uds, fully tig ht en t he[...]

- 33 - d) Insert heig ht adjustm ent pin int o hole corresponding t o desir ed cut t ing height and inst all hair pin cotter. See decal on t he side of deck lif t plate. e) Mov e lever out of transport ( or 4.5” (11. 4 cm ) cut ting height ) position and down onto height adjustment pin to mow at selected height . f) To t ransport, m ove lever bac[...]

- 34 - j) On lef t side, adjust f ront swivel using the lock ing nut behind the swivel until the f r ont chain is tight and all slack is removed f r om link age. Do not lift fr ont of deck of f 3/ 4” ( 19 m m) block. Secur e f ront swivel using locking nut in fr ont of swivel. Repeat for r ight side. k) Recheck t hat t he 3/ 4” (19 mm) block s [...]

- 35 - FIGURE 12 MULE DRIVE BELT A DJUSTMENT 5.2.5 Deck Belt T ension . a) The deck belt is t ensioned by a self-tensioning idler, no adju stment is necessary . 5.2.6 Adjust Seat Switch a) If necessar y, adj ust the seat actuator r od leng th to where the machine will shut of f when the operator raises of f t he seat (with brake disengaged or PTO e[...]

- 36 - b) Measure the leng t h of the spring . Measurement should be 2. 75” ( 7. 0 cm) between washers (see Figure 14). c) If adj ustment is necessary, t ig ht en t he nut directly below the yoke and loosen the bottom nut (bottom one of the two tight ened t og ether) below the spring. T urn the nut direct ly below t he washer (t op nut of the two[...]

- 37 - d) Check where lever is relative to notch in console (should be cent ered allowing lever to pivot outward to the neut r al lock position). e) If adj ustment is needed, loosen t he nut against the yok e and while applying slight r ear ward pressur e on t he m otion control lever, t ur n t he head of the adjustment bolt in the appropriat e dir[...]

- 38 - a) This adjustm ent must be made with the drive wheels turning. Fir s t raise the fr am e and block up so that drive wheels can rotate f reely. b) Remove the electrical connection f rom the seat saf ety switch, located directly to the lef t of t he seat switch assembly beside the hydraulic oil r eser voir. Temporarily install a j um per wire[...]

- 39 - 5.2.14 Caster pivot bearing s pre-load adjustm ent . a) Remove dust cap f rom caster and t ig hten nyloc nut until washers are flat and back off 1/4 of a t u r n t o pr oper ly set the pre-load on the bearing s. I f disassembled, m ak e sure the spring washers are reinst alled as shown in Figure 18. 5.2.15 Seat armr est adj ust ment . a) Lif[...]

- 40 - c) Check reverse indicat or and motion contr ol link age adjust m ent. See section 5.2.12 and 5. 2. 13. 7.2 M OWER CUTS UNEVENLY . a) Check air pressur e in t ires; 13 psi/drive, 13 psi/pneum at ic casters. A more unif orm cutt ing heig ht may be obtained with higher t ir e pr essur e on rough t er r a in. A lower tire pressure provides mor [...]

- 41 - ENGINE TROUBLESHOOTING TA BLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LI NE DIRTY AIR FILTER FAU LT Y SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN INSUFFICIENT BATT ERY CHARGE Will not start X X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X X X X Operates [...]

- 42 - 8. ELECTRICA L DIAGRA M[...]

- 43 - 9. HYDRA ULIC DIAGRA M[...]

- 44 - 10. 2-Yea r Limited Warranty Exmark Turf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part [...]

- 45 - SERVICE RECORD Date Descripti on of Work Done Service Done By[...]

- 46 -[...]

® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT KI T MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF ST RIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A C[...]